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KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL (CEBM019905) – PDF DOWNLOAD
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- KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM019905
- SERIAL NUMBERS
A30001-A30048, A30056-A30057,
A30065-A30066, A30071-A30072,
A30076-A30077, A30081-A30084
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Description
KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL (CEBM019905)
KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL (CEBM019905) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL (CEBM019905)
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of U.S. standard and metric (SI) 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. When assembly instructions are provided without references to specific torque values, standard torque values should be used.
- Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel.
- It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU HD1500-7 DUMP TRUCK SERVICE REPAIR MANUAL (CEBM019905)
COVER ........................................................................................................... 1 FOREWORD......................................................................................................... 4 TABLE OF CONTENTS................................................................................................ 6 SECTION A - GENERAL INFORMATION - INDEX........................................................................ 8 SECTION A2 - MAJOR COMPONENTS AND SPECIFICATIONS............................................................ 10 SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX ........................................................... 14 GENERAL SAFETY AND OPERATION............................................................................. 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...................................................................... 17 Prevention Of Injury By Work Equipment............................................................... 18 Fire Extinguisher And First Aid Kit.................................................................. 18 Precautions For ROPS................................................................................. 18 Precautions For Attachments.......................................................................... 18 HAUL ROADS........................................................................................... 19 PRECAUTIONS DURING OPERATION......................................................................... 19 BEFORE STARTING THE ENGINE....................................................................... 19 Fire Prevention.............................................................................. 20 Preparing For Operation...................................................................... 20 Ventilation In Enclosed Areas................................................................ 20 In Operator’s Cab - Before Starting The Engine............................................... 20 Mirrors, Windows, And Lights................................................................. 20 OPERATING THE MACHINE............................................................................ 21 When Starting The Engine..................................................................... 21 Precautions For Starting Machine............................................................. 21 Truck Operation - General.................................................................... 21 Traveling.................................................................................... 22 Traveling In Reverse......................................................................... 22 Traveling On Slopes.......................................................................... 22 Ensure Good Visibility....................................................................... 22 Operate Carefully On Snow.................................................................... 23 Avoid Damage To Dump Body.................................................................... 23 Driving Near High Voltage Cables............................................................. 23 When Dumping................................................................................. 23 Working On Loose Ground...................................................................... 23 Loading The Body............................................................................. 23 Parking The Machine.......................................................................... 23 TOWING........................................................................................... 24 WORKING NEAR BATTERIES........................................................................... 24 Battery Hazard Prevention.................................................................... 24 Starting With Booster Cables................................................................. 24 MAINTENANCE PRECAUTIONS.............................................................................. 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 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 Cold Weather Heating System...................................................................... 35 ENGINE START-UP SAFETY PRACTICES..................................................................... 36 Cold Weather Starting............................................................................ 36 Jump Starting.................................................................................... 37 AFTER THE ENGINE HAS STARTED......................................................................... 37 MACHINE OPERATION SAFETY PRECAUTIONS................................................................. 40 LOADING.............................................................................................. 41 HAULING.............................................................................................. 41 RETARDER OPERATION................................................................................... 42 PASSING.............................................................................................. 42 DUMPING.............................................................................................. 43 Raising the Dump Body............................................................................ 43 Lowering The Dump Body........................................................................... 44 SAFE PARKING PROCEDURES.............................................................................. 44 TURNING OFF THE ENGINE............................................................................... 45 SUDDEN LOSS OF ENGINE POWER.......................................................................... 45 Secondary Steering And Braking................................................................... 45 DISABLED TRUCK DUMPING............................................................................... 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 Removal.......................................................................................... 96 Installation..................................................................................... 97 Body Pad Adjustment.............................................................................. 97 BODY GUIDE........................................................................................... 99 BODY-UP RETENTION CABLE.............................................................................. 100 ROCK EJECTORS........................................................................................ 100 Inspection....................................................................................... 100 SECTION B4 - FUEL TANK - INDEX .............................................................................. 102 FUEL TANK................................................................................................ 104 Removal.............................................................................................. 104 Cleaning............................................................................................. 105 Repair............................................................................................... 105 Installation......................................................................................... 105 FUEL GAUGE AND SENDING UNIT.......................................................................... 106 Removal.......................................................................................... 106 Installation..................................................................................... 106 WIGGINS QUICK FILL FUEL SYSTEM....................................................................... 106 FUEL RECEIVER.................................................................................... 106 FUEL TANK BREATHER............................................................................... 107 Removal...................................................................................... 107 Installation................................................................................. 107 Disassembly.................................................................................. 107 Assembly..................................................................................... 107 LEFT SIDE FILL................................................................................... 108 SECTION C - ENGINE - INDEX ..................................................................................... 110 SECTION C3 - COOLING SYSTEM - INDEX ......................................................................... 112 COOLING SYSTEM........................................................................................... 114 DESCRIPTION.......................................................................................... 114 LEAKS AND CONTAMINATION.............................................................................. 115 RADIATOR FILL PROCEDURE.............................................................................. 115 RADIATOR REMOVAL..................................................................................... 116 RADIATOR REPAIR...................................................................................... 118 Internal Inspection.............................................................................. 118 External Cleaning................................................................................ 118 Disassembly...................................................................................... 119 Cleaning and Inspection.......................................................................... 120 Assembly......................................................................................... 120 Pressure Testing................................................................................. 121 Additional Service Information................................................................... 121 RADIATOR INSTALLATION................................................................................ 122 TRANSMISSION AND BRAKE COOLERS....................................................................... 123 Removal.......................................................................................... 124 Disassembly...................................................................................... 124 Cleaning And Inspection.......................................................................... 125 Assembly......................................................................................... 125 Inspection....................................................................................... 126 Installation..................................................................................... 127 SECTION C4 - ENGINE - INDEX ................................................................................. 128 ENGINE................................................................................................... 130 Removal.............................................................................................. 130 Inspection........................................................................................... 133 Installation......................................................................................... 134 DRIVE LINE ADAPTER................................................................................... 135 Removal.......................................................................................... 136 Disassembly...................................................................................... 137 Cleaning and Inspection.......................................................................... 139 Assembly......................................................................................... 141 Installation..................................................................................... 145 Bearing Tools.................................................................................... 146 SECTION C5 - AIR FILTRATION SYSTEM - INDEX .................................................................. 148 AIR FILTRATION SYSTEM.................................................................................... 150 AIR CLEANER.......................................................................................... 150 Operation........................................................................................ 150 General Maintenance.............................................................................. 150 FILTER SERVICE INDICATOR......................................................................... 152 MAIN FILTER ELEMENT.............................................................................. 152 Removal...................................................................................... 152 Installation................................................................................. 152 SAFETY FILTER ELEMENT............................................................................ 152 Removal...................................................................................... 152 Installation................................................................................. 152 MAIN FILTER CLEANING............................................................................. 153 PRECLEANER CLEANING.............................................................................. 154 AIR INTAKE GUIDELINES............................................................................ 155 Installation................................................................................. 155 AIR INTAKE TROUBLESHOOTING........................................................................... 156 SECTION C7 - FAN CLUTCH - INDEX ............................................................................. 158 FAN CLUTCH............................................................................................... 160 REMOVAL & INSTALLATION TOOLING....................................................................... 160 FAN CLUTCH - DISASSEMBLY............................................................................. 163 CLEANING AND INSPECTION.............................................................................. 173 ASSEMBLY - FAN CLUTCH................................................................................ 177 TEST PROCEDURE....................................................................................... 191 SECTION D - ELECTRICAL SYSTEM - INDEX ........................................................................... 192 SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX .......................................................... 194 BATTERIES AND STARTING SYSTEM............................................................................ 196 BATTERIES............................................................................................ 196 MAINTENANCE AND SERVICE.......................................................................... 196 Electrolyte Levels........................................................................... 196 Cleaning..................................................................................... 196 Other Maintenance............................................................................ 197 ENGINE PRELUB™ SYSTEM................................................................................ 