Komatsu HD1500-7 Dump Truck Shop Manual CEBM016105 PDF

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM016105 – PDF DOWNLOAD

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM016105 – PDF DOWNLOAD 

Language : English
Pages : 1304
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM016105 – PDF DOWNLOAD 

SERIAL NUMBERS A30001 & UP
With SSA16V159 Engine

FOREWORD:

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

• All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
• This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
• The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
• A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
• The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM016105 – PDF DOWNLOAD 

SERIAL NUMBERS A30001 & UP
With SSA16V159 Engine

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 18
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
ENGINE START-UP SAFETY PRACTICES 35
Cold Weather Starting 36
Jump Starting 36
AFTER THE ENGINE HAS STARTED 37
MACHINE OPERATION SAFETY PRECAUTIONS 39
LOADING 40
HAULING 41
RETARDER OPERATION 41
PASSING 42
DUMPING 42
Raising the Dump Body 43
Lowering The Dump Body 43
SAFE PARKING PROCEDURES 44
TURNING OFF THE ENGINE 44
SUDDEN LOSS OF ENGINE POWER 44
Secondary Steering And Braking 44
DISABLED TRUCK DUMPING 45
Hookup 45
Raising the Body 46
Lowering the Body 46
DISABLED TRUCK STEERING AND BRAKING 47
TOWING 49
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 DRIVE CLUTCH – INDEX 158
FAN DRIVE CLUTCH 160
DISASSEMBLY 160
ASSEMBLY 167
INSPECTION OF PARTS 178
REBUILD TOOLS 182
SECTION D – ELECTRICAL SYSTEM – INDEX 184
SECTION D2 – BATTERIES AND STARTING SYSTEM – INDEX 186
BATTERIES AND STARTING SYSTEM 188
BATTERIES 188
MAINTENANCE AND SERVICE 188
Electrolyte Levels 188
Cleaning 188
Other Maintenance 189
PRELUB™ SYSTEM 191
OPERATION 191
Oil Pressure Switch 192
Check Valve 192
TROUBLESHOOTING 193
STARTING SYSTEM 195
CRANKING MOTORS 195
Removal 195
Disassembly 196
Cleaning and Inspection 196
Armature Servicing 196
Field Coil Checks 197
Field Coil Removal 197
Solenoid Checks 199
Assembly 200
Installation 202
TROUBLESHOOTING 202
Preliminary Inspection 202
No-Load Test 202
Interpreting The Results of The Tests 203
MAGNETIC SWITCH 204
Removal 204
Installation 204
Coil Test 204
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 206
ELECTRICAL SYSTEM COMPONENTS 208
CAB MOUNTED COMPONENTS 208
CIRCUIT BREAKERS 210
RELAY CENTER 211
FUSE PANEL 216
EXTERIOR COMPONENTS 220
BATTERY BOX 220
BATTERY DISCONNECT SWITCH 220
GROUND LEVEL SHUT OFF SWITCH 220
CONTROL POWER RELAYS 220
CIRCUIT BREAKERS 220
BATTERY EQUALIZER 220
Test 220
BODY POSITION SWITCHES 222
Proximity Switch Operation 222
Body-Up Switch Adjustment 223
Hoist Limit Switch Adjustment 223
SPEED SENSORS 225
Sensor Adjustment 226
GENERAL TROUBLESHOOTING 226
SECTION D10 – CHARGING SYSTEM – INDEX 228
CHARGING SYSTEM 230
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 230
Excessive heat 230
Dirt and dust 230
Vibration 230
PREVENTIVE MAINTENANCE PROCEDURES 231
Alternator Cleanliness 231
Alternator Mounting 231
Belt Tension And Condition 231
TROUBLESHOOTING 231
ALTERNATOR PERFORMANCE TEST 231
ALTERNATOR CABLE TEST 232
VOLTAGE REGULATOR ADJUSTMENT 233
ALTERNATOR 234
Removal 234
Installation 235
SECTION D11 – AUTOMATIC TRANSMISSION CONTROLLER – INDEX 238
AUTOMATIC TRANSMISSION CONTROLLER 240
GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 241
TRANSMISSION OPERATING MODES 242
NETWORK DATA 242
SHIFT LOGIC 244
Shift Lever Position D, Up-Shifting 244
Shift Lever Position D, Down-Shifting 244
Shift Lever Positions 6, 5, 4, 3, 2, L 244
Shift Lever Positions R 244
Shift Lever Position N 244
Gear Shift Time Delay 244
SAFETY FUNCTIONALITY 245
Down-Shift Inhibitor Function 245
Neutral Safety Function 245
Directional Inhibit Function 245
Powertrain Overrun Prevention 245
Reverse Safety (Dump Body Raised) 245
Speed Range Limit Function (Dump Body Raised) 245
Self-diagnostic function 245
ATC REAL TIME MONITORING 246
LIMP HOME MODE 246
Limp Home Procedure 1 249
Limp Home Procedure 2 249
Limp Home Procedure 3 249
Limp Home Procedure 4 249
Limp Home Procedure 5 249
Limp Home Procedure 6 249
Limp Home Procedure 7 249
SECTION D15 – MACHINE MONITOR – INDEX 250
MACHINE MONITOR 252
CHARACTER DISPLAY 252
Mode Select Switches 1 & 2 253
Service Meter 253
Odometer 253
Operation Information 253
Reverse Travel Odometer 254
Filter And Oil Change Display 254
Display Items 255
Resetting The Filter/Oil Replacement Meter 255
Inputting Telephone Numbers 256
