Komatsu HD1500-7 Dump Truck Shop Manual CEBM023701 PDF

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM023701 –  PDF DOWNLOAD

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM023701  – PDF DOWNLOAD

Language : English
Pages : 1314
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM023701  – PDF DOWNLOAD

• SERIAL NUMBERS A30109 – A30110 A40111 & UP
• ENGINE  SSA16V159

FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
MAJOR COMPONENTS AND SPECIFICATIONS 11
SPECIFICATIONS 13
SECTION A3 15
GENERAL SAFETY AND OPERATION 15
INDEX 15
GENERAL SAFETY AND OPERATION 17
Safety Rules 17
Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Prevention Of Injury By Work Equipment 19
Fire Extinguisher And First Aid Kit 19
Precautions For ROPS 19
Precautions For Attachments 19
HAUL ROADS 20
PRECAUTIONS DURING OPERATION 20
BEFORE STARTING THE ENGINE 20
Fire Prevention 21
Preparing For Operation 21
Ventilation In Enclosed Areas 21
In Operator’s Cab – Before Starting The Engine 21
Mirrors, Windows, And Lights 21
OPERATING THE MACHINE 22
When Starting The Engine 22
Precautions For Starting Machine 22
Truck Operation – General 22
Traveling 23
Traveling In Reverse 23
Traveling On Slopes 23
Ensure Good Visibility 23
Operate Carefully On Snow 24
Avoid Damage To Dump Body 24
Driving Near High Voltage Cables 24
When Dumping 24
Working On Loose Ground 24
Loading The Body 24
Parking The Machine 24
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Starting With Booster Cables 25
MAINTENANCE PRECAUTIONS 26
Warning Tag 26
Proper Tools 26
Stopping The Engine Before Service 26
Securing The Dump Body 26
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keep The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Water Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High Pressure Hoses 29
Precautions With High Pressure Oil 29
Precautions When Performing Maintenance Near High Temperature Or High Pressure 29
Rotating Fan And Belts 29
Waste Materials 29
TIRES 30
Handling Tires 30
Storing Tires After Removal 30
WHEN REPAIRS ARE NECESSARY 31
ADDITIONAL JOB SITE RULES 32
OPERATING INSTRUCTIONS 33
PREPARING FOR OPERATION 33
Safety Is Thinking Ahead 33
Walk Around Inspection 33
Cold Weather Heating System 36
ENGINE START-UP SAFETY PRACTICES 37
Cold Weather Starting 37
Jump Starting 38
AFTER THE ENGINE HAS STARTED 38
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
RETARDER OPERATION 43
PASSING 43
DUMPING 44
Raising the Dump Body 44
Lowering The Dump Body 45
SAFE PARKING PROCEDURES 45
TURNING OFF THE ENGINE 46
SUDDEN LOSS OF ENGINE POWER 46
Secondary Steering And Braking 46
DISABLED TRUCK DUMPING 47
Hookup 47
Raising the Body 48
Lowering the Body 48
DISABLED TRUCK STEERING AND BRAKING 49
TOWING 51
WARNINGS AND CAUTIONS 53
TORQUE TABLES AND CONVERSION CHARTS 61
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 62
STANDARD TIGHTENING TORQUES For Class 10 9 Cap screws & Class 10 Nuts 62
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws 63
SAE Grade 9 Cap screws 64
Hardware Tightening Method 72
SECTION A7 73
STORAGE PROCEDURES 73
INDEX 73
STORAGE AND IDLE MACHINE PREPARATION 75
SHORT TERM IDLE PERIODS 75
PREPARATION FOR STORAGE 75
REMOVAL FROM STORAGE 76
RECONDITIONING AN IDLE VEHICLE 78
ENGINE OPERATION 81
AFTER THE ENGINE HAS STARTED 81
SHORT TERM ENGINE STORAGE 82
Preparing the Engine 82
Removing the Engine from Long Term Storage 84
TRANSMISSION PRESERVATION AND STORAGE 84
Storage, New Transmission 84
Storage, One Year- Without Oil 84
Storage, One Year – With Oil – Normally Installed On The Truck 85
Restoring The Transmission For Service 85
SECTION B STRUCTURES 87
SECTION B2 STRUCTURAL COMPONENTS 89
STRUCTURAL COMPONENTS 91
PREPARATION 91
GRILLE, HOOD AND LADDERS 92
DECKS 93
CENTER DECK 93
Removal 93
Installation 93
RIGHT DECK AND COMPONENTS 93
Removal 93
Installation 93
LEFT DECK AND CAB 94
Installation 94
SECTION B3 DUMP BODY 95
DUMP BODY 97
Removal 97
Installation 99
BODY PADS 99
Removal 99
Installation 100
Body Pad Adjustment 100
BODY GUIDE 102
BODY-UP RETENTION CABLE 103
ROCK EJECTORS 103
Inspection 103
SECTION B4 FUEL TANK 105
FUEL TANK 107
Removal 107
Cleaning 108
Repair 108
Installation 108
FUEL GAUGE AND SENDING UNIT 109
Removal 109
Installation 109
WIGGINS QUICK FILL FUEL SYSTEM 109
FUEL RECEIVER 109
FUEL TANK BREATHER 110
Removal 110
Installation 110
Disassembly 110
Assembly 110
LEFT SIDE FILL 111
SECTION C 113
SECTION C3 115
COOLING SYSTEM 115
INDEX 115
COOLING SYSTEM 117
DESCRIPTION 117
LEAKS AND CONTAMINATION 118
RADIATOR FILL PROCEDURE 118
RADIATOR REMOVAL 119
RADIATOR REPAIR 121
Internal Inspection 121
External Cleaning 121
Disassembly 122
Cleaning and Inspection 123
Assembly 123
Pressure Testing 124
Additional Service Information 124
RADIATOR INSTALLATION 125
TRANSMISSION AND BRAKE COOLERS 126
Removal 127
Disassembly 127
Cleaning And Inspection 128
Assembly 128
Inspection 129
Installation 130
SECTION C4 131
ENGINE 131
INDEX 131
ENGINE 133
Removal 133
Inspection 136
Installation 137
DRIVE LINE ADAPTER 138
Removal 139
Disassembly 140
Cleaning and Inspection 142
Assembly 144
Installation 148
Bearing Tools 149