199 OPERATION........................................................................................ 199 Oil Pressure Switch.......................................................................... 201 Check Valve.................................................................................. 201 Timer Solenoid............................................................................... 201 MAINTENANCE...................................................................................... 201 Prelub™ System Operation..................................................................... 201 Prelub Pump.................................................................................. 201 Check Valve.................................................................................. 202 Timer Solenoid............................................................................... 202 PRELUB CIRCUIT TROUBLESHOOTING................................................................... 203 STARTING SYSTEM...................................................................................... 205 CRANKING MOTORS.................................................................................. 205 Removal...................................................................................... 205 Disassembly.................................................................................. 206 Cleaning and Inspection...................................................................... 206 Armature Servicing........................................................................... 206 Field Coil Checks............................................................................ 207 Field Coil Removal........................................................................... 207 Solenoid Checks.............................................................................. 209 Assembly..................................................................................... 210 Installation................................................................................. 212 TROUBLESHOOTING.................................................................................. 212 Preliminary Inspection....................................................................... 212 No-Load Test................................................................................. 212 Interpreting The Results of The Tests........................................................ 213 MAGNETIC SWITCH.................................................................................. 214 Removal...................................................................................... 214 Installation................................................................................. 214 Coil Test.................................................................................... 214 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX ........................................................... 216 ELECTRICAL SYSTEM COMPONENTS............................................................................. 218 CAB MOUNTED COMPONENTS............................................................................... 218 CIRCUIT BREAKERS................................................................................. 220 RELAY CENTER..................................................................................... 221 FUSE PANEL....................................................................................... 226 EXTERIOR COMPONENTS.................................................................................. 230 BATTERY BOX...................................................................................... 230 BATTERY DISCONNECT SWITCH........................................................................ 230 GROUND LEVEL SHUT OFF SWITCH..................................................................... 230 CONTROL POWER RELAYS............................................................................. 230 CIRCUIT BREAKERS................................................................................. 230 BATTERY EQUALIZER................................................................................ 230 Test......................................................................................... 230 BODY POSITION SWITCHES........................................................................... 232 Proximity Switch Operation................................................................... 232 Body-Up Switch Adjustment.................................................................... 233 Hoist Limit Switch Adjustment................................................................ 233 SPEED SENSORS.................................................................................... 235 Sensor Adjustment............................................................................ 236 GENERAL TROUBLESHOOTING.............................................................................. 236 SECTION D10 - CHARGING SYSTEM - INDEX ....................................................................... 238 CHARGING SYSTEM.......................................................................................... 240 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION........................................................ 240 Excessive heat................................................................................... 240 Dirt and dust.................................................................................... 240 Vibration........................................................................................ 240 PREVENTIVE MAINTENANCE PROCEDURES.................................................................... 241 Alternator Cleanliness........................................................................... 241 Alternator Mounting.............................................................................. 241 Belt Tension And Condition....................................................................... 241 TROUBLESHOOTING...................................................................................... 241 ALTERNATOR PERFORMANCE TEST...................................................................... 241 ALTERNATOR CABLE TEST............................................................................ 242 VOLTAGE REGULATOR ADJUSTMENT......................................................................... 243 ALTERNATOR........................................................................................... 244 Removal.......................................................................................... 244 Installation..................................................................................... 245 SECTION D11 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX ..................................................... 248 AUTOMATIC TRANSMISSION CONTROLLER........................................................................ 250 GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES........................................... 251 TRANSMISSION OPERATING MODES......................................................................... 252 NETWORK DATA......................................................................................... 252 SHIFT LOGIC.......................................................................................... 254 Shift Lever Position D, Up-Shifting.............................................................. 254 Shift Lever Position D, Down-Shifting............................................................ 254 Shift Lever Positions 6, 5, 4, 3, 2, L........................................................... 254 Shift Lever Positions R.......................................................................... 254 Shift Lever Position N........................................................................... 254 Gear Shift Time Delay............................................................................ 254 SAFETY FUNCTIONALITY............................................................................. 255 Down-Shift Inhibitor Function................................................................ 255 Neutral Safety Function...................................................................... 255 Directional Inhibit Function................................................................. 255 Powertrain Overrun Prevention................................................................ 255 Reverse Safety (Dump Body Raised)............................................................ 255 Speed Range Limit Function (Dump Body Raised)................................................ 255 Self-diagnostic function..................................................................... 255 ATC REAL TIME MONITORING............................................................................. 256 LIMP HOME MODE....................................................................................... 256 Limp Home Procedure 1............................................................................ 259 Limp Home Procedure 2............................................................................ 259 Limp Home Procedure 3............................................................................ 259 Limp Home Procedure 4............................................................................ 259 Limp Home Procedure 5............................................................................ 259 Limp Home Procedure 6............................................................................ 259 Limp Home Procedure 7............................................................................ 259 SECTION D15 - MACHINE MONITOR - INDEX ....................................................................... 260 MACHINE MONITOR.......................................................................................... 262 CHARACTER DISPLAY.................................................................................... 262 Mode Select Switches 1 & 2....................................................................... 263 Service Meter.................................................................................... 263 Odometer......................................................................................... 263 Operation Information............................................................................ 263 Reverse Travel Odometer.......................................................................... 264 Filter And Oil Change Display.................................................................... 264 Display Items.................................................................................... 265 Resetting The Filter/Oil Replacement Meter....................................................... 265 Inputting Telephone Numbers...................................................................... 266 Selecting A Language............................................................................. 266 ACTION CODE DISPLAYS................................................................................. 267 E03 Codes........................................................................................ 267 E02 Codes........................................................................................ 268 E01 Codes........................................................................................ 268 REAL TIME MONITOR.................................................................................... 269 USING REAL TIME MONITOR.......................................................................... 269 Viewing Two Streams of Data At Once.......................................................... 270 Real Time Monitoring Codes................................................................... 271 MACHINE MONITOR FLOW CHART....................................................................... 275 SECTION D20 - FAILURE CODES - INDEX ......................................................................... 280 FAILURE CODES............................................................................................ 282 ACTION CODE DISPLAYS................................................................................. 282 CHECKING FAILURE CODES............................................................................... 283 LIMP HOME MODE....................................................................................... 284 FAILURE CODE TABLE................................................................................... 285 SECTION D21 - TROUBLESHOOTING............................................................................... 302 FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES........................................................ 302 FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION............................................... 303 FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR............................................ 305 FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR............................................ 305 FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 306 FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING........................................................... 307 FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 309 FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING.............................................................. 311 FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING............................................................... 313 FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING............................................................... 315 FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING............................................................... 317 FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING............................................................... 319 FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF................................. 321 FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION.......................................................... 323 FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF.............................. 325 FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION...................................................... 329 FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 331 FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION....................................................... 335 FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 337 FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION....................................................... 341 FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 343 FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION....................................................... 347 FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 349 FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION....................................................... 353 FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION.................................................... 355 FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 356 FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION....................................................... 359 FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING............................................................... 361 FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION........................................................... 363 FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION..................................................... 364 FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE...................................................... 365 FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR............................................. 366 FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE.................................................. 367 FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE........................................... 368 FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE........................................... 369 FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION...................................................... 370 FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED...................................... 371 FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION............................................................ 372 FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE................................................ 373 FAILURE CODE [B@BCNS] ENGINE: OVERHEAT................................................................... 