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KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SEN05273-05 – PDF DOWNLOAD
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Description
KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SEN05273-05 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SEN05273-05 – PDF DOWNLOAD
Language : English
Pages : 1320
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SEN05273-05 – PDF DOWNLOAD
COVER............................................................................................................ 1 FOREWORD......................................................................................................... 5 TABLE OF CONTENTS................................................................................................ 7 SECTION A GENERAL INFORMATION INDEX.............................................................................. 9 SECTION A2 - MAJOR COMPONENTS AND SPECIFICATIONS............................................................. 11 SECTION A3 - SAFETY - INDEX.................................................................................. 15 SAFETY................................................................................................... 17 Safety Rules......................................................................................... 17 Safety Features...................................................................................... 17 Clothing And Personal Items.......................................................................... 17 Unauthorized Modification............................................................................ 17 Leaving The Operator’s Seat.......................................................................... 17 Mounting And Dismounting............................................................................. 18 Fire Prevention For Fuel And Oil..................................................................... 18 Precautions With High Temperature Fluids............................................................. 18 Asbestos Dust Hazard Prevention...................................................................... 19 Prevention Of Injury By Work Equipment............................................................... 19 Fire Extinguisher And First Aid Kit.................................................................. 19 Precautions For ROPS................................................................................. 19 Precautions For Attachments.......................................................................... 19 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 SECTION A4 - WARNINGS AND CAUTIONS........................................................................... 53 SECTION A5 - STANDARD TABLES................................................................................. 59 SECTION A7 - STORAGE PROCEDURES - INDEX...................................................................... 67 STORAGE AND IDLE MACHINE PREPARATION..................................................................... 69 SHORT TERM IDLE PERIODS.............................................................................. 69 PREPARATION FOR STORAGE.............................................................................. 69 REMOVAL FROM STORAGE................................................................................. 70 RECONDITIONING AN IDLE VEHICLE....................................................................... 72 ENGINE OPERATION..................................................................................... 75 AFTER THE ENGINE HAS STARTED......................................................................... 75 SHORT TERM ENGINE STORAGE............................................................................ 76 Preparing the Engine............................................................................. 76 Removing the Engine from Long Term Storage....................................................... 78 TRANSMISSION PRESERVATION AND STORAGE................................................................ 78 Storage, New Transmission........................................................................ 78 Storage, One Year- Without Oil................................................................... 78 Storage, One Year - With Oil - Normally Installed On The Truck................................... 79 Restoring The Transmission For Service........................................................... 79 SECTION B - STRUCTURES - INDEX................................................................................... 81 SECTION B2 - STRUCTURAL COMPONENTS - INDEX................................................................... 83 STRUCTURAL COMPONENTS.................................................................................... 85 PREPARATION.......................................................................................... 85 GRILLE, HOOD AND LADDERS............................................................................. 86 DECKS............................................................................................ 87 CENTER DECK.......................................................................................... 87 Removal.......................................................................................... 87 Installation..................................................................................... 87 RIGHT DECK AND COMPONENTS........................................................................ 87 Removal...................................................................................... 87 Installation................................................................................. 87 LEFT DECK AND CAB................................................................................ 88 Installation................................................................................. 88 SECTION B3 - DUMP BODY - INDEX.............................................................................. 89 DUMP BODY................................................................................................ 91 Removal.............................................................................................. 91 Installation......................................................................................... 93 BODY PADS............................................................................................ 93 Body Pad Adjustment.............................................................................. 94 BODY GUIDE........................................................................................... 94 BODY-UP RETENTION CABLE.............................................................................. 95 ROCK EJECTORS........................................................................................ 95 Inspection....................................................................................... 95 SECTION B4 - FUEL TANK - INDEX............................................................................... 97 FUEL TANK................................................................................................ 99 Removal.............................................................................................. 99 Cleaning............................................................................................. 100 Repair............................................................................................... 100 Installation......................................................................................... 100 FUEL GAUGE AND SENDING UNIT.......................................................................... 101 Removal.......................................................................................... 101 Installation..................................................................................... 101 WIGGINS QUICK FILL FUEL SYSTEM....................................................................... 101 FUEL RECEIVER.................................................................................... 101 FUEL TANK BREATHER............................................................................... 102 Removal...................................................................................... 102 Installation................................................................................. 102 Disassembly.................................................................................. 102 Assembly..................................................................................... 102 LEFT SIDE FILL................................................................................... 103 SECTION C - ENGINE - INDEX...................................................................................... 105 SECTION C3 - COOLING SYSTEM - INDEX.......................................................................... 107 COOLING SYSTEM........................................................................................... 109 DESCRIPTION.......................................................................................... 109 LEAKS AND CONTAMINATION.............................................................................. 110 RADIATOR FILL PROCEDURE.............................................................................. 110 RADIATOR REMOVAL..................................................................................... 111 RADIATOR REPAIR.................................................................................. 112 Internal Inspection.......................................................................... 112 External Cleaning............................................................................ 112 Disassembly.................................................................................. 113 Cleaning and Inspection...................................................................... 114 Assembly..................................................................................... 114 Pressure Testing............................................................................. 115 Additional Service Information............................................................... 115 RADIATOR INSTALLATION................................................................................ 116 TRANSMISSION AND BRAKE COOLERS................................................................... 117 Removal...................................................................................... 118 Disassembly.................................................................................. 