SECTION C5 151
AIR FILTRATION SYSTEM 151
INDEX 151
AIR FILTRATION SYSTEM 153
AIR CLEANER 153
Operation 153
AIR CLEANER MAINTENANCE 153
Filter Service Indicator 155
Replacing The Elements 155
MAIN FILTER CLEANING 156
PRECLEANER CLEANING 157
AIR INTAKE GUIDELINES 158
Installation 158
AIR INTAKE TROUBLESHOOTING 159
SECTION C7 161
FAN CLUTCH 161
INDEX 161
FAN CLUTCH 163
REMOVAL & INSTALLATION TOOLING 163
FAN CLUTCH – DISASSEMBLY 166
CLEANING AND INSPECTION 176
ASSEMBLY – FAN CLUTCH 180
TEST PROCEDURE 194
SECTION D 195
ELECTRICAL SYSTEM 195
INDEX 195
SECTION D2 197
BATTERIES AND STARTING SYSTEM 197
INDEX 197
BATTERIES AND STARTING SYSTEM 199
BATTERIES 199
MAINTENANCE AND SERVICE 199
Electrolyte Levels 199
Cleaning 199
Other Maintenance 200
ENGINE PRELUB™ SYSTEM 202
OPERATION 202
Oil Pressure Switch 204
Check Valve 204
Timer Solenoid 204
MAINTENANCE 204
Prelub™ System Operation 204
Prelub Pump 204
Check Valve 205
Timer Solenoid 205
PRELUB CIRCUIT TROUBLESHOOTING 206
STARTING SYSTEM 208
CRANKING MOTORS 208
Removal 208
Disassembly 209
Cleaning and Inspection 209
Armature Servicing 209
Field Coil Checks 210
Field Coil Removal 210
Solenoid Checks 212
Assembly 213
Installation 215
TROUBLESHOOTING 215
Preliminary Inspection 215
No-Load Test 215
Interpreting The Results of The Tests 216
MAGNETIC SWITCH 217
Removal 217
Installation 217
Coil Test 217
SECTION D3 219
ELECTRICAL SYSTEM COMPONENTS 219
INDEX 219
ELECTRICAL SYSTEM COMPONENTS 221
CAB MOUNTED COMPONENTS 221
CIRCUIT BREAKERS 223
RELAY CENTER 224
FUSE PANEL 229
EXTERIOR COMPONENTS 233
BATTERY BOX 233
BATTERY DISCONNECT SWITCH 233
GROUND LEVEL SHUT OFF SWITCH 233
CONTROL POWER RELAYS 233
CIRCUIT BREAKERS 233
BATTERY EQUALIZER 233
Test 233
BODY POSITION SWITCHES 235
Proximity Switch Operation 235
Body-Up Switch Adjustment 236
Hoist Limit Switch Adjustment 236
SPEED SENSORS 238
Sensor Adjustment 239
GENERAL TROUBLESHOOTING 239
SECTION D10 241
CHARGING SYSTEM 241
INDEX 241
CHARGING SYSTEM 243
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 243
Excessive heat 243
Dirt and dust 243
Vibration 243
PREVENTIVE MAINTENANCE PROCEDURES 244
Alternator Cleanliness 244
Alternator Mounting 244
Belt Tension And Condition 244
TROUBLESHOOTING 244
ALTERNATOR PERFORMANCE TEST 244
ALTERNATOR CABLE TEST 245
VOLTAGE REGULATOR ADJUSTMENT 246
ALTERNATOR 247
Removal 247
Installation 248
SECTION D15 251
MACHINE MONITOR 251
INDEX 251
MACHINE MONITOR 253
CHARACTER DISPLAY 253
Mode Select Switches 1 & 2 254
Service Meter 254
Odometer 254
Operation Information 254
Reverse Travel Odometer 255
Filter And Oil Change Display 255
Display Items 256
Resetting The Filter/Oil Replacement Meter 256
Inputting Telephone Numbers 257
Selecting A Language 257
ACTION CODE DISPLAYS 258
E03 Codes 258
E02 Codes 259
E01 Codes 259
REAL TIME MONITOR 260
USING REAL TIME MONITOR 260
Viewing Two Streams of Data At Once 261
DIP Switch 262
Real Time Monitoring Codes 263
MACHINE MONITOR FLOW CHART 267
SECTION D20 271
FAILURE CODES 271
INDEX 271
FAILURE CODES 273
ACTION CODE DISPLAYS 273
CHECKING FAILURE CODES 274
LIMP HOME MODE 275
FAILURE CODE TABLE 276
TROUBLESHOOTING 293
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES 293
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION 294
FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR 296
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR 296
FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR 297
FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING 298
FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR 300
FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING 302
FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING 304
FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING 306
FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING 308
FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING 310
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 312
FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION 314
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 316
FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION 320
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 322
FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION 326
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 328
FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION 332
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 334
FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION 338
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 340
FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION 344
FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION 346
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 347
FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION 350
FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING 352
FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION 354
FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION 355
FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE 356
FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR 357
FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE 358
FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE 359
FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE 360
FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION 361
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED 362
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION 363
FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE 364
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 365
FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW 366
FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING 367
FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING 368
FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING 369
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING 370
FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION 371
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION 372
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION 373
FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION 374
FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR 376
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW 380
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW 381
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR 382
FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR 383
FAILURE CODE [DAQV00] NEUTRAL COAST CAUTION 384
FAILURE CODE [DAQW00] NEUTRAL OVER SPEED CAUTION 385
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR 386
FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT 387
FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT 388
FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR 389
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR 390
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION 391
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW 392
FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR 393
FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR 394
FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR 396
FAILURE CODE [dBBRKR] KOMTRAX Plus: COMMUNICATION ERROR 397
FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT 398
FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE 400
FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT 402
FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT 403
FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT 404
FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT 405
FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT 406
FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT 408
FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT 410
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT 412
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT 414
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT 416
FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT 418
FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT 420
FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT 422
FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT 426
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 429
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND 430
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT 431
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND 432
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT 433
FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT 434
FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND 435
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 436
FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 437
FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 438
FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 439
FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 440
FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 441
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 442
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE 443
FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION 444
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE 445
FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION 446
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT 447
FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE 448
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT 449
FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE 450
FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE 452
FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION 453
FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT 454
FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION 455
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 456
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION 457
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT 458
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION 459
FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION 460
FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION 461
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 462
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 463
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 464
FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 465
FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 466
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 467
FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT 468
FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT 469
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 470
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 471
FAILURE CODE [DW7FMA] MANUAL SECONDARY BRAKE VALVE: FAILURE 472
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT 473
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON) 474
FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT 475
FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT 476
FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER 477
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 478
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 480
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT 482
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT 483
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER 484
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 485
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 486
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 488
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 489
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER 490
FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION 491
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION 492
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 494
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 495
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER 496
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 497
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 498
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 499
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 500
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 502
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 504
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 506
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 510
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 512
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 514
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 518
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 520
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 522
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 526
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 528
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 530
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 534
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 536
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 538
FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 542
FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 544
FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 546
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 550
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 552
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 554
SECTION D30 557
KOMTRAX Plus INITIALIZATION 557
INDEX 557
INITIALIZATION OF KOMTRAX Plus CONTROLLER 559
Executing Quick PM 570
Downloading Existing KOMTRAX Plus Setting Data 575
Confirmation of Downloaded Data 576
Disconnecting the PC 576
Reporting to Komatsu 576
REPLACING THE KOMTRAX Plus CONTROLLER 578
Prior to Removing KOMTRAX Plus Controller 578
Confirming and Saving KOMTRAX Plus Controller Settings (Versions older than 3 5 2 1) 578
Loading Saved KOMTRAX Plus Settings To New KOMTRAX Plus Controller (Versions older than 3 5 2 1) 582
Confirming and Saving KOMTRAX Plus Controller Settings (Version 3 5 2 1 or newer) 584
Loading Saved KOMTRAX Plus Settings To New KOMTRAX Plus Controller (Version 3 5 2 1 or newer) 585
FINAL KOMTRAX Plus PROCEDURES- POST INSTALLATION 586
SETTING PAYLOAD METER USING KOMTRAX Plus 587
Correct the Load Weight Calculation 588
SECTION D31 597
KOMTRAX Plus 597
INDEX 597
KOMTRAX Plus 599
KOMTRAX Plus DOWNLOADING 600
PAYLOAD METER 601
NORMAL OPERATION DISPLAY 602
EXTERNAL DISPLAY LAMPS 603
PREDICTED LOAD DISPLAY 603
CALIBRATING PLM 604
DATA STORED IN PAYLOAD METER 605
PLM DOWNLOADING 606
Downloading From Inside Of The Cab 606
Downloading From Ground Level Box 606
SETTING THE MACHINE ID AND OPEN ID 607
PAYLOAD – CYCLE DATA ITEM 608
ADDITIONAL FUNCTIONS 608
Other Settings 608
SECTION F 609
SECTION F2 611
TORQUE CONVERTER AND TRANSMISSION 611
INDEX 611
TORQUE CONVERTER AND TRANSMISSION 613
TORQUE CONVERTER 614
MAIN RELIEF VALVE 616
Function 616
Operation 616
TORQUE CONVERTER RELIEF VALVE 616
Function 616
Operation 616
TORQUE CONVERTER REGULATOR VALVE 618
Operation 618
LOCK-UP CLUTCH 619
Lock-up Clutch Accumulator 619
HYDRAULIC PUMP 620
TORQUE CONVERTER STALL CHECK 621
TRANSMISSION 622
LUBRICATION RELIEF VALVE 624
Function 624
TRANSMISSION CONTROL VALVE 625
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 627
Pressure Control Valve 628
Flow Sensor Valve 628
ECMV and Proportional Solenoid 628
ECMV and Fill Switch 628
ECMV Operation 629
ECMV REPAIR 632
Preparation 632
Filter Replacement Procedure 632