374 FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW........................................................ 375 FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING............................................. 376 FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING........................................ 377 FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING......................................... 378 FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING.................................................. 379 FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION...................................... 380 FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION.................................... 381 FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION.................................... 382 FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION................................................... 383 FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR............................................... 385 FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW.................................. 389 FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW........................... 390 FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR..................................... 391 FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR....................................... 392 FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR...................................... 393 FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT............................................ 394 FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT.......................................... 395 FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR........................................................ 396 FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR........................... 397 FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION............................. 398 FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW................ 399 FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR......................................... 400 FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR........................................... 401 FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR.......................................... 403 FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR.......................................................... 404 FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT................................................ 405 FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE............................................. 407 FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT.......................................................... 409 FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT......................................................... 410 FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT....................................................... 411 FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT...................................................... 412 FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT................................................ 413 FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT.............................................. 415 FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 417 FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 419 FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 421 FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 423 FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT........................................... 425 FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 427 FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT.......................................................... 429 FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT......................................................... 433 FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE..................... 436 FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND...................... 437 FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT................ 438 FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND....................... 439 FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT................. 440 FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT............... 441 FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND..................... 442 FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE................. 443 FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 444 FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 445 FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 446 FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 447 FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 448 FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................. 449 FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE........................... 450 FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION............................ 451 FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE.......................... 452 FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION........................... 453 FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT.................................................... 454 FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE............................................. 455 FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT......................................... 456 FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE......................................... 457 FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE................................................... 459 FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION............................................ 460 FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT.................................................. 461 FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION................................................... 462 FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT................................ 463 FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION................................. 464 FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT......................... 465 FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION.......................... 466 FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION......................................... 467 FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION.......................................... 468 FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 469 FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 470 FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 471 FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 472 FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 473 FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL.... 474 FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT........................................ 475 FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT......................................... 476 FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT.................................... 477 FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT................................... 478 FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE.............................................. 479 FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT.............................. 480 FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)........................................ 481 FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT........................................................ 482 FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT....................................................... 483 FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER...................................................... 484 FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................................ 485 FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)....................... 487 FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT....................................... 489 FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT...................................... 490 FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER..................................... 491 FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)............... 492 FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)........................ 493 FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT........................................ 495 FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT....................................... 496 FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER...................................... 497 FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION......................................... 498 FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION..................................... 499 FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT......................................... 501 FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT........................................ 502 FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER....................................... 503 FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................. 504 FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT.................................... 505 FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT................................... 506 FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................. 507 FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT...................................... 509 FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT..................................... 511 FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................... 513 FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 517 FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 519 FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 521 FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 525 FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 527 FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 529 FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 533 FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 535 FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 537 FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 541 FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 543 FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 545 FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT......................................... 549 FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT........................................ 551 FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER....................................... 553 FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 557 FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 559 FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 561 SECTION D30 - VHMS INITIALIZATION - INDEX................................................................... 564 INITIALIZATION OF VHMS CONTROLLER........................................................................ 566 Executing Quick PM................................................................................... 577 Downloading Existing VHMS Setting Data............................................................... 582 Confirmation of Downloaded Data...................................................................... 583 Disconnecting the PC................................................................................. 583 Reporting to Komatsu................................................................................. 583 REPLACING THE VHMS CONTROLLER............................................................................ 585 Prior to Removing VHMS Controller.................................................................... 585 Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)......................... 585 Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)..................... 589 Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)............................ 591 Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)........................ 592 FINAL VHMS PROCEDURES-POST INSTALLATION.................................................................. 593 Correct the Load Weight Calculation.................................................................. 595 SECTION D31 - VEHICLE HEALTH MONITORING SYSTEM (VHMS) - INDEX ............................................... 604 VEHICLE HEALTH MONITORING SYSTEM (VHMS).................................................................. 606 VHMS DOWNLOADING..................................................................................... 607 PAYLOAD METER........................................................................................ 608 NORMAL OPERATION DISPLAY......................................................................... 609 EXTERNAL DISPLAY LAMPS........................................................................... 610 PREDICTED LOAD DISPLAY........................................................................... 610 CALIBRATING PLM.................................................................................. 611 DATA STORED IN PAYLOAD METER..................................................................... 612 PLM DOWNLOADING.................................................................................. 613 Downloading From Inside Of The Cab........................................................... 613 Downloading From Ground Level Box............................................................ 613 SETTING THE MACHINE ID AND OPEN ID............................................................... 614 PAYLOAD - CYCLE DATA ITEM........................................................................ 615 ADDITIONAL FUNCTIONS............................................................................. 615 Other Settings............................................................................... 615 SECTION F - TRANSMISSION/TORQUE CONVERTER - INDEX ............................................................... 616 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX ...................................................... 618 TORQUE CONVERTER AND TRANSMISSION........................................................................ 620 TORQUE CONVERTER..................................................................................... 621 MAIN RELIEF VALVE................................................................................ 623 Function..................................................................................... 623 Operation.................................................................................... 623 TORQUE CONVERTER RELIEF VALVE.................................................................... 623 Function..................................................................................... 623 Operation.................................................................................... 623 TORQUE CONVERTER REGULATOR VALVE................................................................. 625 Operation.................................................................................... 625 LOCK-UP CLUTCH................................................................................... 626 Lock-up Clutch Accumulator................................................................... 626 HYDRAULIC PUMP................................................................................... 627 TORQUE CONVERTER STALL CHECK..................................................................... 628 TRANSMISSION......................................................................................... 629 LUBRICATION RELIEF VALVE......................................................................... 631 Function..................................................................................... 631 TRANSMISSION CONTROL VALVE....................................................................... 