118 Cleaning And Inspection...................................................................... 119 Assembly..................................................................................... 119 Inspection................................................................................... 120 Installation................................................................................. 121 SECTION C4 - ENGINE - INDEX.................................................................................. 123 ENGINE................................................................................................... 125 Removal.............................................................................................. 125 Inspection........................................................................................... 128 Installation......................................................................................... 129 DRIVE LINE ADAPTER................................................................................... 130 Removal.......................................................................................... 131 Disassembly...................................................................................... 132 Cleaning and Inspection.......................................................................... 134 Assembly......................................................................................... 136 Installation..................................................................................... 140 Bearing Tools.................................................................................... 141 SECTION C5 - AIR FILTRATION SYSTEM - INDEX................................................................... 143 AIR FILTRATION SYSTEM.................................................................................... 145 AIR CLEANER.......................................................................................... 145 Operation........................................................................................ 145 AIR CLEANER MAINTENANCE.......................................................................... 145 Filter Service Indicator..................................................................... 147 Replacing The Elements....................................................................... 147 MAIN FILTER CLEANING............................................................................. 148 PRECLEANER CLEANING.............................................................................. 149 AIR INTAKE TROUBLESHOOTING........................................................................... 150 SECTION C7 - FAN CLUTCH - INDEX.............................................................................. 151 FAN CLUTCH............................................................................................... 153 REMOVAL & INSTALLATION TOOLING....................................................................... 153 FAN CLUTCH - DISASSEMBLY............................................................................. 156 CLEANING AND INSPECTION.............................................................................. 166 ASSEMBLY - FAN CLUTCH................................................................................ 170 TEST PROCEDURE....................................................................................... 184 SECTION D - ELECTRICAL SYSTEM - INDEX............................................................................ 185 SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX........................................................... 187 BATTERIES AND STARTING SYSTEM............................................................................ 189 BATTERIES............................................................................................ 189 MAINTENANCE AND SERVICE.......................................................................... 189 Electrolyte Levels........................................................................... 189 Cleaning..................................................................................... 189 Other Maintenance............................................................................ 190 ENGINE PRELUB™ SYSTEM................................................................................ 192 OPERATION........................................................................................ 192 Oil Pressure Switch.......................................................................... 194 Check Valve.................................................................................. 194 Timer Solenoid............................................................................... 194 MAINTENANCE...................................................................................... 194 Prelub™ System Operation..................................................................... 194 Prelub Pump.................................................................................. 194 Check Valve.................................................................................. 195 Timer Solenoid............................................................................... 195 PRELUB CIRCUIT TROUBLESHOOTING................................................................... 196 STARTING SYSTEM...................................................................................... 198 CRANKING MOTORS.................................................................................. 198 Removal...................................................................................... 198 Disassembly.................................................................................. 199 Cleaning and Inspection...................................................................... 199 Armature Servicing........................................................................... 199 Field Coil Checks............................................................................ 200 Field Coil Removal........................................................................... 200 Solenoid Checks.............................................................................. 202 Assembly..................................................................................... 203 Installation................................................................................. 205 TROUBLESHOOTING.................................................................................. 205 Preliminary Inspection....................................................................... 205 No-Load Test................................................................................. 205 Interpreting The Results of The Tests........................................................ 206 MAGNETIC SWITCH.................................................................................. 207 Removal...................................................................................... 207 Installation................................................................................. 207 Coil Test.................................................................................... 207 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX............................................................ 209 ELECTRICAL SYSTEM COMPONENTS............................................................................. 211 CAB MOUNTED COMPONENTS............................................................................... 211 CIRCUIT BREAKERS................................................................................. 213 RELAY CENTER..................................................................................... 214 FUSE PANEL....................................................................................... 219 EXTERIOR COMPONENTS.................................................................................. 223 BATTERY BOX...................................................................................... 223 BATTERY DISCONNECT SWITCH........................................................................ 223 GROUND LEVEL SHUT OFF SWITCH..................................................................... 223 CONTROL POWER RELAYS............................................................................. 223 CIRCUIT BREAKERS................................................................................. 223 BATTERY EQUALIZER................................................................................ 223 Test......................................................................................... 223 BODY POSITION SWITCHES........................................................................... 225 Proximity Switch Operation................................................................... 225 Body-Up Switch Adjustment.................................................................... 226 Hoist Limit Switch Adjustment................................................................ 226 SPEED SENSORS.................................................................................... 228 Sensor Adjustment............................................................................ 229 GENERAL TROUBLESHOOTING.............................................................................. 229 SECTION D10 - CHARGING SYSTEM - INDEX........................................................................ 231 CHARGING SYSTEM.......................................................................................... 233 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION........................................................ 233 Excessive heat................................................................................... 233 Dirt and dust.................................................................................... 233 Vibration........................................................................................ 233 PREVENTIVE MAINTENANCE PROCEDURES.................................................................... 234 Alternator Cleanliness........................................................................... 234 Alternator Mounting.............................................................................. 234 Belt Tension And Condition....................................................................... 234 TROUBLESHOOTING...................................................................................... 