ECMV Identification 633
ECMV Removal 633
Disassembly 633
Assembly 635
Installation 635
TRANSMISSION FILTERS 637
Service 637
Installation 637
TRANSMISSION SPEED SENSORS 638
Adjustment Procedure 638
TRANSMISSION OIL LEVEL CHECK 639
TRANSMISSION OIL PRESSURE CHECK 640
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 642
Preliminary Checks 642
TRANSMISSION REMOVAL 646
TRANSMISSION INSTALLATION 647
SECTION F3 651
TRANSMISSION OIL COOLER & STRAINERS 651
INDEX 651
TRANSMISSION OIL COOLER & STRAINERS 653
TRANSMISSION OIL COOLER 653
Removal and Installation 653
Repair 653
TRANSMISSION OIL STRAINER 653
Removal 654
Inspection 654
Installation 654
SECTION F5 655
DRIVE SHAFTS 655
INDEX 655
DRIVE SHAFTS 657
FRONT DRIVE SHAFT 657
Removal 657
Disassembly 657
Assembly 657
Installation 658
FRONT DRIVE SHAFT ALIGNMENT 659
REAR DRIVE SHAFT 662
Removal 662
Disassembly 663
Assembly 663
Installation 664
SECTION F8 665
TORQUE CONVERTER REBUILD 665
INDEX 665
TORQUE CONVERTER REBUILD 667
REMOVAL 667
INSTALLATION 669
DISASSEMBLY 671
PTO COVER DISASSEMBLY 679
CLEANING & INSPECTION 680
TABLE I COMPONENT WEAR LIMITS 681
TABLE II Gear Backlash 681
ASSEMBLY 682
ONE-WAY CLUTCH ASSEMBLY 683
STATOR BEARING PRE-LOAD ADJUSTMENT 685
PTO DRIVE ASSEMBLY 689
SPECIAL TOOLS 694
SECTION F9 697
TRANSMISSION REBUILD 697
INDEX 697
TRANSMISSION REBUILD 699
TRANSMISSION DISASSEMBLY 699
Number One Clutch Housing Disassembly 705
Bearing Cage & Cover Disassembly 707
Number Four Carrier Disassembly 708
Output Shaft Cover Disassembly 710
Rear Case Bearing Removal 710
Output Shaft Removal 710
Output Shaft Disassembly 711
Number Five/Six Carrier Disassembly 711
CLEANING AND INSPECTION 712
INSPECTION TABLE INDEX 712
TRANSMISSION ASSEMBLY 718
GENERAL INSTRUCTIONS 718
Number Five/Six Carrier Assembly 718
Output Shaft Assembly 719
Number Seven Clutch Assembly 720
Rear Case Assembly 721
Rear Case & Carrier Assembly 721
Number Six Clutch Assembly 723
Number Four Carrier Assembly 724
Number Four Carrier Bearing Cage Assembly 725
Number Five Clutch Assembly 725
Number Four Clutch Assembly 726
Number Three Clutch Assembly 726
Clutch Test 727
Number Two Clutch Ring Gear Installation 727
Number Three Carrier & Number Two Clutch Assembly 728
Number One Carrier Assembly 728
Number One Clutch Assembly 731
Checks Prior to Final Assembly 734
Final Assembly 734
Input Shaft Installation 735
External Components 737
SECTION G 739
DRIVE AXLE, SPINDLES AND WHEELS 739
INDEX 739
SECTION G2 741
TIRES AND RIMS 741
INDEX 741
TIRES AND RIMS 743
GENERAL INFORMATION 743
FRONT TIRES AND RIMS 744
Removal 744
Installation 745
REAR TIRE AND RIM 745
Removal 745
Installation 747
TIRE MATCHING 748
RIM 748
Tire Removal From Rim 748
Tire Installation On Rim 749
FRONT WHEEL STUD INSTALLATION 750
REAR WHEEL STUD INSTALLATION 751
SECTION G3 753
FRONT WHEEL HUB AND SPINDLE 753
INDEX 753
FRONT WHEEL HUB AND SPINDLE 755
OIL SAMPLE ANALYSIS 755
Oil Sampling Guidelines 755
Guidelines For Obtaining A Sample 755
FRONT WHEEL HUB 756
Removal 756
Disassembly 756
Inspection 756
Assembly 757
Installation 759
Front Wheel Hub Bearing Adjustment 759
FRONT SPINDLE 760
A-ARM 760
Removal 760
Inspection 760
Installation 760
CENTER TIE ROD PIVOT 761
Removal 761
Inspection 761
Installation 761
TOE IN ADJUSTMENT 762
Adjustment Procedure 762
SECTION G4 767
REAR AXLE ATTACHMENTS 767
INDEX 767
REAR AXLE ATTACHMENTS 769
CENTER LINK AND LOWER LINKS 769
Removal 769
Inspection 770
Spherical Bearing Replacement 770
Installation 770
PANHARD ROD (DIAGONAL LINK) 771
Removal 771
Inspection 772
Installation 772
SECTION G5 773
REAR AXLE AND FINAL DRIVE ASSEMBLY 773
INDEX 773
REAR AXLE & FINAL DRIVE ASSEMBLY 775
DIFFERENTIAL OPERATION 775
Straight-away-travel 775
Turning 775
REAR AXLE ASSEMBLY 776
Removal 776
Installation 776
DIFFERENTIAL OIL LEVEL CHECK 777
DIFFERENTIAL ASSEMBLY 778
Removal 778
Installation 779
Disassembly 779
Pinion Carrier Assembly 782
Differential Gear Unit 782
Differential Gear Unit 783
Cleaning and Inspection 786
Assembly 786
Differential Bearing 786
Assembly Of Differential Gear Assembly 786
Installation Of Differential Assembly 788
Input Pinion and Carrier Assembly 789
Adjusting Tooth Contact, Backlash 793
SECTION G6 797
FINAL DRIVE PLANETARIES AND WHEEL HUBS 797
INDEX 797
FINAL DRIVE PLANETARIES AND WHEEL HUBS 799
FINAL DRIVE 799
Oil Level Check 800
FINAL DRIVE CARRIER ASSEMBLY 800
Removal 800
Installation 801
Disassembly 801
Assembly 802
FINAL DRIVE ASSEMBLY 803
Disassembly 803
Assembly 805
SECTION H 807
SUSPENSIONS 807
INDEX 807
SECTION H2 809
FRONT SUSPENSION 809
INDEX 809
FRONT SUSPENSION 811
Removal 813
Installation 814
Disassembly 815
Cleaning and Inspection 817
Assembly 817
Pressure Tests 819
DAMPING VALVE REPAIR 820
Disassembly 820
Assembly 821
SECTION H3 823
REAR SUSPENSION 823
INDEX 823
REAR SUSPENSION 825
Operation 826
Removal 827
Installation 827
Disassembly 827
Cleaning and Inspection 831
Assembly 831
LEAK TESTING 832
SPHERICAL BEARINGS 832
Removal 832
Inspection 832
Installation 832
SECTION H4 833
SUSPENSION OILING AND CHARGING 833
INDEX 833
SUSPENSION OILING AND CHARGING 835
GENERAL INFORMATION 835