Selecting A Language 256
ACTION CODE DISPLAYS 257
E03 Codes 257
E02 Codes 258
E01 Codes 258
REAL TIME MONITOR 259
USING REAL TIME MONITOR 259
Viewing Two Streams of Data At Once 260
Real Time Monitoring Codes 261
MACHINE MONITOR FLOW CHART 265
SECTION D20 – FAILURE CODES – INDEX 270
FAILURE CODES 272
ACTION CODE DISPLAYS 272
CHECKING FAILURE CODES 273
LIMP HOME MODE 274
FAILURE CODE TABLE 275
SECTION D21 – TROUBLESHOOTING 292
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES 292
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION 293
FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR 295
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR 295
FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR 296
FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING 297
FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR 299
FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING 301
FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING 303
FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING 305
FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING 307
FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING 309
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 311
FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION 313
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 315
FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION 319
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 321
FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION 325
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 327
FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION 331
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 333
FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION 337
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 339
FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION 343
FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION 345
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 346
FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION 349
FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING 351
FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION 353
FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION 354
FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE 355
FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR 356
FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE 357
FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE 358
FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE 359
FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION 360
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED 361
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION 362
FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE 363
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 364
FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW 365
FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING 366
FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING 367
FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING 368
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING 369
FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION 370
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION 371
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION 372
FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION 373
FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR 375
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW 379
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW 380
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR 381
FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR 382
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR 383
FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT 384
FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT 385
FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR 386
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR 387
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION 388
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW 389
FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR 390
FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR 391
FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR 393
FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR 394
FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT 395
FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE 397
FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT 399
FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT 400
FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT 401
FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT 402
FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT 403
FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT 405
FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT 407
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT 409
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT 411
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT 413
FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT 415
FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT 417
FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT 419
FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT 423
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 426
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND 427
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT 428
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND 429
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT 430
FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT 431
FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND 432
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 433
FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 434
FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 435
FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 436
FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 437
FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 438
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 439
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE 440
FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION 441
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE 442
FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION 443
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT 444
FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE 445
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT 446
FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE 447
FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE 449
FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION 450
FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT 451
FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION 452
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 453
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION 454
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT 455
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION 456
FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION 457
FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION 458
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 459
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 460
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 461
FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 462
FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 463
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 464
FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT 465
FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT 466
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 467
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 468
FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE 469
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT 470
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON) 471
FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT 472
FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT 473
FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER 474
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 475
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 477
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT 479
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT 480
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER 481
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 482
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 483
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 485
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 486
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER 487
FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION 488
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION 489
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 491
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 492
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER 493
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 494
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 495
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 496
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 497
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 499
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 501
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 503
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 507
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 509
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 511
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 515
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 517
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 519
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 523
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 525
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 527
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 531
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 533
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 535
FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 539
FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 541
FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 543
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 547
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 549
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 551
SECTION D30 – VHMS INITIALIZATION – INDEX 554
INITIALIZATION OF VHMS CONTROLLER 556
Executing Quick PM 567
Downloading Existing VHMS Setting Data 572
Confirmation of Downloaded Data 573
Disconnecting the PC 573
Reporting to Komatsu 573
REPLACING THE VHMS CONTROLLER 575
Prior to Removing VHMS Controller 575
Confirming and Saving VHMS Controller Settings (Versions older than 3 5 2 1) 575
Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3 5 2 1) 579
Confirming and Saving VHMS Controller Settings (Version 3 5 2 1 or newer) 581
Loading Saved VHMS Settings To New VHMS Controller (Version 3 5 2 1 or newer) 582
FINAL VHMS PROCEDURES-POST INSTALLATION 583
Correct the Load Weight Calculation 585
SECTION D31 – VEHICLE HEALTH MONITORING SYSTEM (VHMS) – INDEX 594
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 596
VHMS DOWNLOADING 597
PAYLOAD METER 598
NORMAL OPERATION DISPLAY 599
EXTERNAL DISPLAY LAMPS 600
PREDICTED LOAD DISPLAY 600
CALIBRATING PLM 601
DATA STORED IN PAYLOAD METER 602
PLM DOWNLOADING 603
Downloading From Inside Of The Cab 603
Downloading From Ground Level Box 603
SETTING THE MACHINE ID AND OPEN ID 604
PAYLOAD – CYCLE DATA ITEM 605
ADDITIONAL FUNCTIONS 605
Other Settings 605
SECTION F – TRANSMISSION/TORQUE CONVERTER – INDEX 606
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 608
TORQUE CONVERTER AND TRANSMISSION 610
TORQUE CONVERTER 611
MAIN RELIEF VALVE 613
Function 613
Operation 613
TORQUE CONVERTER RELIEF VALVE 613
Function 613
Operation 613
TORQUE CONVERTER REGULATOR VALVE 615
Operation 615
LOCK-UP CLUTCH 616
Lock-up Clutch Accumulator 616
HYDRAULIC PUMP 617
TORQUE CONVERTER STALL CHECK 618
TRANSMISSION 619
LUBRICATION RELIEF VALVE 621
Function 621
TRANSMISSION CONTROL VALVE 622
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 624
Pressure Control Valve 625
Flow Sensor Valve 625
ECMV and Proportional Solenoid 625
ECMV and Fill Switch 625
ECMV Operation 626
ECMV REPAIR 629
Preparation 629
Filter Replacement Procedure 629
ECMV Identification 630
ECMV Removal 630
Disassembly 630
Assembly 632
Installation 632
TRANSMISSION FILTERS 634
Service 634
Installation 634
TRANSMISSION SPEED SENSORS 635
Adjustment Procedure 635
TRANSMISSION OIL LEVEL CHECK 636
TRANSMISSION OIL PRESSURE CHECK 637
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 639
Preliminary Checks 639
TRANSMISSION REMOVAL 643
TRANSMISSION INSTALLATION 644
SECTION F3 – TRANSMISSION OIL COOLER & STRAINERS – INDEX 648
TRANSMISSION OIL COOLER & STRAINERS 650
TRANSMISSION OIL COOLER 650
Removal and Installation 650
Repair 650
TRANSMISSION OIL STRAINER 650
Removal 651
Inspection 651
Installation 651
SECTION F5 – DRIVE SHAFTS – INDEX 652
DRIVE SHAFTS 654
FRONT DRIVE SHAFT 654
Removal 654
Disassembly 654
Assembly 654
Installation 655
FRONT DRIVE SHAFT ALIGNMENT 656
REAR DRIVE SHAFT 659
Removal 659
Disassembly 660
Assembly 660
Installation 660
SECTION F8 – TORQUE CONVERTER REBUILD – INDEX 662
TORQUE CONVERTER REBUILD 664
REMOVAL 664
INSTALLATION 666
DISASSEMBLY 668
PTO COVER DISASSEMBLY 676
CLEANING & INSPECTION 677
TABLE I COMPONENT WEAR LIMITS 678
TABLE II Gear Backlash 678