632 ELECTRONIC CONTROL MODULATION VALVE (ECMV)....................................................... 634 Pressure Control Valve....................................................................... 635 Flow Sensor Valve............................................................................ 635 ECMV and Proportional Solenoid............................................................... 635 ECMV and Fill Switch......................................................................... 635 ECMV Operation............................................................................... 636 ECMV REPAIR...................................................................................... 639 Preparation.................................................................................. 639 Filter Replacement Procedure................................................................. 639 ECMV Identification.......................................................................... 640 ECMV Removal................................................................................. 640 Disassembly.................................................................................. 640 Assembly..................................................................................... 642 Installation................................................................................. 642 TRANSMISSION FILTERS............................................................................. 644 Service...................................................................................... 644 Installation................................................................................. 644 TRANSMISSION SPEED SENSORS....................................................................... 645 Adjustment Procedure......................................................................... 645 TRANSMISSION OIL LEVEL CHECK..................................................................... 646 TRANSMISSION OIL PRESSURE CHECK.................................................................. 647 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING.................................................... 649 Preliminary Checks............................................................................... 649 TRANSMISSION REMOVAL............................................................................. 653 TRANSMISSION INSTALLATION........................................................................ 654 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION (-40°C) - INDEX .............................................. 658 TORQUE CONVERTER AND TRANSMISSION (-40°C)................................................................ 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 COLD RELIEF VALVE................................................................................ 666 Operation.................................................................................... 666 LOCK-UP CLUTCH................................................................................... 666 Lock-up Clutch Accumulator................................................................... 667 HYDRAULIC PUMP................................................................................... 668 TORQUE CONVERTER STALL CHECK..................................................................... 669 TRANSMISSION..................................................................................... 670 LUBRICATION RELIEF VALVE......................................................................... 672 Function..................................................................................... 672 TRANSMISSION CONTROL VALVE....................................................................... 673 ELECTRONIC CONTROL MODULATION VALVE (ECMV)....................................................... 675 Pressure Control Valve....................................................................... 676 Flow Sensor Valve............................................................................ 676 ECMV and Proportional Solenoid............................................................... 676 ECMV and Fill Switch......................................................................... 676 ECMV Operation............................................................................... 677 ECMV REPAIR...................................................................................... 680 Preparation.................................................................................. 680 Filter Replacement Procedure................................................................. 680 ECMV Identification.......................................................................... 681 ECMV Removal................................................................................. 681 Disassembly.................................................................................. 681 Assembly..................................................................................... 683 Installation................................................................................. 683 TRANSMISSION FILTERS............................................................................. 685 Service...................................................................................... 685 Installation................................................................................. 685 COLD OIL FILTER RELIEF VALVE..................................................................... 686 TRANSMISSION SPEED SENSORS....................................................................... 686 Adjustment Procedure......................................................................... 687 TRANSMISSION OIL LEVEL CHECK..................................................................... 687 TRANSMISSION OIL PRESSURE CHECK.................................................................. 688 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING.................................................... 690 Preliminary Checks............................................................................... 690 TRANSMISSION REMOVAL............................................................................. 694 TRANSMISSION INSTALLATION........................................................................ 695 SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX .................................................... 698 TRANSMISSION OIL COOLER & STRAINERS...................................................................... 700 TRANSMISSION OIL COOLER.............................................................................. 700 Removal and Installation......................................................................... 700 Repair........................................................................................... 700 TRANSMISSION OIL STRAINER............................................................................ 700 Removal.......................................................................................... 701 Inspection....................................................................................... 701 Installation..................................................................................... 701 SECTION F5 - DRIVE SHAFTS - INDEX ........................................................................... 702 DRIVE SHAFTS............................................................................................. 704 FRONT DRIVE SHAFT.................................................................................... 704 Removal.......................................................................................... 704 Disassembly...................................................................................... 704 Assembly......................................................................................... 704 Installation..................................................................................... 705 FRONT DRIVE SHAFT ALIGNMENT...................................................................... 706 REAR DRIVE SHAFT..................................................................................... 709 Removal.......................................................................................... 709 Disassembly...................................................................................... 710 Assembly......................................................................................... 710 Installation..................................................................................... 710 SECTION F8 - TORQUE CONVERTER REBUILD - INDEX ............................................................... 712 TORQUE CONVERTER REBUILD................................................................................. 714 REMOVAL.............................................................................................. 714 INSTALLATION......................................................................................... 716 DISASSEMBLY.......................................................................................... 718 PTO COVER DISASSEMBLY............................................................................ 726 CLEANING & INSPECTION................................................................................ 727 TABLE I. COMPONENT WEAR LIMITS................................................................... 728 TABLE II. Gear Backlash.......................................................................... 728 ASSEMBLY............................................................................................. 729 ONE-WAY CLUTCH ASSEMBLY.......................................................................... 730 STATOR BEARING PRE-LOAD ADJUSTMENT............................................................... 732 PTO DRIVE ASSEMBLY............................................................................... 736 SPECIAL TOOLS........................................................................................ 741 SECTION F8 - TORQUE CONVERTER REBUILD (-40°C) - INDEX ....................................................... 744 TORQUE CONVERTER REBUILD (-40°C)......................................................................... 746 REMOVAL.............................................................................................. 746 INSTALLATION......................................................................................... 749 DISASSEMBLY.......................................................................................... 751 PTO COVER DISASSEMBLY............................................................................ 759 CLEANING & INSPECTION................................................................................ 760 TABLE I. COMPONENT WEAR LIMITS................................................................... 761 TABLE II. Gear Backlash.......................................................................... 761 ASSEMBLY............................................................................................. 762 ONE-WAY CLUTCH ASSEMBLY.......................................................................... 763 STATOR BEARING PRE-LOAD ADJUSTMENT............................................................... 765 PTO DRIVE ASSEMBLY............................................................................... 769 SPECIAL TOOLS........................................................................................ 775 SECTION F9 - TRANSMISSION REBUILD - INDEX ................................................................... 776 TRANSMISSION REBUILD..................................................................................... 778 TRANSMISSION DISASSEMBLY............................................................................. 778 Number One Clutch Housing Disassembly............................................................ 782 Bearing Cage & Cover Disassembly................................................................. 785 Number Four Carrier Disassembly.................................................................. 786 Output Shaft Cover Disassembly................................................................... 787 Rear Case Bearing Removal........................................................................ 787 Output Shaft Removal............................................................................. 788 Output Shaft Disassembly......................................................................... 788 Number Five/Six Carrier Disassembly.............................................................. 788 CLEANING AND INSPECTION.............................................................................. 790 INSPECTION TABLE INDEX........................................................................... 790 TRANSMISSION ASSEMBLY................................................................................ 796 GENERAL INSTRUCTIONS............................................................................. 796 Number Five/Six Carrier Assembly............................................................. 796 Output Shaft Assembly........................................................................ 797 Number Seven Clutch Assembly................................................................. 798 Rear Case Assembly........................................................................... 799 Rear Case & Carrier Assembly................................................................. 799 Number Six Clutch Assembly................................................................... 801 Number Four Carrier Assembly................................................................. 802 Number Four Carrier Bearing Cage Assembly.................................................... 803 Number Five Clutch Assembly.................................................................. 803 Number Four Clutch Assembly.................................................................. 804 Number Three Clutch Assembly................................................................. 804 Clutch Test.................................................................................. 805 Number Two Clutch Ring Gear Installation..................................................... 805 Number Three Carrier & Number Two Clutch Assembly............................................ 806 Number One Carrier Assembly.................................................................. 806 Number One Clutch Assembly................................................................... 809 Checks Prior to Final Assembly............................................................... 811 Final Assembly............................................................................... 811 Input Shaft Installation..................................................................... 812 External Components.......................................................................... 814 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX ............................................................. 816 SECTION G2 - TIRES AND RIMS - INDEX......................................................................... 818 TIRES AND RIMS........................................................................................... 820 GENERAL INFORMATION.................................................................................. 820 FRONT TIRES AND RIMS................................................................................. 821 Removal.......................................................................................... 821 Installation..................................................................................... 822 REAR TIRE AND RIM.................................................................................... 822 Removal.......................................................................................... 822 Installation..................................................................................... 824 TIRE MATCHING........................................................................................ 825 RIM.................................................................................................. 825 Tire Removal From Rim............................................................................ 825 Tire Installation On Rim......................................................................... 826 FRONT WHEEL STUD INSTALLATION........................................................................ 827 REAR WHEEL STUD INSTALLATION......................................................................... 