Equipment List 835
FRONT SUSPENSION 837
Front Suspension Oiling 837
Front Suspension Nitrogen Charging 840
REAR SUSPENSION 842
GENERAL INFORMATION 842
Rear Suspension Oiling 842
Rear Suspension Nitrogen Charging 846
FRONT AND REAR CYLINDER LENGTH ADJUSTMENT 846
SECTION J 849
BRAKE SYSTEM 849
INDEX 849
SECTION J2 851
BRAKE SYSTEM OPERATION 851
INDEX 851
BRAKE SYSTEM OPERATION 853
DESCRIPTION 853
SERVICE BRAKE OPERATION 853
SECONDARY BRAKING AND AUTOMATIC APPLY 854
BRAKE SYSTEM COMPONENTS 856
BRAKE MANIFOLD CARTRIDGE VALVES 858
SERVICE BRAKE CIRCUIT 861
RETARDING CIRCUIT 863
PARKING BRAKE CIRCUIT 865
AUTO APPLY 867
AUXILIARY BRAKE CIRCUIT 869
BRAKE LOCK CIRCUIT 871
AUTOMATIC SPIN REGULATOR 873
BRAKE COOLING CIRCUIT 875
BRAKE COOLING VALVE 876
COLD OIL DIVERTER VALVES 879
SECTION J3 881
BRAKE CIRCUIT COMPONENT SERVICE 881
INDEX 881
BRAKE CIRCUIT COMPONENT SERVICE 883
BRAKE VALVE 884
Rebuild Criteria 884
Removal 884
Installation 885
Disassembly 886
Cleaning and Inspection 887
Assembly 889
Actuator Base Threaded Inserts 889
Boot and Cap 889
Valve Body Seal Installation 889
Regulator Sleeve O-Ring Installation 889
Actuator Plunger O-ring Installation 890
Assembly of Valve 891
BENCH TEST AND ADJUSTMENT 892
Test Bench Only 892
Test Set Up Procedure 892
Brake Valve Output Pressure Adjustment 894
Final Test and Adjustment 895
Proximity Switch Installation and Adjustment 897
Installation Of Brake Pedal Actuator Assembly to Brake Valve 897
BRAKE ACCUMULATORS 898
Removal 899
Installation 899
Disassembly 899
Cleaning and Inspection 901
Assembly 901
Leak Testing 903
ACCUMULATOR CHARGING 904
Temperature During Precharge 906
ACCUMULATOR STORAGE 907
Installation 907
BRAKE COOLING VALVE (BCV) 908
RETARDER CONTROL LEVER 909
Removal 909
Installation 909
Disassembly and Adjustment 909
Potentiometer Check 911
Assembly 911
Retard Lever Calibration 912
SECTION J4 913
BRAKE CIRCUIT CHECKOUT 913
INDEX 913
BRAKE CIRCUIT CHECK-OUT 915
REQUIRED EQUIPMENT 915
PREPARATION 915
BRAKE CIRCUIT TESTING 916
Initial System Setup 916
Parking Brake 917
Brake Lock 918
Low-Brake Pressure and Auto-Apply 918
Validation 919
Retarding 919
BRAKE SYSTEM DATA SHEET 920
BRAKE CIRCUIT TROUBLESHOOTING 923
SECTION J5 927
FRONT WET DISC BRAKES 927
INDEX 927
FRONT WET DISC BRAKES 929
BRAKE MAINTENANCE 930
Checking Disc Wear 930
FRONT BRAKE ASSEMBLY 932
Removal 932
Installation 932
Disassembly 932
Cleaning and Inspection 933
Assembly 934
Floating Seal Installation 937
BRAKE BLEEDING 940
SECTION J6 941
REAR WET DISC BRAKES 941
INDEX 941
REAR WET DISC BRAKES 943
DESCRIPTION 943
OPERATION 943
MAINTENANCE 944
Checking Brake Disc Wear 944
REMOVAL 945
INSTALLATION 946
BRAKE REBUILD 948
Disassembly 948
Cleaning and Inspection 949
Assembly 949
Floating Seal Installation 951
WET DISC BRAKE BLEEDING 954
SECTION J7 955
PARKING BRAKE 955
INDEX 955
PARKING BRAKE 957
Description 957
Parking Brake Service Criteria 957
Removal 958
Installation 958
PARKING BRAKE SPRING CYLINDER REPLACEMENT 960
Removal 960
Installation 960
AUTOMATIC SLACK ADJUSTER 960
Adjustment Procedure 960
PARKING BRAKE CHECK-OUT 961
SECTION L HYDRAULIC SYSTEM INDEX 963
SECTION L2 965
HYDRAULIC SYSTEM OVERVIEW 965
INDEX 965
HYDRAULIC SYSTEM OVERVIEW 967
SYSTEM COMPONENTS 967
HYDRAULIC TANK 967
BLEED-DOWN MANIFOLD 969
HOIST VALVE 969
HOIST PUMP 969
BRAKE COOLING PUMP 970
BRAKE CONTROL VALVE (BCV) 970
SECTION L3 971
HYDRAULIC SYSTEM COMPONENT REPAIR 971
INDEX 971
HYDRAULIC COMPONENT REPAIR 973
HYDRAULIC TANK 973
FILLING INSTRUCTIONS 973
MAINTENANCE 973
Removal 974
Installation 976
Gap Measurement – Hydraulic Tank Mounting 976
STRAINERS AND DIFFUSERS 977
Removal 977
Cleaning and Inspection 977
Installation 978
HYDRAULIC TANK BREATHER 978
Service 979
HYDRAULIC SYSTEM FLUSHING 979
HYDRAULIC PUMPS 980
Removal 980
Installation 981
PUMP REBUILD 982
Disassembly 982
Inspection Of Parts 985
Assembly 985
Bearing Replacement 988
Seal Replacement 988
TROUBLESHOOTING GUIDE 991
SECTION L4 993
STEERING CIRCUIT 993
INDEX 993
STEERING CIRCUIT 995
OPERATION 995
COMPONENT DESCRIPTION 995
Steering Control Valve 995
Bleed-down Manifold 995
Bleed-down Solenoid 996
Accumulators 997
Flow Amplifier 997
High Pressure Filter 997
Warning Devices 997
FLOW AMPLIFIER OPERATION 999
STEERING/BRAKE PUMP 1007
COMPONENTS 1007
OPERATION 1009
SECTION L5 1011
STEERING CONTROL UNIT 1011
INDEX 1011
STEERING CONTROL UNIT 1013
Removal 1013
Installation 1013
REBUILD PROCEDURE 1014
Disassembly 1015
Cleaning and Inspection 1016
Assembly 1018
SECTION L6 1023
STEERING CIRCUIT COMPONENT REPAIR 1023
INDEX 1023
STEERING CIRCUIT COMPONENT REPAIR 1025
BLEED-DOWN MANIFOLD 1025
Removal 1025
Adjusting Relief Valve 1025
Testing and Adjustment 1026
FLOW AMPLIFIER 1027
Removal 1027
Installation 1027
Disassembly 1027
Assembly 1030
ACCUMULATORS 1031
Removal 1031
Installation 1032
Disassembly 1033
Cleaning and Inspection 1033
Assembly 1033
Leak Testing 1034
STEERING ACCUMULATOR CHARGING 1036
Temperature During Precharge 1039
ACCUMULATOR STORAGE 1039
Installation 1040
STEERING CYLINDER 1041
Removal 1041
Installation 1041
STEERING CYLINDER REBUILD 1042
Disassembly 1042
Cleaning and Inspection 1042