234 ALTERNATOR PERFORMANCE TEST...................................................................... 234 ALTERNATOR CABLE TEST............................................................................ 235 VOLTAGE REGULATOR ADJUSTMENT......................................................................... 236 ALTERNATOR........................................................................................... 237 Removal.......................................................................................... 237 Installation..................................................................................... 238 SECTION D15 - MACHINE MONITOR - INDEX........................................................................ 241 MACHINE MONITOR.......................................................................................... 243 CHARACTER DISPLAY.................................................................................... 243 Mode Select Switches 1 & 2....................................................................... 244 Service Meter.................................................................................... 244 Odometer......................................................................................... 244 Operation Information............................................................................ 244 Reverse Travel Odometer.......................................................................... 245 Filter And Oil Change Display.................................................................... 245 Display Items.................................................................................... 246 Resetting The Filter/Oil Replacement Meter....................................................... 246 Inputting Telephone Numbers...................................................................... 247 Selecting A Language............................................................................. 247 ACTION CODE DISPLAYS................................................................................. 248 E03 Codes........................................................................................ 248 E02 Codes........................................................................................ 249 E01 Codes........................................................................................ 249 REAL TIME MONITOR.................................................................................... 250 USING REAL TIME MONITOR.......................................................................... 250 Viewing Two Streams of Data At Once.......................................................... 251 MACHINE MONITOR FLOW CHART....................................................................... 256 SECTION D20 - FAILURE CODES - INDEX.......................................................................... 261 FAILURE CODES............................................................................................ 263 ACTION CODE DISPLAYS................................................................................. 263 CHECKING FAILURE CODES............................................................................... 264 LIMP HOME MODE....................................................................................... 265 FAILURE CODE TABLE................................................................................... 266 SECTION D21 - TROUBLESHOOTING................................................................................ 283 FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES........................................................ 283 FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION............................................... 284 FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR............................................ 286 FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR............................................ 286 FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 287 FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING........................................................... 288 FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 290 FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING.............................................................. 292 FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING............................................................... 294 FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING............................................................... 296 FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING............................................................... 298 FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING............................................................... 300 FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF................................. 302 FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION.......................................................... 304 FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF.............................. 306 FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION...................................................... 310 FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 312 FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION....................................................... 316 FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 318 FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION....................................................... 322 FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 324 FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION....................................................... 328 FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 330 FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION....................................................... 334 FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION.................................................... 336 FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 337 FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION....................................................... 340 FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING............................................................... 342 FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION........................................................... 344 FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION..................................................... 345 FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE...................................................... 346 FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR............................................. 347 FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE.................................................. 348 FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE........................................... 349 FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE........................................... 350 FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION...................................................... 351 FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED...................................... 352 FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION............................................................ 353 FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE................................................ 354 FAILURE CODE [B@BCNS] ENGINE: OVERHEAT................................................................... 355 FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW........................................................ 356 FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING............................................. 357 FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING........................................ 358 FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING......................................... 359 FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING.................................................. 360 FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION...................................... 361 FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION.................................... 362 FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION.................................... 363 FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION................................................... 364 FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR............................................... 366 FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW.................................. 370 FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW........................... 371 FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR..................................... 372 FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR....................................... 373 FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR...................................... 374 FAILURE CODE [DAQV00] NEUTRAL COAST CAUTION.............................................................. 375 FAILURE CODE [DAQW00] NEUTRAL OVER SPEED CAUTION......................................................... 376 FAILURE CODE [DAS0MA] ENGINE MALFUNCTION: RED INDICATOR LIGHT............................................ 