828 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX ............................................................ 830 FRONT WHEEL HUB AND SPINDLE.............................................................................. 832 OIL SAMPLE ANALYSIS.................................................................................. 832 Oil Sampling Guidelines.......................................................................... 832 Guidelines For Obtaining A Sample................................................................ 832 FRONT WHEEL HUB...................................................................................... 833 Removal.......................................................................................... 833 Disassembly...................................................................................... 833 Inspection....................................................................................... 833 Assembly......................................................................................... 834 Installation..................................................................................... 836 Front Wheel Hub Bearing Adjustment............................................................... 836 FRONT SPINDLE........................................................................................ 837 A-ARM................................................................................................ 837 Removal.......................................................................................... 837 Inspection....................................................................................... 837 Installation..................................................................................... 837 CENTER TIE ROD PIVOT................................................................................. 838 Removal.......................................................................................... 838 Inspection....................................................................................... 838 Installation..................................................................................... 838 TOE IN ADJUSTMENT.................................................................................... 839 Adjustment Procedure............................................................................. 839 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX .................................................................. 844 REAR AXLE ATTACHMENTS.................................................................................... 846 CENTER LINK AND LOWER LINKS.......................................................................... 846 Removal.......................................................................................... 846 Inspection....................................................................................... 847 Spherical Bearing Replacement.................................................................... 847 Installation..................................................................................... 847 PANHARD ROD (DIAGONAL LINK).......................................................................... 848 Removal.......................................................................................... 848 Inspection....................................................................................... 849 Installation..................................................................................... 849 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX ..................................................... 850 REAR AXLE & FINAL DRIVE ASSEMBLY......................................................................... 852 DIFFERENTIAL OPERATION............................................................................... 852 Straight-away-travel............................................................................. 852 Turning.......................................................................................... 852 REAR AXLE ASSEMBLY............................................................................... 853 Removal...................................................................................... 853 Installation................................................................................. 853 DIFFERENTIAL OIL LEVEL CHECK..................................................................... 854 DIFFERENTIAL ASSEMBLY............................................................................ 855 Removal...................................................................................... 855 Installation................................................................................. 856 Disassembly.................................................................................. 856 Pinion Carrier Assembly...................................................................... 859 Differential Gear Unit....................................................................... 859 Differential Gear Unit....................................................................... 860 Cleaning and Inspection...................................................................... 863 Assembly..................................................................................... 863 Differential Bearing......................................................................... 863 Assembly Of Differential Gear Assembly....................................................... 863 Installation Of Differential Assembly........................................................ 865 Input Pinion and Carrier Assembly............................................................ 866 Adjusting Tooth Contact, Backlash............................................................ 870 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX ................................................. 874 FINAL DRIVE PLANETARIES AND WHEEL HUBS................................................................... 876 FINAL DRIVE.......................................................................................... 876 Oil Level Check.................................................................................. 877 FINAL DRIVE CARRIER ASSEMBLY..................................................................... 877 Removal...................................................................................... 877 Installation................................................................................. 878 Disassembly.................................................................................. 878 Assembly..................................................................................... 879 FINAL DRIVE ASSEMBLY............................................................................. 880 Disassembly.................................................................................. 880 Assembly..................................................................................... 882 SECTION H - SUSPENSIONS - INDEX ................................................................................. 884 SECTION H2 - FRONT SUSPENSION - INDEX ....................................................................... 886 FRONT SUSPENSION......................................................................................... 888 Removal.............................................................................................. 890 Installation......................................................................................... 891 Disassembly.......................................................................................... 892 Cleaning and Inspection.............................................................................. 894 Assembly............................................................................................. 894 Pressure Tests....................................................................................... 895 DAMPING VALVE REPAIR................................................................................. 896 Disassembly...................................................................................... 896 Assembly......................................................................................... 897 SECTION H3 - REAR SUSPENSION - INDEX ........................................................................ 898 REAR SUSPENSION.......................................................................................... 900 Operation............................................................................................ 901 Removal.............................................................................................. 902 Installation......................................................................................... 902 Disassembly.......................................................................................... 902 Cleaning and Inspection.............................................................................. 906 Assembly............................................................................................. 906 LEAK TESTING......................................................................................... 907 SPHERICAL BEARINGS................................................................................... 907 Removal.......................................................................................... 907 Inspection....................................................................................... 907 Installation..................................................................................... 907 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX ......................................................... 908 SUSPENSION OILING AND CHARGING........................................................................... 910 GENERAL INFORMATION.................................................................................. 910 Equipment List................................................................................... 910 FRONT SUSPENSION..................................................................................... 912 Front Suspension Oiling.......................................................................... 912 Front Suspension Nitrogen Charging............................................................... 915 REAR SUSPENSION...................................................................................... 917 GENERAL INFORMATION.............................................................................. 917 Rear Suspension Oiling....................................................................... 917 Rear Suspension Nitrogen Charging............................................................ 921 FRONT AND REAR CYLINDER LENGTH ADJUSTMENT............................................................ 921 SECTION J - BRAKE SYSTEM - INDEX ................................................................................ 924 SECTION J2 - BRAKE SYSTEM OPERATION - INDEX ................................................................. 926 BRAKE SYSTEM OPERATION................................................................................... 928 DESCRIPTION.......................................................................................... 928 SERVICE BRAKE OPERATION.............................................................................. 929 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 929 BRAKE SYSTEM COMPONENTS.............................................................................. 931 BRAKE MANIFOLD CARTRIDGE VALVES...................................................................... 933 SERVICE BRAKE CIRCUIT................................................................................ 937 RETARDING CIRCUIT................................................................................ 939 PARKING BRAKE CIRCUIT............................................................................ 941 AUTO APPLY....................................................................................... 943 AUXILIARY BRAKE CIRCUIT.......................................................................... 945 BRAKE LOCK CIRCUIT............................................................................... 947 AUTOMATIC SPIN REGULATOR......................................................................... 949 BRAKE COOLING CIRCUIT................................................................................ 951 BRAKE COOLING VALVE.............................................................................. 952 COLD OIL DIVERTER VALVES......................................................................... 955 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX ........................................................ 956 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 958 BRAKE VALVE.......................................................................................... 959 Rebuild Criteria................................................................................. 959 Removal.......................................................................................... 959 Installation..................................................................................... 960 Disassembly...................................................................................... 961 Cleaning and Inspection.......................................................................... 962 Assembly......................................................................................... 964 Actuator Base Threaded Inserts................................................................... 964 Boot and Cap..................................................................................... 964 Valve Body Seal Installation..................................................................... 964 Regulator Sleeve O-Ring Installation............................................................. 964 Actuator Plunger O-ring Installation............................................................. 965 Assembly of Valve................................................................................ 966 BENCH TEST AND ADJUSTMENT............................................................................ 967 Test Bench Only.................................................................................. 967 Test Set Up Procedure............................................................................ 967 Brake Valve Output Pressure Adjustment........................................................... 969 Final Test and Adjustment........................................................................ 970 Proximity Switch Installation and Adjustment..................................................... 972 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 972 BRAKE ACCUMULATORS................................................................................... 973 Removal.......................................................................................... 974 Installation..................................................................................... 974 Disassembly...................................................................................... 974 Cleaning and Inspection.......................................................................... 976 Assembly......................................................................................... 976 Leak Testing..................................................................................... 978 ACCUMULATOR CHARGING................................................................................. 979 Temperature During Precharge..................................................................... 981 ACCUMULATOR STORAGE.................................................................................. 982 Installation..................................................................................... 982 BRAKE COOLING VALVE (BCV)............................................................................ 983 RETARDER CONTROL LEVER............................................................................... 984 Removal.......................................................................................... 984 Installation..................................................................................... 984 Disassembly and Adjustment....................................................................... 984 Potentiometer Check.............................................................................. 986 Assembly......................................................................................... 