Assembly 1043
Testing 1043
STEERING/BRAKE PUMP 1043
Removal 1043
Installation 1044
PUMP REBUILD 1045
Disassembly 1045
Control Group 1046
Valve Plate Group 1047
Rotating Group 1047
Drive Shaft Group 1048
Swashblock Group 1048
Inspection 1048
Control Group 1048
Valve Plate Group 1049
Rotating Group 1049
Swashblock Group 1050
Drive Shaft Group 1050
Assembly 1050
Swashblock Group 1050
Drive Shaft Group 1051
Rotating Group 1051
Valve Plate Group 1052
Control Group 1053
STEERING CIRCUIT FILTER 1054
Removal 1054
Installation 1054
TROUBLESHOOTING CHART 1055
SECTION L7 1057
HOIST CIRCUIT 1057
INDEX 1057
HOIST CIRCUIT 1059
HOIST CIRCUIT OPERATION 1059
COMPONENT DESCRIPTION 1060
Hydraulic Tank 1060
Hoist Pump 1060
Hoist Valve 1060
Hoist Pilot Valve 1061
Power Up Solenoid 1062
Pilot Operated Check Valve 1062
Power Down Spool Limit Solenoid 1062
HOIST CIRCUIT HYDRAULIC FLOW 1063
POWER UP 1065
HOLD 1067
POWER DOWN 1069
FLOAT 1071
SECTION L8 1073
HOIST CIRCUIT COMPONENT REPAIR 1073
INDEX 1073
HOIST CIRCUIT COMPONENT REPAIR 1075
HOIST VALVE 1075
Removal 1075
Installation 1075
O-Ring Replacement 1076
INLET SECTION 1077
Disassembly 1077
Cleaning and Inspection 1078
Assembly 1078
SPOOL SECTION 1078
Disassembly 1078
Cleaning and Inspection 1079
Assembly 1081
HOIST PILOT VALVE 1082
Removal 1082
Installation 1082
Disassembly 1083
Cleaning and Inspection 1084
Assembly 1084
HOIST CYLINDERS 1085
Removal 1085
Installation 1087
Disassembly 1087
Cleaning and Inspection 1089
Assembly – Quill And Cylinder 1090
Quill Installation 1090
Installation Of Check Balls And Plugs In Quill 1091
Assembly of Cylinder 1092
Pressure Testing 1093
SECTION L9 1095
HYDRAULIC SYSTEM FILTERS 1095
INDEX 1095
HYDRAULIC SYSTEM FILTERS 1097
HIGH PRESSURE FILTER 1097
Removal 1097
Installation 1098
LOW PRESSURE FILTERS 1098
BRAKE COOLING & HOIST FILTERS 1098
TRANSMISSION FILTER 1098
Removal 1099
Installation 1099
SECTION L10 1101
HYDRAULIC CHECK-OUT PROCEDURE 1101
INDEX 1101
HYDRAULIC CHECK-OUT PROCEDURE 1103
GENERAL INFORMATION 1103
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1103
Equipment Requirements 1104
Installation Of Gauges 1104
Initial Startup And Flushing 1104
Component Checkout And Adjustment 1105
CHECKING HOIST SYSTEM PRESSURES 1107
Equipment Requirements 1107
Steering Components Leakage Test 1109
HYDRAULIC SYSTEM CHECKOUT DATA SHEET 1110
SECTION M 1111
OPTIONS AND SPECIAL TOOLS 1111
INDEX 1111
SECTION M7 HOT START SYSTEM INDEX 1113
HOT START SYSTEM 1115
SYSTEM OPERATION 1115
HEATER INFORMATION 1116
TROUBLESHOOTING GUIDELINES 1118
SPECIAL TOOLS 1119
SECTION N 1123
OPERATOR CAB 1123
INDEX 1123
SECTION N2 1125
OPERATOR CAB 1125
INDEX 1125
OPERATOR CAB 1127
Removal 1128
Installation 1130
CAB DOORS 1130
Removal 1130
Installation 1131
Door Striker Adjustment 1131
Door Handle Plunger Adjustment 1132
DOOR PANEL 1133
Removal 1133
Installation 1134
DOOR WINDOW 1135
Removal 1135
Installation 1136
DOOR HANDLE AND DOOR LATCH 1139
Removal 1139
Installation 1139
REPLACING THE DOOR WINDOW REGULATOR 1139
DOOR SEALS 1140
Removal 1140
Installation 1140
DOOR OPENING SEAL 1140
Removal 1140
Installation 1140
GLASS REPLACEMENT (Adhesive – Bonded Windows) 1141
Replacement 1142
WINDSHIELD AND REAR GLASS 1143
Removal 1143
Installation 1144
SECTION N3 CAB COMPONENTS INDEX 1145
CAB COMPONENTS 1147
WINDSHIELD WIPERS 1147
WIPER MOTOR 1147
Removal 1147
Installation 1147
WIPER ARM 1147
Removal 1147
Installation 1148
WIPER LINKAGE 1148
Removal 1148
Installation 1148
WINDSHIELD WASHER 1149
Operation 1149
Service 1149
OPERATOR SEAT 1150
Adjustment 1150
Inspection 1151
Removal 1151
Installation 1151
SEAT BELT 1152
Removal 1152
Installation 1153
SECTION N4 1155
HEATING AND AIR CONDITIONING 1155
INDEX 1155
HEATING AND AIR CONDITIONING 1157
HEATER/AIR CONDITIONER UNIT 1157
Fan Speed Control Knob 1157
Temperature Control Knob 1157
Air Flow Directional Knob 1157
Heater/Air Conditioner Vents 1158
COMPONENTS 1158
Fuse 1158
Relays 1158
Heater Core 1158
Fan Motor And Speed Control 1159
Actuators 1159
Cab Air Filter 1159
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1162
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1162
PRINCIPLES OF REFRIGERATION 1162
Air Conditioning 1162
Refrigeration – The Act Of Cooling 1163
The Refrigeration Cycle 1163
AIR CONDITIONER SYSTEM COMPONENTS 1164
Compressor (Refrigerant Pump) 1164
Service Valves 1164
Condenser 1164
Receiver-Drier 1164
Expansion Block Valve 1165
Accumulator 1165
Evaporator 1165
ELECTRICAL CIRCUIT 1166
Thermostat 1166
Compressor Clutch 1166
Trinary™ Switch 1167
SYSTEM SERVICING 1168
SERVICE TOOLS AND EQUIPMENT 1169
Recovery/Recycle Station 1169
Leak Detector 1169
Service Valves 1170
Vacuum Pump 1170
Manifold Gauge Set 1171
Installing Manifold Gauge Set 1172
Purging Air From Service Hoses 1172
SYSTEM PERFORMANCE TEST 1173
SYSTEM OIL 1174
Handling and Reusing PAG Oil 1174
Oil Quantity 1174
Checking System Oil 1174
REFRIGERANT 1175
Recycled Refrigerant 1175
Reclaimed Refrigerant 1175
Refrigerant Quantity 1175
R-134a Refrigerant Containers 1176
SYSTEM LEAK TESTING 1176
Electronic Leak Detector 1177
Tracer Dyes 1177
Soap and Water 1177