377 FAILURE CODE [DAS0MC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT.......................................... 378 FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR........................................................ 379 FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR........................... 380 FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION............................. 381 FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW................ 382 FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR......................................... 383 FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR........................................... 384 FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR.......................................... 386 FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR.......................................................... 387 FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT................................................ 388 FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE............................................. 390 FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT.......................................................... 392 FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT......................................................... 393 FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT....................................................... 394 FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT...................................................... 395 FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT................................................ 396 FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT.............................................. 398 FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 400 FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 402 FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 404 FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 406 FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT........................................... 408 FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 410 FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT.......................................................... 412 FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT......................................................... 416 FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE..................... 419 FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND...................... 420 FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT................ 421 FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND....................... 422 FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT................. 423 FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT............... 424 FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND..................... 425 FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE................. 426 FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 427 FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 428 FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 429 FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 430 FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 431 FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................. 432 FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE........................... 433 FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION............................ 434 FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE.......................... 435 FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION........................... 436 FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT.................................................... 437 FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE............................................. 438 FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT......................................... 439 FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE......................................... 440 FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE................................................... 442 FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION............................................ 443 FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT.................................................. 444 FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION................................................... 445 FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT................................ 446 FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION................................. 447 FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT......................... 448 FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION.......................... 449 FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION......................................... 450 FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION.......................................... 451 FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 452 FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 453 FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 454 FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 455 FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 456 FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL.... 457 FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT........................................ 458 FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT......................................... 459 FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT.................................... 460 FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT................................... 461 FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE.............................................. 462 FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT.............................. 463 FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)........................................ 464 FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT........................................................ 465 FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT....................................................... 466 FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER...................................................... 467 FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................................ 468 FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)....................... 470 FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT....................................... 472 FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT...................................... 473 FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER..................................... 474 FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)............... 475 FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)........................ 476 FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT........................................ 478 FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT....................................... 479 FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER...................................... 480 FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION......................................... 481 FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION..................................... 482 FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT......................................... 484 FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT........................................ 485 FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER....................................... 486 FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................. 487 FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT.................................... 488 FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT................................... 489 FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................. 490 FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT...................................... 492 FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT..................................... 494 FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................... 496 FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 500 FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 502 FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 504 FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 508 FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 510 FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 512 FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 516 FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 518 FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 520 FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 524 FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 526 FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 528 FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT......................................... 532 FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT........................................ 534 FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER....................................... 536 FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 540 FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 542 FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 544 SECTION D30 - VHMS INITIALIZATION - INDEX.................................................................... 547 INITIALIZATION OF VHMS CONTROLLER........................................................................ 549 Executing Quick PM................................................................................... 560 Downloading Existing VHMS Setting Data............................................................... 565 Confirmation of Downloaded Data...................................................................... 566 Disconnecting the PC................................................................................. 566 Reporting to Komatsu................................................................................. 566 REPLACING THE VHMS CONTROLLER............................................................................ 568 Prior to Removing VHMS Controller.................................................................... 568 Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)......................... 568 Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)..................... 572 Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)............................ 574 Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)........................ 575 FINAL VHMS PROCEDURES-POST INSTALLATION.................................................................. 576 Correct the Load Weight Calculation.................................................................. 578 SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX.............................................................. 587 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX....................................................... 589 TORQUE CONVERTER AND TRANSMISSION........................................................................ 591 TRANSMISSION......................................................................................... 591 TORQUE CONVERTER..................................................................................... 592 MAIN RELIEF VALVE................................................................................ 