986 Retard Lever Calibration......................................................................... 987 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX ................................................................. 988 BRAKE CIRCUIT CHECK-OUT.................................................................................. 990 REQUIRED EQUIPMENT................................................................................... 990 PREPARATION.......................................................................................... 990 BRAKE CIRCUIT TESTING................................................................................ 991 Initial System Setup............................................................................. 991 Parking Brake.................................................................................... 992 Brake Lock....................................................................................... 993 Low-Brake Pressure and Auto-Apply................................................................ 993 Validation....................................................................................... 994 Retarding........................................................................................ 994 BRAKE SYSTEM DATA SHEET.............................................................................. 995 BRAKE CIRCUIT TROUBLESHOOTING........................................................................ 998 SECTION J5 - FRONT WET DISC BRAKES - INDEX ..................................................................1002 FRONT WET DISC BRAKES....................................................................................1004 BRAKE MAINTENANCE....................................................................................1005 Checking Disc Wear...............................................................................1005 FRONT BRAKE ASSEMBLY.................................................................................1007 Removal..........................................................................................1007 Installation.....................................................................................1007 Disassembly......................................................................................1007 Cleaning and Inspection..........................................................................1008 Assembly.........................................................................................1009 Floating Seal Installation.......................................................................1012 BRAKE BLEEDING.......................................................................................1015 SECTION J6 - REAR WET DISC BRAKES - INDEX ...................................................................1016 REAR WET DISC BRAKES.....................................................................................1018 DESCRIPTION..........................................................................................1018 OPERATION............................................................................................1018 MAINTENANCE..........................................................................................1019 Checking Brake Disc Wear.........................................................................1019 REMOVAL..........................................................................................1020 INSTALLATION.....................................................................................1021 BRAKE REBUILD....................................................................................1023 Disassembly..................................................................................1023 Cleaning and Inspection......................................................................1024 Assembly.....................................................................................1024 Floating Seal Installation...................................................................1026 WET DISC BRAKE BLEEDING..........................................................................1029 SECTION J7 - PARKING BRAKE - INDEX ..........................................................................1030 PARKING BRAKE............................................................................................1032 Description..........................................................................................1032 Parking Brake Service Criteria.......................................................................1032 Removal..............................................................................................1033 Installation.........................................................................................1033 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................................1035 Removal..........................................................................................1035 Installation.....................................................................................1035 AUTOMATIC SLACK ADJUSTER.............................................................................1035 Adjustment Procedure.............................................................................1035 PARKING BRAKE CHECK-OUT..............................................................................1036 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................1038 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX ..............................................................1040 HYDRAULIC SYSTEM OVERVIEW................................................................................1042 SYSTEM COMPONENTS....................................................................................1042 HYDRAULIC TANK...................................................................................1042 BLEED-DOWN MANIFOLD..............................................................................1044 HOIST VALVE......................................................................................1044 HOIST PUMP.......................................................................................1044 BRAKE COOLING PUMP...............................................................................1045 BRAKE CONTROL VALVE (BCV)........................................................................1045 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX ......................................................1046 HYDRAULIC COMPONENT REPAIR...............................................................................1048 HYDRAULIC TANK.......................................................................................1048 FILLING INSTRUCTIONS.............................................................................1048 MAINTENANCE......................................................................................1048 Removal......................................................................................1049 Installation.................................................................................1051 Gap Measurement - Hydraulic Tank Mounting....................................................1051 STRAINERS AND DIFFUSERS..........................................................................1052 Removal......................................................................................1052 Cleaning and Inspection......................................................................1052 Installation.................................................................................1053 HYDRAULIC TANK BREATHER..............................................................................1053 Service..........................................................................................1054 HYDRAULIC SYSTEM FLUSHING............................................................................1054 HYDRAULIC PUMPS......................................................................................1055 Removal..........................................................................................1055 Installation.....................................................................................1056 PUMP REBUILD.....................................................................................1057 Disassembly..................................................................................1057 Inspection Of Parts..........................................................................1060 Assembly.....................................................................................1060 Bearing Replacement..........................................................................1063 Seal Replacement.............................................................................1063 TROUBLESHOOTING GUIDE............................................................................1066 SECTION L4 - STEERING CIRCUIT - INDEX .......................................................................1068 STEERING CIRCUIT.........................................................................................1070 OPERATION............................................................................................1070 COMPONENT DESCRIPTION................................................................................1070 Steering Control Valve...........................................................................1070 Bleed-down Manifold..............................................................................1070 Bleed-down Solenoid..............................................................................1071 Accumulators.....................................................................................1072 Flow Amplifier...................................................................................1072 High Pressure Filter.............................................................................1072 Warning Devices..................................................................................1072 FLOW AMPLIFIER OPERATION.............................................................................1074 STEERING/BRAKE PUMP..................................................................................1082 COMPONENTS.......................................................................................1082 OPERATION........................................................................................1084 SECTION L5 - STEERING CONTROL UNIT - INDEX ..................................................................1086 STEERING CONTROL UNIT....................................................................................1088 Removal..............................................................................................1088 Installation.........................................................................................1088 REBUILD PROCEDURE....................................................................................1089 Disassembly......................................................................................1090 Cleaning and Inspection..........................................................................1091 Assembly.........................................................................................1093 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX ......................................................1098 STEERING CIRCUIT COMPONENT REPAIR........................................................................1100 BLEED-DOWN MANIFOLD..................................................................................1100 Removal..........................................................................................1100 Adjusting Relief Valve...........................................................................1100 Testing and Adjustment...........................................................................1101 FLOW AMPLIFIER...................................................................................1102 Removal......................................................................................1102 Installation.................................................................................1102 Disassembly..................................................................................1102 Assembly.....................................................................................1105 ACCUMULATORS.....................................................................................1106 Removal......................................................................................1106 Installation.................................................................................1107 Disassembly..................................................................................1108 Cleaning and Inspection......................................................................1108 Assembly.....................................................................................1108 Leak Testing.................................................................................1109 STEERING ACCUMULATOR CHARGING....................................................................1111 Temperature During Precharge.................................................................1114 ACCUMULATOR STORAGE..............................................................................1114 Installation.................................................................................1115 STEERING CYLINDER................................................................................1116 Removal......................................................................................1116 Installation.................................................................................1116 STEERING CYLINDER REBUILD........................................................................1117 Disassembly..................................................................................1117 Cleaning and Inspection......................................................................1117 Assembly.....................................................................................1118 Testing......................................................................................1118 STEERING/BRAKE PUMP..............................................................................1118 Removal......................................................................................1118 Installation.................................................................................1119 PUMP REBUILD.....................................................................................1120 Disassembly..................................................................................1120 Control Group................................................................................1121 Valve Plate Group............................................................................1122 Rotating Group...............................................................................1122 Drive Shaft Group............................................................................1123 Swashblock Group.............................................................................1123 Inspection...................................................................................1123 Control Group................................................................................1123 Valve Plate Group............................................................................1124 Rotating Group...............................................................................1124 Swashblock Group.............................................................................1125 Drive Shaft Group............................................................................1125 Assembly.....................................................................................1125 Swashblock Group.............................................................................1125 Drive Shaft Group............................................................................1126 Rotating Group...............................................................................1126 Valve Plate Group............................................................................1127 Control Group................................................................................1128 STEERING CIRCUIT FILTER..........................................................................1129 Removal......................................................................................1129 