ASSEMBLY 679
ONE-WAY CLUTCH ASSEMBLY 680
STATOR BEARING PRE-LOAD ADJUSTMENT 682
PTO DRIVE ASSEMBLY 686
SPECIAL TOOLS 691
SECTION F9 – TRANSMISSION REBUILD – INDEX 694
TRANSMISSION REBUILD 696
TRANSMISSION DISASSEMBLY 696
Number One Clutch Housing Disassembly 700
Bearing Cage & Cover Disassembly 703
Number Four Carrier Disassembly 704
Output Shaft Cover Disassembly 705
Rear Case Bearing Removal 705
Output Shaft Removal 706
Output Shaft Disassembly 706
Number Five/Six Carrier Disassembly 706
CLEANING AND INSPECTION 708
INSPECTION TABLE INDEX 708
TRANSMISSION ASSEMBLY 714
GENERAL INSTRUCTIONS 714
Number Five/Six Carrier Assembly 714
Output Shaft Assembly 715
Number Seven Clutch Assembly 716
Rear Case Assembly 717
Rear Case & Carrier Assembly 717
Number Six Clutch Assembly 719
Number Four Carrier Assembly 720
Number Four Carrier Bearing Cage Assembly 721
Number Five Clutch Assembly 721
Number Four Clutch Assembly 722
Number Three Clutch Assembly 722
Clutch Test 723
Number Two Clutch Ring Gear Installation 723
Number Three Carrier & Number Two Clutch Assembly 724
Number One Carrier Assembly 724
Number One Clutch Assembly 727
Checks Prior to Final Assembly 729
Final Assembly 729
Input Shaft Installation 730
External Components 732
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 734
SECTION G2 – TIRES AND RIMS – INDEX 736
TIRES AND RIMS 738
GENERAL INFORMATION 738
FRONT TIRES AND RIMS 739
Removal 739
Installation 740
REAR TIRE AND RIM 740
Removal 740
Installation 742
TIRE MATCHING 743
RIM 743
Tire Removal From Rim 743
Tire Installation On Rim 744
FRONT WHEEL STUD INSTALLATION 745
REAR WHEEL STUD INSTALLATION 746
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 748
FRONT WHEEL HUB AND SPINDLE 750
OIL SAMPLE ANALYSIS 750
Oil Sampling Guidelines 750
Guidelines For Obtaining A Sample 750
FRONT WHEEL HUB 751
Removal 751
Disassembly 751
Inspection 751
Assembly 752
Installation 754
Front Wheel Hub Bearing Adjustment 754
FRONT SPINDLE 755
A-ARM 755
Removal 755
Inspection 755
Installation 755
CENTER TIE ROD PIVOT 756
Removal 756
Inspection 756
Installation 756
TOE IN ADJUSTMENT 757
Adjustment Procedure 757
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 762
REAR AXLE ATTACHMENTS 764
CENTER LINK AND LOWER LINKS 764
Removal 764
Inspection 765
Spherical Bearing Replacement 765
Installation 765
PANHARD ROD (DIAGONAL LINK) 766
Removal 766
Inspection 767
Installation 767
SECTION G5 – REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 768
REAR AXLE & FINAL DRIVE ASSEMBLY 770
DIFFERENTIAL OPERATION 770
Straight-away-travel 770
Turning 770
REAR AXLE ASSEMBLY 771
Removal 771
Installation 771
DIFFERENTIAL OIL LEVEL CHECK 772
DIFFERENTIAL ASSEMBLY 773
Removal 773
Installation 774
Disassembly 774
Pinion Carrier Assembly 777
Differential Gear Unit 777
Differential Gear Unit 778
Cleaning and Inspection 781
Assembly 781
Differential Bearing 781
Assembly Of Differential Gear Assembly 781
Installation Of Differential Assembly 783
Input Pinion and Carrier Assembly 784
Adjusting Tooth Contact, Backlash 788
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 792
FINAL DRIVE PLANETARIES AND WHEEL HUBS 794
FINAL DRIVE 794
Oil Level Check 795
FINAL DRIVE CARRIER ASSEMBLY 795
Removal 795
Installation 796
Disassembly 796
Assembly 797
FINAL DRIVE ASSEMBLY 798
Disassembly 798
Assembly 800
SECTION H – SUSPENSIONS – INDEX 802
SECTION H2 – FRONT SUSPENSION – INDEX 804
FRONT SUSPENSION 806
Removal 808
Installation 809
Disassembly 810
Cleaning and Inspection 812
Assembly 812
Pressure Tests 813
DAMPING VALVE REPAIR 814
Disassembly 814
Assembly 815
SECTION H3 – REAR SUSPENSION – INDEX 816
REAR SUSPENSION 818
Operation 819
Removal 820
Installation 820
Disassembly 820
Cleaning and Inspection 824
Assembly 824
LEAK TESTING 825
SPHERICAL BEARINGS 825
Removal 825
Inspection 825
Installation 825
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 826
SUSPENSION OILING AND CHARGING 828
GENERAL INFORMATION 828
Equipment List 828
FRONT SUSPENSION 830
Front Suspension Oiling 830
Front Suspension Nitrogen Charging 833
REAR SUSPENSION 835
GENERAL INFORMATION 835
Rear Suspension Oiling 835
Rear Suspension Nitrogen Charging 839
FRONT AND REAR CYLINDER LENGTH ADJUSTMENT 839
SECTION J – BRAKE SYSTEM – INDEX 842
SECTION J2 – BRAKE SYSTEM OPERATION – INDEX 844
BRAKE SYSTEM OPERATION 846
DESCRIPTION 846
SERVICE BRAKE OPERATION 847
SECONDARY BRAKING AND AUTOMATIC APPLY 847
BRAKE SYSTEM COMPONENTS 849
BRAKE MANIFOLD CARTRIDGE VALVES 851
SERVICE BRAKE CIRCUIT 855
RETARDING CIRCUIT 857
PARKING BRAKE CIRCUIT 859