594 Function..................................................................................... 594 Operation.................................................................................... 594 TORQUE CONVERTER RELIEF VALVE.................................................................... 594 Function..................................................................................... 594 Operation.................................................................................... 594 TORQUE CONVERTER REGULATOR VALVE................................................................. 596 Operation.................................................................................... 596 LOCK-UP CLUTCH................................................................................... 597 Lock-up Clutch Accumulator................................................................... 597 HYDRAULIC PUMP................................................................................... 598 TORQUE CONVERTER STALL CHECK..................................................................... 599 TRANSMISSION..................................................................................... 600 LUBRICATION RELIEF VALVE......................................................................... 602 Function..................................................................................... 602 TRANSMISSION CONTROL VALVE....................................................................... 603 ELECTRONIC CONTROL MODULATION VALVE (ECMV)....................................................... 605 Pressure Control Valve....................................................................... 606 Flow Sensor Valve............................................................................ 606 ECMV and Proportional Solenoid............................................................... 606 ECMV and Fill Switch......................................................................... 606 ECMV Operation............................................................................... 607 ECMV REPAIR PROCEDURE............................................................................ 610 Filter Replacement Procedure................................................................. 610 ECMV Removal................................................................................. 611 Disassembly.................................................................................. 611 Assembly..................................................................................... 612 ECMV Identification.......................................................................... 613 TRANSMISSION FILTERS............................................................................. 614 Service...................................................................................... 614 Installation................................................................................. 614 TRANSMISSION REMOVAL............................................................................. 615 TRANSMISSION INSTALLATION........................................................................ 616 TRANSMISSION OIL LEVEL CHECK..................................................................... 618 SECTION F3 - TRANSMISSION OIL COOLER AND STRAINERS - INDEX................................................... 619 TRANSMISSION OIL COOLER & STRAINERS...................................................................... 621 TRANSMISSION OIL COOLER.............................................................................. 621 Removal and Installation......................................................................... 621 Repair........................................................................................... 621 TRANSMISSION OIL STRAINER............................................................................ 621 Removal.......................................................................................... 622 Inspection....................................................................................... 622 Installation..................................................................................... 622 SECTION F5 - DRIVE SHAFTS - INDEX............................................................................ 623 DRIVE SHAFTS............................................................................................. 625 FRONT DRIVE SHAFT.................................................................................... 625 Removal.......................................................................................... 625 Disassembly...................................................................................... 625 Assembly......................................................................................... 625 Installation..................................................................................... 626 FRONT DRIVE SHAFT ALIGNMENT...................................................................... 627 REAR DRIVE SHAFT..................................................................................... 630 Removal.......................................................................................... 630 Disassembly...................................................................................... 631 Assembly......................................................................................... 631 Installation..................................................................................... 631 SECTION F8 - TORQUE CONVERTER REBUILD - INDEX................................................................ 633 TORQUE CONVERTER REBUILD................................................................................. 635 REMOVAL.............................................................................................. 635 INSTALLATION......................................................................................... 637 DISASSEMBLY.......................................................................................... 639 PTO COVER DISASSEMBLY............................................................................ 647 CLEANING & INSPECTION................................................................................ 648 TABLE I. COMPONENT WEAR LIMITS................................................................... 649 TABLE II. Gear Backlash.......................................................................... 649 ASSEMBLY............................................................................................. 650 ONE-WAY CLUTCH ASSEMBLY.......................................................................... 651 STATOR BEARING PRE-LOAD ADJUSTMENT............................................................... 653 PTO DRIVE ASSEMBLY............................................................................... 656 SPECIAL TOOLS........................................................................................ 662 SECTION F9 - TRANSMISSION REBUILD - INDEX.................................................................... 663 TRANSMISSION DISASSEMBLY................................................................................. 665 Number One Clutch Housing Disassembly................................................................ 671 Bearing Cage & Cover Disassembly..................................................................... 673 Number Four Carrier Disassembly...................................................................... 674 Output Shaft Cover Disassembly....................................................................... 676 Rear Case Bearing Removal............................................................................ 676 Output Shaft Removal................................................................................. 676 Output Shaft Disassembly............................................................................. 677 Number Five/Six Carrier Disassembly.................................................................. 677 CLEANING AND INSPECTION.................................................................................. 678 INSPECTION TABLE INDEX............................................................................... 678 TRANSMISSION ASSEMBLY.................................................................................... 684 GENERAL INSTRUCTIONS................................................................................. 684 Number Five/Six Carrier Assembly................................................................. 684 Output Shaft Assembly............................................................................ 685 Number Seven Clutch Assembly..................................................................... 686 Rear Case Assembly............................................................................... 687 Rear Case & Carrier Assembly..................................................................... 687 Number Six Clutch Assembly....................................................................... 689 Number Four Carrier Assembly..................................................................... 690 Number Four Carrier Bearing Cage Assembly........................................................ 691 Number Five Clutch Assembly...................................................................... 691 Number Four Clutch Assembly...................................................................... 692 Number Three Clutch Assembly..................................................................... 692 Clutch Test...................................................................................... 693 Number Two Clutch Ring Gear Installation......................................................... 693 Number Three Carrier & Number Two Clutch Assembly................................................ 694 Number One Carrier Assembly...................................................................... 694 Checks Prior to Final Assembly................................................................... 701 Final Assembly................................................................................... 702 Input Shaft Installation......................................................................... 703 External Components.............................................................................. 705 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX.............................................................. 707 SECTION G2 - TIRES AND RIMS - INDEX.......................................................................... 