Installation.................................................................................1129 TROUBLESHOOTING CHART....................................................................................1130 SECTION L7 - HOIST CIRCUIT - INDEX ..........................................................................1132 HOIST CIRCUIT............................................................................................1134 HOIST CIRCUIT OPERATION..............................................................................1134 COMPONENT DESCRIPTION............................................................................1135 Hydraulic Tank...............................................................................1135 Hoist Pump...................................................................................1135 Hoist Valve..................................................................................1135 Hoist Pilot Valve............................................................................1136 Power Up Solenoid............................................................................1137 Pilot Operated Check Valve...................................................................1137 Power Down Spool Limit Solenoid..............................................................1137 HOIST CIRCUIT HYDRAULIC FLOW.....................................................................1138 POWER UP.....................................................................................1140 HOLD.........................................................................................1142 POWER DOWN...................................................................................1144 FLOAT........................................................................................1146 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX .........................................................1148 HOIST CIRCUIT COMPONENT REPAIR...........................................................................1150 HOIST VALVE..........................................................................................1150 Removal..........................................................................................1150 Installation.....................................................................................1150 O-Ring Replacement...............................................................................1151 INLET SECTION....................................................................................1152 Disassembly..................................................................................1152 Cleaning and Inspection......................................................................1153 Assembly.....................................................................................1153 SPOOL SECTION....................................................................................1153 Disassembly..................................................................................1153 Cleaning and Inspection......................................................................1154 Assembly.....................................................................................1156 HOIST PILOT VALVE....................................................................................1157 Removal..........................................................................................1157 Installation.....................................................................................1157 Disassembly......................................................................................1158 Cleaning and Inspection..........................................................................1159 Assembly.........................................................................................1159 HOIST CYLINDERS......................................................................................1160 Removal..........................................................................................1160 Installation.....................................................................................1162 Disassembly......................................................................................1162 Cleaning and Inspection..........................................................................1164 Assembly - Quill And Cylinder....................................................................1165 Quill Installation...............................................................................1165 Installation Of Check Balls And Plugs In Quill...................................................1166 Assembly of Cylinder.............................................................................1167 Pressure Testing.................................................................................1168 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX ...............................................................1170 HYDRAULIC SYSTEM FILTERS.................................................................................1172 HIGH PRESSURE FILTER.................................................................................1172 Removal..........................................................................................1172 Installation.....................................................................................1173 LOW PRESSURE FILTERS.................................................................................1173 BRAKE COOLING & HOIST FILTERS....................................................................1173 TRANSMISSION FILTER..............................................................................1173 Removal......................................................................................1174 Installation.................................................................................1174 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX .........................................................1176 HYDRAULIC CHECK-OUT PROCEDURE............................................................................1178 GENERAL INFORMATION..................................................................................1178 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................................................1178 Equipment Requirements...........................................................................1179 Installation Of Gauges...........................................................................1179 Initial Startup And Flushing.....................................................................1179 Component Checkout And Adjustment................................................................1180 CHECKING HOIST SYSTEM PRESSURES......................................................................1182 Equipment Requirements...........................................................................1182 Steering Components Leakage Test.................................................................1184 HYDRAULIC SYSTEM CHECKOUT DATA SHEET.................................................................1185 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX ...................................................................1186 SECTION M7 - HOT START SYSTEM - INDEX........................................................................1188 HOT START SYSTEM.........................................................................................1190 SYSTEM OPERATION.....................................................................................1190 HEATER INFORMATION...................................................................................1191 TROUBLESHOOTING GUIDELINES...........................................................................1193 SECTION M8 - SPECIAL TOOLS..................................................................................1194 SECTION N - OPERATOR CAB - INDEX ................................................................................1198 SECTION N2 - OPERATOR CAB - INDEX ...........................................................................1200 OPERATOR CAB.............................................................................................1202 Removal..............................................................................................1203 Installation.........................................................................................1205 CAB DOORS............................................................................................1205 Removal..........................................................................................1205 Installation.....................................................................................1206 Door Striker Adjustment..........................................................................1206 Door Handle Plunger Adjustment...................................................................1207 DOOR PANEL.......................................................................................1208 Removal......................................................................................1208 Installation.................................................................................1208 DOOR WINDOW......................................................................................1209 Removal......................................................................................1209 Installation.................................................................................1211 WINDOW REGULATOR.................................................................................1213 Removal......................................................................................1213 Installation.................................................................................1213 DOOR HANDLE AND DOOR LATCH.......................................................................1213 Removal......................................................................................1213 Installation.................................................................................1213 DOOR SEALS...........................................................................................1214 Removal..........................................................................................1214 Installation.....................................................................................1214 DOOR OPENING SEAL....................................................................................1214 Removal..........................................................................................1214 Installation.....................................................................................1214 GLASS REPLACEMENT....................................................................................1215 Replacement......................................................................................1215 WINDSHIELD AND REAR GLASS........................................................................1216 Removal......................................................................................1216 Installation.................................................................................1217 SECTION N3 - CAB COMPONENTS - INDEX .........................................................................1218 CAB COMPONENTS...........................................................................................1220 WIPER MOTOR..........................................................................................1220 Removal..........................................................................................1220 Installation.....................................................................................1220 WIPER ARM............................................................................................1221 Removal..........................................................................................1221 Installation.....................................................................................1221 WIPER LINKAGE........................................................................................1222 Removal..........................................................................................1222 Installation.....................................................................................1222 WINDSHIELD WASHER....................................................................................1222 Operation........................................................................................1222 Service..........................................................................................1222 OPERATOR SEAT........................................................................................1223 Adjustment.......................................................................................1223 Seat Removal.....................................................................................1224 Seat Installation................................................................................1224 Seat Belt Replacement............................................................................1224 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX ..........................................................1226 HEATING AND AIR CONDITIONING.............................................................................1228 OPERATION............................................................................................1228 Fan Control Knob.................................................................................1228 Temperature Control Knob.........................................................................1228 Directional Control Knob.........................................................................1228 Heater Vents.....................................................................................1228 COMPONENTS...........................................................................................1229 Fuse and Circuit Breaker.........................................................................1229 Relays...........................................................................................1229 Heater Core......................................................................................1229 Fan Motor And Speed Control......................................................................1230 Actuators........................................................................................1230 Cab Air Filter...................................................................................1230 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.............................................................1233 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................1233 PRINCIPLES OF REFRIGERATION..........................................................................1233 Air Conditioning.................................................................................1234 The Refrigeration Cycle..........................................................................1234 AIR CONDITIONER SYSTEM COMPONENTS....................................................................1235 Compressor (Refrigerant Pump)....................................................................1235 Service Valves...................................................................................1235 Condenser........................................................................................1235 Receiver-Drier...................................................................................1235 Expansion Block Valve............................................................................1236 Accumulator......................................................................................1236 Evaporator.......................................................................................1237 ELECTRICAL CIRCUIT...............................................................................1237 Thermostat...................................................................................1237 Compressor Clutch............................................................................1238 Trinary™ Switch..............................................................................1238 AIR CONDITIONING SYSTEM SERVICING WARNINGS.......................................................1239 SERVICE TOOLS AND EQUIPMENT......................................................................1240 Recovery/Recycle Station.....................................................................1240 Leak