AUTO APPLY 861
AUXILIARY BRAKE CIRCUIT 863
BRAKE LOCK CIRCUIT 865
AUTOMATIC SPIN REGULATOR 867
BRAKE COOLING CIRCUIT 869
BRAKE COOLING VALVE 870
COLD OIL DIVERTER VALVES 873
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 874
BRAKE CIRCUIT COMPONENT SERVICE 876
BRAKE VALVE 877
Rebuild Criteria 877
Removal 877
Installation 878
Disassembly 879
Cleaning and Inspection 880
Assembly 882
Actuator Base Threaded Inserts 882
Boot and Cap 882
Valve Body Seal Installation 882
Regulator Sleeve O-Ring Installation 882
Actuator Plunger O-ring Installation 883
Assembly of Valve 884
BENCH TEST AND ADJUSTMENT 885
Test Bench Only 885
Test Set Up Procedure 885
Brake Valve Output Pressure Adjustment 887
Final Test and Adjustment 888
Proximity Switch Installation and Adjustment 890
Installation Of Brake Pedal Actuator Assembly to Brake Valve 890
BRAKE ACCUMULATORS 891
Removal 892
Installation 892
Disassembly 892
Cleaning and Inspection 894
Assembly 894
Leak Testing 896
ACCUMULATOR CHARGING 897
Temperature During Precharge 899
ACCUMULATOR STORAGE 900
Installation 900
BRAKE COOLING VALVE (BCV) 901
RETARDER CONTROL LEVER 902
Removal 902
Installation 902
Disassembly and Adjustment 902
Potentiometer Check 904
Assembly 904
Retard Lever Calibration 905
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 906
BRAKE CIRCUIT CHECK-OUT 908
REQUIRED EQUIPMENT 908
PREPARATION 908
BRAKE CIRCUIT TESTING 909
Initial System Setup 909
Parking Brake 910
Brake Lock 911
Low-Brake Pressure and Auto-Apply 911
Validation 912
Retarding 912
BRAKE SYSTEM DATA SHEET 913
BRAKE CIRCUIT TROUBLESHOOTING 916
SECTION J5 – FRONT WET DISC BRAKES – INDEX 920
FRONT WET DISC BRAKES 922
BRAKE MAINTENANCE 923
Checking Disc Wear 923
FRONT BRAKE ASSEMBLY 925
Removal 925
Installation 925
Disassembly 925
Cleaning and Inspection 926
Assembly 927
Floating Seal Installation 930
BRAKE BLEEDING 933
SECTION J6 – REAR WET DISC BRAKES – INDEX 934
REAR WET DISC BRAKES 936
DESCRIPTION 936
OPERATION 936
MAINTENANCE 937
Checking Brake Disc Wear 937
REMOVAL 938
INSTALLATION 939
BRAKE REBUILD 941
Disassembly 941
Cleaning and Inspection 942
Assembly 942
Floating Seal Installation 944
WET DISC BRAKE BLEEDING 947
SECTION J7 – PARKING BRAKE – INDEX 948
PARKING BRAKE 950
Description 950
Parking Brake Service Criteria 950
Removal 951
Installation 951
PARKING BRAKE SPRING CYLINDER REPLACEMENT 953
Removal 953
Installation 953
AUTOMATIC SLACK ADJUSTER 953
Adjustment Procedure 953
PARKING BRAKE CHECK-OUT 954
SECTION L – HYDRAULIC SYSTEM – INDEX 956
SECTION L2 – HYDRAULIC SYSTEM OVERVIEW – INDEX 958
HYDRAULIC SYSTEM OVERVIEW 960
SYSTEM COMPONENTS 960
HYDRAULIC TANK 960
BLEED-DOWN MANIFOLD 962
HOIST VALVE 962
HOIST PUMP 962
BRAKE COOLING PUMP 963
BRAKE CONTROL VALVE (BCV) 963
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 964
HYDRAULIC COMPONENT REPAIR 966
HYDRAULIC TANK 966
FILLING INSTRUCTIONS 966
MAINTENANCE 966
Removal 967
Installation 969
Gap Measurement – Hydraulic Tank Mounting 969
STRAINERS AND DIFFUSERS 970
Removal 970
Cleaning and Inspection 970
Installation 971
HYDRAULIC TANK BREATHER 971
Service 972
HYDRAULIC SYSTEM FLUSHING 972
HYDRAULIC PUMPS 973
Removal 973
Installation 974
PUMP REBUILD 975
Disassembly 975
Inspection Of Parts 978
Assembly 978
Bearing Replacement 981
Seal Replacement 981
TROUBLESHOOTING GUIDE 984
SECTION L4 – STEERING CIRCUIT – INDEX 986
STEERING CIRCUIT 988
OPERATION 988
COMPONENT DESCRIPTION 988
Steering Control Valve 988
Bleed-down Manifold 988
Bleed-down Solenoid 989
Accumulators 990
Flow Amplifier 990
High Pressure Filter 990
Warning Devices 990
FLOW AMPLIFIER OPERATION 992
STEERING/BRAKE PUMP 1000
COMPONENTS 1000
OPERATION 1002
SECTION L5 – STEERING CONTROL UNIT – INDEX 1004
STEERING CONTROL UNIT 1006
Removal 1006
Installation 1006
REBUILD PROCEDURE 1007
Disassembly 1008
Cleaning and Inspection 1009
Assembly 1011
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 1016
STEERING CIRCUIT COMPONENT REPAIR 1018
BLEED-DOWN MANIFOLD 1018
Removal 1018
Adjusting Relief Valve 1018
Testing and Adjustment 1019
FLOW AMPLIFIER 1020
Removal 1020
Installation 1020
Disassembly 1020
Assembly 1023
ACCUMULATORS 1024
Removal 1024
Installation 1025
Disassembly 1026
Cleaning and Inspection 1026
Assembly 1026
Leak Testing 1027
STEERING ACCUMULATOR CHARGING 1029
Temperature During Precharge 1032
ACCUMULATOR STORAGE 1032
Installation 1033
STEERING CYLINDER 1034
Removal 1034
Installation 1034
STEERING CYLINDER REBUILD 1035
Disassembly 1035
Cleaning and Inspection 1035
Assembly 1036
Testing 1036
STEERING/BRAKE PUMP 1036