709 TIRES AND RIMS........................................................................................... 711 GENERAL INFORMATION.................................................................................. 711 FRONT TIRES AND RIMS................................................................................. 712 Removal.......................................................................................... 712 Installation..................................................................................... 713 REAR TIRE AND RIM.................................................................................... 713 Removal.......................................................................................... 713 Installation..................................................................................... 715 TIRE MATCHING........................................................................................ 715 RIM.................................................................................................. 716 Tire Removal From Rim............................................................................ 716 Tire Installation On Rim......................................................................... 716 FRONT WHEEL STUD INSTALLATION........................................................................ 717 REAR WHEEL STUD INSTALLATION......................................................................... 718 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX............................................................. 721 FRONT WHEEL HUB AND SPINDLE.............................................................................. 723 OIL SAMPLE ANALYSIS.................................................................................. 723 Oil Sampling Guidelines.......................................................................... 723 Guidelines For Obtaining A Sample................................................................ 723 FRONT WHEEL HUB...................................................................................... 724 Removal.......................................................................................... 724 Disassembly...................................................................................... 724 Inspection....................................................................................... 724 Assembly......................................................................................... 725 Installation..................................................................................... 727 Front Wheel Hub Bearing Adjustment............................................................... 727 FRONT SPINDLE........................................................................................ 728 A-ARM................................................................................................ 728 Removal.......................................................................................... 728 Inspection....................................................................................... 728 Installation..................................................................................... 728 CENTER TIE ROD PIVOT................................................................................. 729 Removal.......................................................................................... 729 Inspection....................................................................................... 729 Installation..................................................................................... 729 TOE IN ADJUSTMENT.................................................................................... 730 Adjustment Procedure............................................................................. 730 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX................................................................... 735 REAR AXLE ATTACHMENTS.................................................................................... 737 CENTER LINK AND LOWER LINKS.......................................................................... 737 Removal.......................................................................................... 737 Inspection....................................................................................... 738 Spherical Bearing Replacement.................................................................... 738 Installation..................................................................................... 738 PANHARD ROD (DIAGONAL LINK).......................................................................... 739 Removal.......................................................................................... 739 Inspection....................................................................................... 740 Installation..................................................................................... 740 SECTION G5 -REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX...................................................... 741 REAR AXLE & FINAL DRIVE ASSEMBLY......................................................................... 743 DIFFERENTIAL OPERATION............................................................................... 743 Straight-away-travel............................................................................. 743 Turning.......................................................................................... 743 REAR AXLE ASSEMBLY............................................................................... 744 Removal...................................................................................... 744 Installation................................................................................. 744 DIFFERENTIAL OIL LEVEL CHECK..................................................................... 745 DIFFERENTIAL ASSEMBLY............................................................................ 746 Removal...................................................................................... 746 Installation................................................................................. 747 Disassembly.................................................................................. 747 Pinion Carrier Assembly...................................................................... 750 Differential Gear Unit....................................................................... 750 Differential Gear Unit....................................................................... 751 Cleaning and Inspection...................................................................... 754 Assembly..................................................................................... 754 Differential Bearing......................................................................... 754 Assembly Of Differential Gear Assembly....................................................... 754 Installation Of Differential Assembly........................................................ 756 Input Pinion and Carrier Assembly............................................................ 757 Adjusting Tooth Contact, Backlash............................................................ 761 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX.................................................. 765 FINAL DRIVE PLANETARIES AND WHEEL HUBS................................................................... 767 FINAL DRIVE.......................................................................................... 767 Oil Level Check.................................................................................. 768 FINAL DRIVE CARRIER ASSEMBLY..................................................................... 768 Removal...................................................................................... 768 Installation................................................................................. 769 Disassembly.................................................................................. 769 Assembly..................................................................................... 770 FINAL DRIVE ASSEMBLY............................................................................. 771 Disassembly.................................................................................. 771 Assembly..................................................................................... 773 SECTION H - SUSPENSIONS - INDEX.................................................................................. 775 SECTION H2 - FRONT SUSPENSION - INDEX........................................................................ 777 FRONT SUSPENSION......................................................................................... 779 Removal.............................................................................................. 781 Installation......................................................................................... 782 Disassembly.......................................................................................... 783 Cleaning and Inspection.............................................................................. 785 Assembly............................................................................................. 785 Pressure Tests....................................................................................... 786 DAMPING VALVE REPAIR................................................................................. 787 Disassembly...................................................................................... 787 Assembly......................................................................................... 788 SECTION H3 - REAR SUSPENSION - INDEX......................................................................... 789 REAR SUSPENSION.......................................................................................... 791 Operation............................................................................................ 792 Removal.............................................................................................. 793 Installation......................................................................................... 793 Disassembly.......................................................................................... 793 Cleaning and Inspection.............................................................................. 797 Assembly............................................................................................. 797 LEAK TESTING......................................................................................... 