RECOVERING AND RECYCLING THE REFRIGERANT 1177
Draining Oil from the Previous Recovery Cycle 1177
Performing the Recovery Cycle 1177
Performing the Recycling Procedure 1178
Evacuating and Charging the A/C System 1178
SYSTEM REPAIR 1178
System Flushing 1178
COMPONENT REPLACEMENT 1178
Hoses and Fittings 1178
Lines 1179
Expansion Valve 1179
Receiver-Drier 1179
Thermostat 1179
Compressor 1179
Accumulator 1180
Clutch 1180
Servicing the Compressor Clutch 1181
Pulley Removal 1183
Clutch Coil Check 1184
Pulley Installation 1184
Clutch Assembly Installation 1184
EVACUATING THE SYSTEM 1186
CHARGING THE A/C SYSTEM 1188
TROUBLESHOOTING 1189
Preliminary Checks 1189
Diagnosis Of Gauge Readings And System Performance 1189
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1190
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1194
SECTION N5 1197
OPERATOR CAB AND CONTROLS 1197
INDEX 1197
OPERATOR CAB AND CONTROLS 1199
STEERING WHEEL AND CONTROLS 1200
Horn Button 1200
ARSC Set Lever 1200
Telescoping/Tilt Wheel Lever 1200
Multi-Function Turn Signal Lever 1200
RETARDER CONTROL LEVER 1201
STEERING COLUMN 1202
Removal 1202
Inspection 1202
Installation 1202
STEERING WHEEL 1203
Removal 1203
Installation 1203
SERVICE BRAKE PEDAL 1204
ACCELERATOR PEDAL 1204
INSTRUMENT PANEL 1205
HEATER / AIR CONDITIONER CONTROLS 1205
RETARDING CAPACITY CHART 1205
RADIO SPEAKERS 1205
AIR CLEANER VACUUM GAUGES 1205
WARNING ALARM BUZZER 1205
AM/FM RADIO / CD PLAYER 1205
CENTER CONSOLE 1206
Hoist Control Lever 1207
Transmission Shift Lever 1207
Parking Brake Switch 1208
LH Window Control Switch 1208
RH Window Control Switch 1208
Auxiliary Power Outlets 1208
INSTRUMENT PANEL AND INDICATORS 1209
UPPER RH SWITCH PANEL 1210
Brake Lock Switch 1210
F1 Start Switch 1210
Hazard Warning Lights Switch 1210
LOWER RH SWITCH PANEL 1211
Key Switch 1211
Ether Starting Aid Switch 1212
ASR Cut Switch 1212
ARSC Switch 1212
Automatic Idle Selector Switch (AISS) 1212
Auxiliary Brake Switch 1213
UPPER LH SWITCH PANEL 1214
Automatic Lubrication System Indicator 1214
LOWER LH SWITCH PANEL 1215
Head Light Switch 1215
Ladder Light Switch 1215
BackUp/Deck Light Switch 1216
Fog Light Switch 1216
Mode Select Switches 1 & 2 1216
Panel Light Dimmer Switch 1216
ELECTRONIC DISPLAY PANEL 1217
PILOT DISPLAY ITEMS 1218
METER DISPLAYS 1220
CAUTION ITEMS 1222
EMERGENCY STOP ITEMS 1224
CHARACTER DISPLAY 1227
REAR ELECTRICAL COMPARTMENT 1228
AUTOMATIC RETARD SPEED CONTROL (ARSC) 1231
AUTOMATIC SPIN REGULATOR (ASR) 1234
SECTION P 1237
LUBRICATION AND SERVICE 1237
INDEX 1237
SECTION P2 1239
LUBRICATION AND SERVICE 1239
INDEX 1239
LUBRICATION AND SERVICE 1241
COOLANT SPECIFICATIONS 1241
Unacceptable Practices 1241
RADIATOR FILL PROCEDURE 1241
HYDRAULIC TANK SERVICE 1242
Filling Instructions 1242
TRANSMISSION OIL LEVEL CHECK 1242
QUICK FILL SERVICE CENTER 1243
PERIODIC REPLACEMENT OF CRITICAL PARTS 1243
10 HOUR (DAILY) INSPECTION 1245
10 HOUR (DAILY) INSPECTION (continued) 1246
250 HOUR INSPECTION 1247
250 HOUR INSPECTION (continued) 1248
250 HOUR INSPECTION (continued) 1249
500 HOUR INSPECTION 1250
1000 HOUR INSPECTION 1251
2000 HOUR INSPECTION 1252
5000 HOUR INSPECTION 1253
SECTION P3 1255
AUTOMATIC LUBRICATION SYSTEM 1255
INDEX 1255
AUTOMATIC LUBRICATION SYSTEM 1257
GENERAL DESCRIPTION 1257
SYSTEM COMPONENTS 1261
SYSTEM OPERATION 1263
INJECTOR OPERATION 1264
LUBRICANT PUMP 1265
Pump Housing Oil Level 1265
Pump Pressure Control 1265
INJECTORS (SL-1 Series “H”)) 1266
Injector Specifications 1266
Injector Adjustment 1266
SYSTEM PRIMING 1267
Filter Assembly 1267
SYSTEM CHECK 1268
Lubrication Controller Check 1268
Lubrication Controller Operation 1268
Lubrication Controller Components 1268
Lubrication Controller Adjustment 1268
SYSTEM TROUBLESHOOTING CHART 1270
PREVENTATIVE MAINTENANCE 1272
Daily Lubrication System Inspection 1272
250 Hour Inspection 1272
1000 Hour Inspection 1273
PUMP REBUILD 1274
Disassembly 1274
Cleaning and Inspection 1277
Assembly 1277
SECTION R SCHEMATICS 1279
EM3670 1281
EM5433 0
XS9600_1 1284
XS9600_2 1285
XS9600_3 1286
XS9600_4 1287
XS9600_5 1288
XS9600_6 1289
XS9600_7 1290
XS9600_8 1291
XS9600_9 1292
XS9600_10 1293
XS9600_11 1294
XS9600_12 1295
XS9600_13 1296
XS9600_14 1297
XS9600_15 1298
XS9600_16 1299
XS9600_17 1300
XS9600_18 1301
XS9600_19 1302
XS9600_20 1303
XS9600_21 1304
XS9600_22 1305
XS9690 sheet 1 page 1 1306
XS9690 sheet 1 page 2 1307
XS9690 sheet 1 page 3 1308
XS9690 sheet 1 page 4 1309
XS9690 sheet 2 page 1 1310
XS9690 sheet 2 page 2 1311
XS9690 sheet 2 page 3 1312
XS9690 sheet 2 page 4 1313

DESCRIPTION:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM023701  – PDF DOWNLOAD

• SERIAL NUMBERS A30109 – A30110 A40111 & UP
• ENGINE  SSA16V159

• 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 per- forming 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 pro- vided 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 manu- facturing 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 totall 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.
• NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations must be removed as often as practical

G.B  21/12/24