Detector................................................................................1241 Manifold Gauge Set...........................................................................1241 Installing Manifold Gauge Set................................................................1242 Purging Air From Service Hoses...............................................................1243 Service Valves...............................................................................1243 Vacuum Pump..................................................................................1244 SYSTEM PERFORMANCE TEST..........................................................................1245 SYSTEM OIL.......................................................................................1246 Handling and Reusing PAG Oil.................................................................1246 Oil Quantity.................................................................................1246 Checking System Oil..........................................................................1246 REFRIGERANT......................................................................................1247 Recycled Refrigerant.........................................................................1247 Reclaimed Refrigerant........................................................................1247 Refrigerant Quantity.........................................................................1248 R-134a Refrigerant Containers................................................................1248 SYSTEM LEAK TESTING..............................................................................1248 Electronic Leak Detector.....................................................................1249 Tracer Dyes..................................................................................1249 Soap and Water...............................................................................1249 RECOVERING AND RECYCLING THE REFRIGERANT.........................................................1249 Draining Oil from the Previous Recovery Cycle................................................1249 Performing the Recovery Cycle................................................................1250 Performing the Recycling Procedure...........................................................1250 Evacuating and Charging the A/C System.......................................................1250 SYSTEM REPAIR....................................................................................1250 System Flushing..............................................................................1251 COMPRESSOR PULLEY AND BELT CHECKS....................................................................1251 Pulley Alignment.................................................................................1251 Belt Tension Check...............................................................................1252 COMPONENT REPLACEMENT............................................................................1254 Hoses and Fittings...........................................................................1254 Lines........................................................................................1254 Receiver-Drier...............................................................................1254 Expansion Valve..............................................................................1254 Thermostat...................................................................................1254 Compressor...................................................................................1255 Accumulator..................................................................................1255 Clutch.......................................................................................1255 Servicing the Compressor Clutch..............................................................1256 Pulley Removal...............................................................................1258 Clutch Coil Check............................................................................1259 Pulley Installation..........................................................................1259 Clutch Assembly Installation.................................................................1260 EVACUATING THE SYSTEM............................................................................1261 CHARGING THE A/C SYSTEM..........................................................................1262 TROUBLESHOOTING..................................................................................1263 Preliminary Checks...........................................................................1263 Diagnosis Of Gauge Readings And System Performance...........................................1263 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...........................................................1264 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...........................................................1270 SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX ..............................................................1272 OPERATOR CAB AND CONTROLS................................................................................1274 STEERING WHEEL AND CONTROLS..........................................................................1275 Horn Button......................................................................................1275 ARSC Set Lever...................................................................................1275 Telescoping/Tilt Wheel Lever.....................................................................1275 Multi-Function Turn Signal Lever.................................................................1275 RETARDER CONTROL LEVER...............................................................................1276 STEERING WHEEL.......................................................................................1277 Removal..........................................................................................1277 Installation.....................................................................................1277 SERVICE BRAKE PEDAL..................................................................................1277 ACCELERATOR PEDAL....................................................................................1277 INSTRUMENT PANEL.....................................................................................1277 HEATER / AIR CONDITIONER CONTROLS....................................................................1278 RETARDING CAPACITY CHART.............................................................................1278 RADIO SPEAKERS.......................................................................................1278 AIR CLEANER VACUUM GAUGES............................................................................1278 WARNING ALARM BUZZER.................................................................................1278 AM/FM RADIO / CD PLAYER..............................................................................1278 CENTER CONSOLE.......................................................................................1279 Hoist Control Lever..............................................................................1280 Transmission Shift Lever.........................................................................1280 Parking Brake Switch.............................................................................1281 LH Window Control Switch.........................................................................1281 RH Window Control Switch.........................................................................1281 Auxiliary Power Outlets..........................................................................1281 INSTRUMENT PANEL AND INDICATORS......................................................................1282 UPPER RH SWITCH PANEL............................................................................1283 Brake Lock Switch............................................................................1283 F1 Start Switch..............................................................................1283 Hazard Warning Lights Switch.................................................................1283 LOWER RH SWITCH PANEL............................................................................1284 Key Switch...................................................................................1284 Ether Starting Aid Switch....................................................................1285 ASR Cut Switch...............................................................................1285 ARSC Switch..................................................................................1285 Automatic Idle Selector Switch (AISS)........................................................1285 Auxiliary Brake Switch.......................................................................1286 UPPER LH SWITCH PANEL............................................................................1287 Automatic Lubrication System Indicator.......................................................1287 LOWER LH SWITCH PANEL............................................................................1288 Head Light Switch............................................................................1288 Ladder Light Switch..........................................................................1288 BackUp/Deck Light Switch.....................................................................1289 Fog Light Switch.............................................................................1289 Mode Select Switches 1 & 2...................................................................1289 Panel Light Dimmer Switch....................................................................1289 ELECTRONIC DISPLAY PANEL.............................................................................1290 PILOT DISPLAY ITEMS..............................................................................1291 METER DISPLAYS...................................................................................1293 CAUTION ITEMS....................................................................................1295 EMERGENCY STOP ITEMS.............................................................................1297 CHARACTER DISPLAY................................................................................1300 REAR ELECTRICAL COMPARTMENT..........................................................................1301 AUTOMATIC RETARD SPEED CONTROL (ARSC)................................................................1304 AUTOMATIC SPIN REGULATOR (ASR).......................................................................1307 SECTION P - LUBRICATION AND SERVICE - INDEX .....................................................................1310 SECTION P2 - LUBRICATION AND SERVICE - INDEX ................................................................1312 LUBRICATION AND SERVICE..................................................................................1314 COOLANT SPECIFICATIONS...............................................................................1314 Unacceptable Practices...........................................................................1314 RADIATOR FILL PROCEDURE..............................................................................1314 HYDRAULIC TANK SERVICE...............................................................................1315 Filling Instructions.............................................................................1315 TRANSMISSION OIL LEVEL CHECK.........................................................................1315 QUICK FILL SERVICE CENTER............................................................................1316 PERIODIC REPLACEMENT OF CRITICAL PARTS...............................................................1316 10 HOUR (DAILY) INSPECTION...........................................................................1318 10 HOUR (DAILY) INSPECTION (continued)...............................................................1319 250 HOUR INSPECTION..................................................................................1320 250 HOUR INSPECTION (continued)......................................................................1321 250 HOUR INSPECTION (continued)......................................................................1322 500 HOUR INSPECTION..................................................................................1323 1000 HOUR INSPECTION.................................................................................1324 2000 HOUR INSPECTION.................................................................................1325 5000 HOUR INSPECTION.................................................................................1326 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX ...........................................................1328 AUTOMATIC LUBRICATION SYSTEM.............................................................................1330 GENERAL DESCRIPTION..................................................................................1330 SYSTEM COMPONENTS....................................................................................1334 SYSTEM OPERATION.....................................................................................1336 INJECTOR OPERATION...................................................................................1337 LUBRICANT PUMP.......................................................................................1338 Pump Housing Oil Level...........................................................................1338 Pump Pressure Control............................................................................1338 INJECTORS (SL-1 Series “H”)).........................................................................1339 Injector Specifications..........................................................................1339 Injector Adjustment..............................................................................1339 SYSTEM PRIMING.......................................................................................1340 Filter Assembly..................................................................................1340 SYSTEM CHECK.........................................................................................1341 Lubrication Controller Check.....................................................................1341 Lubrication Controller Operation.................................................................1341 Lubrication Controller Components................................................................1341 Lubrication Controller Adjustment................................................................1341 SYSTEM TROUBLESHOOTING CHART.........................................................................1343 PREVENTATIVE MAINTENANCE.............................................................................1345 Daily Lubrication System Inspection..............................................................1345 250 Hour Inspection..............................................................................1345 1000 Hour Inspection.............................................................................1346 PUMP REBUILD.........................................................................................1347 Disassembly......................................................................................1347 Cleaning and Inspection..........................................................................1350 Assembly.........................................................................................1350 SECTION R - SYSTEM SCHEMATICS - INDEX ...........................................................................1352 HYDRAULIC SYSTEM SCHEMATIC...................................................................................1354 HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40°C) .............................................................1355 BRAKE SYSTEM SCHEMATIC......................................................................................1356 HOOKUP SCHEMATIC............................................................................................1357 ELECTRICAL WIRING SCHEMATIC.................................................................................1365 CONNECTOR LOCATOR ...........................................................................................1388
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