Removal 1036
Installation 1037
PUMP REBUILD 1038
Disassembly 1038
Control Group 1039
Valve Plate Group 1040
Rotating Group 1040
Drive Shaft Group 1041
Swashblock Group 1041
Inspection 1041
Control Group 1041
Valve Plate Group 1042
Rotating Group 1042
Swashblock Group 1043
Drive Shaft Group 1043
Assembly 1043
Swashblock Group 1043
Drive Shaft Group 1044
Rotating Group 1044
Valve Plate Group 1045
Control Group 1046
STEERING CIRCUIT FILTER 1047
Removal 1047
Installation 1047
TROUBLESHOOTING CHART 1048
SECTION L7 – HOIST CIRCUIT – INDEX 1050
HOIST CIRCUIT 1052
HOIST CIRCUIT OPERATION 1052
COMPONENT DESCRIPTION 1053
Hydraulic Tank 1053
Hoist Pump 1053
Hoist Valve 1053
Hoist Pilot Valve 1054
Power Up Solenoid 1055
Pilot Operated Check Valve 1055
Power Down Spool Limit Solenoid 1055
HOIST CIRCUIT HYDRAULIC FLOW 1056
POWER UP 1058
HOLD 1060
POWER DOWN 1062
FLOAT 1064
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1066
HOIST CIRCUIT COMPONENT REPAIR 1068
HOIST VALVE 1068
Removal 1068
Installation 1068
O-Ring Replacement 1069
INLET SECTION 1070
Disassembly 1070
Cleaning and Inspection 1071
Assembly 1071
SPOOL SECTION 1071
Disassembly 1071
Cleaning and Inspection 1072
Assembly 1074
HOIST PILOT VALVE 1075
Removal 1075
Installation 1075
Disassembly 1076
Cleaning and Inspection 1077
Assembly 1077
HOIST CYLINDERS 1078
Removal 1078
Installation 1080
Disassembly 1080
Cleaning and Inspection 1082
Assembly – Quill And Cylinder 1083
Quill Installation 1083
Installation Of Check Balls And Plugs In Quill 1084
Assembly of Cylinder 1085
Pressure Testing 1086
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1088
HYDRAULIC SYSTEM FILTERS 1090
HIGH PRESSURE FILTER 1090
Removal 1090
Installation 1091
LOW PRESSURE FILTERS 1091
BRAKE COOLING & HOIST FILTERS 1091
TRANSMISSION FILTER 1091
Removal 1092
Installation 1092
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 1094
HYDRAULIC CHECK-OUT PROCEDURE 1096
GENERAL INFORMATION 1096
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1096
Equipment Requirements 1097
Installation Of Gauges 1097
Initial Startup And Flushing 1097
Component Checkout And Adjustment 1098
CHECKING HOIST SYSTEM PRESSURES 1100
Equipment Requirements 1100
Steering Components Leakage Test 1102
HYDRAULIC SYSTEM CHECKOUT DATA SHEET 1103
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1104
SECTION M7 – HOT START SYSTEM – INDEX 1106
HOT START SYSTEM 1108
SYSTEM OPERATION 1108
HEATER INFORMATION 1109
TROUBLESHOOTING GUIDELINES 1111
SECTION M8 – SPECIAL TOOLS 1112
SECTION N – OPERATOR CAB – INDEX 1116
SECTION N2 – OPERATOR CAB – INDEX 1118
OPERATOR CAB 1120
Removal 1121
Installation 1123
CAB DOORS 1123
Removal 1123
Installation 1124
Door Striker Adjustment 1124
Door Handle Plunger Adjustment 1125
DOOR PANEL 1126
Removal 1126
Installation 1126
DOOR WINDOW 1127
Removal 1127
Installation 1129
WINDOW REGULATOR 1131
Removal 1131
Installation 1131
DOOR HANDLE AND DOOR LATCH 1131
Removal 1131
Installation 1131
DOOR SEALS 1132
Removal 1132
Installation 1132
DOOR OPENING SEAL 1132
Removal 1132
Installation 1132
GLASS REPLACEMENT 1133
Replacement 1133
WINDSHIELD AND REAR GLASS 1134
Removal 1134
Installation 1135
SECTION N3 – CAB COMPONENTS – INDEX 1136
CAB COMPONENTS 1138
WIPER MOTOR 1138
Removal 1138
Installation 1138
WIPER ARM 1139
Removal 1139
Installation 1139
WIPER LINKAGE 1140
Removal 1140
Installation 1140
WINDSHIELD WASHER 1140
Operation 1140
Service 1140
OPERATOR SEAT 1141
Adjustment 1141
Seat Removal 1142
Seat Installation 1142
Seat Belt Replacement 1142
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX 1144
HEATING AND AIR CONDITIONING 1146
OPERATION 1146
Fan Control Knob 1146
Temperature Control Knob 1146
Directional Control Knob 1146
Heater Vents 1146
COMPONENTS 1147
Fuse and Circuit Breaker 1147
Relays 1147
Heater Core 1147
Fan Motor And Speed Control 1148
Actuators 1148
Cab Air Filter 1148
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1151
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1151
PRINCIPLES OF REFRIGERATION 1151
Air Conditioning 1152
The Refrigeration Cycle 1152
AIR CONDITIONER SYSTEM COMPONENTS 1153
Compressor (Refrigerant Pump) 1153
Service Valves 1153
Condenser 1153
Receiver-Drier 1153
Expansion Block Valve 1154
Accumulator 1154
Evaporator 1155
ELECTRICAL CIRCUIT 1155
Thermostat 1155
Compressor Clutch 1156
Trinary™ Switch 1156
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1157
SERVICE TOOLS AND EQUIPMENT 1158
Recovery/Recycle Station 1158
Leak Detector 1159
Manifold Gauge Set 1159
Installing Manifold Gauge Set 1160