798 SPHERICAL BEARINGS................................................................................... 798 Removal.......................................................................................... 798 Inspection....................................................................................... 798 Installation..................................................................................... 798 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX.......................................................... 799 SUSPENSION OILING AND CHARGING........................................................................... 801 GENERAL INFORMATION.................................................................................. 801 Equipment List................................................................................... 801 FRONT SUSPENSION..................................................................................... 803 Front Suspension Oiling.......................................................................... 803 Front Suspension Nitrogen Charging............................................................... 806 REAR SUSPENSION...................................................................................... 808 GENERAL INFORMATION.............................................................................. 808 Rear Suspension Oiling....................................................................... 808 Rear Suspension Nitrogen Charging............................................................ 812 FRONT AND REAR CYLINDER LENGTH ADJUSTMENT............................................................ 812 SECTION J - BRAKE SYSTEM - INDEX................................................................................. 815 SECTION J2- BRAKE SYSTEM OPERATION - INDEX................................................................... 817 BRAKE SYSTEM OPERATION................................................................................... 819 DESCRIPTION.......................................................................................... 819 SERVICE BRAKE OPERATION.............................................................................. 820 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 820 BRAKE SYSTEM COMPONENTS.............................................................................. 822 BRAKE MANIFOLD CARTRIDGE VALVES...................................................................... 824 SERVICE BRAKE CIRCUIT................................................................................ 828 RETARDING CIRCUIT................................................................................ 830 PARKING BRAKE CIRCUIT............................................................................ 832 AUTO APPLY....................................................................................... 834 AUXILIARY BRAKE CIRCUIT.......................................................................... 836 BRAKE LOCK CIRCUIT............................................................................... 838 AUTOMATIC SPIN REGULATOR......................................................................... 840 BRAKE COOLING CIRCUIT................................................................................ 842 BRAKE COOLING VALVE.............................................................................. 843 COLD OIL DIVERTER VALVES......................................................................... 846 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX......................................................... 847 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 849 BRAKE VALVE.......................................................................................... 850 Rebuild Criteria................................................................................. 850 Removal.......................................................................................... 850 Installation..................................................................................... 851 Disassembly...................................................................................... 852 Cleaning and Inspection.......................................................................... 853 Assembly......................................................................................... 855 Actuator Base Threaded Inserts................................................................... 855 Boot and Cap..................................................................................... 855 Valve Body Seal Installation..................................................................... 855 Regulator Sleeve O-Ring Installation............................................................. 855 Actuator Plunger O-ring Installation............................................................. 856 Assembly of Valve................................................................................ 857 BENCH TEST AND ADJUSTMENT............................................................................ 858 Test Bench Only.................................................................................. 858 Test Set Up Procedure............................................................................ 858 Brake Valve Output Pressure Adjustment........................................................... 860 Final Test and Adjustment........................................................................ 861 Proximity Switch Installation and Adjustment..................................................... 863 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 863 BRAKE ACCUMULATORS................................................................................... 864 Removal.......................................................................................... 865 Installation..................................................................................... 865 Disassembly...................................................................................... 865 Cleaning and Inspection.......................................................................... 867 Assembly......................................................................................... 867 Leak Testing..................................................................................... 869 ACCUMULATOR CHARGING................................................................................. 870 Temperature During Precharge..................................................................... 872 ACCUMULATOR STORAGE.................................................................................. 873 Installation..................................................................................... 873 BRAKE COOLING VALVE (BCV)............................................................................ 874 RETARDER CONTROL LEVER............................................................................... 875 Removal.......................................................................................... 875 Installation..................................................................................... 875 Disassembly and Adjustment....................................................................... 875 Potentiometer Check.............................................................................. 877 Assembly......................................................................................... 877 Retard Lever Calibration......................................................................... 878 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX.................................................................. 879 BRAKE CIRCUIT CHECK-OUT.................................................................................. 881 REQUIRED EQUIPMENT................................................................................... 881 PREPARATION.......................................................................................... 881 BRAKE CIRCUIT TESTING................................................................................ 882 Initial System Setup............................................................................. 882 Parking Brake.................................................................................... 883 Brake Lock....................................................................................... 884 Low-Brake Pressure and Auto-Apply................................................................ 884 Validation....................................................................................... 885 Retarding........................................................................................ 885 BRAKE SYSTEM DATA SHEET.............................................................................. 886 BRAKE CIRCUIT TROUBLESHOOTING........................................................................ 889 SECTION J5 - FRONT WET DISC BRAKES - INDEX................................................................... 893 FRONT WET DISC BRAKES.................................................................................... 895 BRAKE MAINTENANCE.................................................................................... 896 Checking Disc Wear............................................................................... 896 FRONT BRAKE ASSEMBLY................................................................................. 898 Removal.......................................................................................... 898 Installation..................................................................................... 898 Disassembly...................................................................................... 898 Cleaning and Inspection.......................................................................... 899 Assembly......................................................................................... 900 Floating Seal Installation....................................................................... 903 BRAKE BLEEDING....................................................................................... 906 SECTION J6 - REAR WET DISC BRAKES - INDEX.................................................................... 907 REAR WET DISC BRAKES..................................................................................... 909 DESCRIPTION.......................................................................................... 909 OPERATION............................................................................................ 