Purging Air From Service Hoses 1161
Service Valves 1161
Vacuum Pump 1162
SYSTEM PERFORMANCE TEST 1163
SYSTEM OIL 1164
Handling and Reusing PAG Oil 1164
Oil Quantity 1164
Checking System Oil 1164
REFRIGERANT 1165
Recycled Refrigerant 1165
Reclaimed Refrigerant 1165
Refrigerant Quantity 1166
R-134a Refrigerant Containers 1166
SYSTEM LEAK TESTING 1166
Electronic Leak Detector 1167
Tracer Dyes 1167
Soap and Water 1167
RECOVERING AND RECYCLING THE REFRIGERANT 1167
Draining Oil from the Previous Recovery Cycle 1167
Performing the Recovery Cycle 1168
Performing the Recycling Procedure 1168
Evacuating and Charging the A/C System 1168
SYSTEM REPAIR 1168
System Flushing 1169
COMPRESSOR PULLEY AND BELT CHECKS 1169
Pulley Alignment 1169
Belt Tension Check 1170
COMPONENT REPLACEMENT 1172
Hoses and Fittings 1172
Lines 1172
Receiver-Drier 1172
Expansion Valve 1172
Thermostat 1172
Compressor 1173
Accumulator 1173
Clutch 1173
Servicing the Compressor Clutch 1174
Pulley Removal 1176
Clutch Coil Check 1177
Pulley Installation 1177
Clutch Assembly Installation 1178
EVACUATING THE SYSTEM 1179
CHARGING THE A/C SYSTEM 1180
TROUBLESHOOTING 1181
Preliminary Checks 1181
Diagnosis Of Gauge Readings And System Performance 1181
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1182
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1188
SECTION N5 – OPERATOR CAB AND CONTROLS – INDEX 1190
OPERATOR CAB AND CONTROLS 1192
STEERING WHEEL AND CONTROLS 1193
Horn Button 1193
ARSC Set Lever 1193
Telescoping/Tilt Wheel Lever 1193
Multi-Function Turn Signal Lever 1193
RETARDER CONTROL LEVER 1194
STEERING WHEEL 1195
Removal 1195
Installation 1195
SERVICE BRAKE PEDAL 1195
ACCELERATOR PEDAL 1195
INSTRUMENT PANEL 1195
HEATER / AIR CONDITIONER CONTROLS 1196
RETARDING CAPACITY CHART 1196
RADIO SPEAKERS 1196
AIR CLEANER VACUUM GAUGES 1196
WARNING ALARM BUZZER 1196
AM/FM RADIO / CD PLAYER 1196
CENTER CONSOLE 1197
Hoist Control Lever 1198
Transmission Shift Lever 1198
Parking Brake Switch 1199
LH Window Control Switch 1199
RH Window Control Switch 1199
Auxiliary Power Outlets 1199
INSTRUMENT PANEL AND INDICATORS 1200
UPPER RH SWITCH PANEL 1201
Brake Lock Switch 1201
F1 Start Switch 1201
Hazard Warning Lights Switch 1201
LOWER RH SWITCH PANEL 1202
Key Switch 1202
Ether Starting Aid Switch 1203
ASR Cut Switch 1203
ARSC Switch 1203
Automatic Idle Selector Switch (AISS) 1203
Auxiliary Brake Switch 1204
UPPER LH SWITCH PANEL 1205
Automatic Lubrication System Indicator 1205
LOWER LH SWITCH PANEL 1206
Head Light Switch 1206
Ladder Light Switch 1206
BackUp/Deck Light Switch 1207
Fog Light Switch 1207
Mode Select Switches 1 & 2 1207
Panel Light Dimmer Switch 1207
ELECTRONIC DISPLAY PANEL 1208
PILOT DISPLAY ITEMS 1209
METER DISPLAYS 1211
CAUTION ITEMS 1213
EMERGENCY STOP ITEMS 1215
CHARACTER DISPLAY 1218
REAR ELECTRICAL COMPARTMENT 1219
AUTOMATIC RETARD SPEED CONTROL (ARSC) 1222
AUTOMATIC SPIN REGULATOR (ASR) 1225
SECTION P – LUBRICATION AND SERVICE – INDEX 1228
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1230
LUBRICATION AND SERVICE 1232
COOLANT SPECIFICATIONS 1232
Unacceptable Practices 1232
RADIATOR FILL PROCEDURE 1232
HYDRAULIC TANK SERVICE 1233
Filling Instructions 1233
TRANSMISSION OIL LEVEL CHECK 1233
QUICK FILL SERVICE CENTER 1234
PERIODIC REPLACEMENT OF CRITICAL PARTS 1234
10 HOUR (DAILY) INSPECTION 1236
10 HOUR (DAILY) INSPECTION (continued) 1237
250 HOUR INSPECTION 1238
250 HOUR INSPECTION (continued) 1239
250 HOUR INSPECTION (continued) 1240
500 HOUR INSPECTION 1241
1000 HOUR INSPECTION 1242
2000 HOUR INSPECTION 1243
5000 HOUR INSPECTION 1244
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 1246
AUTOMATIC LUBRICATION SYSTEM 1248
GENERAL DESCRIPTION 1248
SYSTEM COMPONENTS 1252
SYSTEM OPERATION 1254
INJECTOR OPERATION 1255
LUBRICANT PUMP 1256
Pump Housing Oil Level 1256
Pump Pressure Control 1256
INJECTORS (SL-1 Series “H”)) 1257
Injector Specifications 1257
Injector Adjustment 1257
SYSTEM PRIMING 1258
Filter Assembly 1258
SYSTEM CHECK 1259
Lubrication Controller Check 1259
Lubrication Controller Operation 1259
Lubrication Controller Components 1259
Lubrication Controller Adjustment 1259
SYSTEM TROUBLESHOOTING CHART 1261
PREVENTATIVE MAINTENANCE 1263
Daily Lubrication System Inspection 1263
250 Hour Inspection 1263
1000 Hour Inspection 1264
PUMP REBUILD 1265
Disassembly 1265
Cleaning and Inspection 1268
Assembly 1268
SECTION R – SYSTEM SCHEMATICS – INDEX 1270
HYDRAULIC SYSTEM SCHEMATIC 1272
BRAKE SYSTEM SCHEMATIC 1273
HOOKUP SCHEMATIC 1274
ELECTRICAL WIRING SCHEMATIC 1282

S.V 15/12/24