909 MAINTENANCE.......................................................................................... 910 Checking Brake Disc Wear......................................................................... 910 REMOVAL.......................................................................................... 911 INSTALLATION..................................................................................... 912 BRAKE REBUILD.................................................................................... 914 Disassembly.................................................................................. 914 Cleaning and Inspection...................................................................... 915 Assembly..................................................................................... 915 Floating Ring Seal Assembly/Installation..................................................... 916 WET DISC BRAKE BLEEDING.......................................................................... 920 SECTION J7 - PARKING BRAKE - INDEX........................................................................... 921 PARKING BRAKE............................................................................................ 923 Description.......................................................................................... 923 Parking Brake Service Criteria....................................................................... 923 Removal.............................................................................................. 924 Installation......................................................................................... 924 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................................ 926 Removal.......................................................................................... 926 Installation..................................................................................... 926 AUTOMATIC SLACK ADJUSTER............................................................................. 926 Adjustment Procedure............................................................................. 926 PARKING BRAKE CHECK-OUT.............................................................................. 927 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................. 929 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX............................................................... 931 HYDRAULIC SYSTEM OVERVIEW................................................................................ 933 SYSTEM COMPONENTS.................................................................................... 933 HYDRAULIC TANK................................................................................... 933 BLEED-DOWN MANIFOLD.............................................................................. 935 HOIST VALVE...................................................................................... 935 HOIST PUMP....................................................................................... 935 BRAKE COOLING PUMP............................................................................... 936 BRAKE CONTROL VALVE (BCV)........................................................................ 936 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX....................................................... 937 HYDRAULIC COMPONENT REPAIR............................................................................... 939 HYDRAULIC TANK....................................................................................... 939 FILLING INSTRUCTIONS............................................................................. 939 MAINTENANCE...................................................................................... 939 Removal...................................................................................... 940 Installation................................................................................. 942 Gap Measurement - Hydraulic Tank Mounting.................................................... 942 STRAINERS AND DIFFUSERS.......................................................................... 943 Removal...................................................................................... 943 Cleaning and Inspection...................................................................... 943 Installation................................................................................. 944 HYDRAULIC TANK BREATHER.............................................................................. 944 Service.......................................................................................... 945 HYDRAULIC SYSTEM FLUSHING............................................................................ 945 HYDRAULIC PUMPS...................................................................................... 946 Removal.......................................................................................... 946 Installation..................................................................................... 947 PUMP REBUILD..................................................................................... 948 Disassembly.................................................................................. 948 Inspection Of Parts.......................................................................... 951 Assembly..................................................................................... 951 Bearing Replacement.......................................................................... 954 Seal Replacement............................................................................. 954 TROUBLESHOOTING GUIDE............................................................................ 957 SECTION L4 - STEERING CIRCUIT - INDEX........................................................................ 959 STEERING CIRCUIT......................................................................................... 961 OPERATION............................................................................................ 961 COMPONENT DESCRIPTION................................................................................ 961 Steering Control Valve........................................................................... 961 Bleed-down Manifold.............................................................................. 961 Bleed-down Solenoid.............................................................................. 962 Accumulators..................................................................................... 963 Flow Amplifier................................................................................... 963 High Pressure Filter............................................................................. 963 Warning Devices.................................................................................. 963 FLOW AMPLIFIER OPERATION............................................................................. 965 STEERING/BRAKE PUMP.................................................................................. 973 COMPONENTS....................................................................................... 973 OPERATION........................................................................................ 975 SECTION L5 - STEERING CONTROL UNIT - INDEX................................................................... 977 STEERING CONTROL UNIT.................................................................................... 979 Removal.............................................................................................. 979 Installation......................................................................................... 979 REBUILD PROCEDURE.................................................................................... 980 Disassembly...................................................................................... 981 Cleaning and Inspection.......................................................................... 982 Assembly......................................................................................... 984 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX....................................................... 989 STEERING CIRCUIT COMPONENT REPAIR........................................................................ 991 BLEED-DOWN MANIFOLD.................................................................................. 991 Removal.......................................................................................... 991 Adjusting Relief Valve........................................................................... 991 Testing and Adjustment........................................................................... 992 FLOW AMPLIFIER................................................................................... 993 Removal...................................................................................... 993 Installation................................................................................. 993 Disassembly.................................................................................. 993 Assembly..................................................................................... 996 ACCUMULATORS..................................................................................... 997 Removal...................................................................................... 997 Installation................................................................................. 998 Disassembly.................................................................................. 999 Cleaning and Inspection...................................................................... 999 Assembly..................................................................................... 999 Leak Testing.................................................................................1000 STEERING ACCUMULATOR CHARGING....................................................................1002 Temperature During Precharge.................................................................1005 ACCUMULATOR STORAGE..............................................................................1005 Installation.................................................................................1006 STEERING CYLINDER................................................................................1007 Removal......................................................................................1007 Installation.................................................................................1007 STEERING CYLINDER REBUILD........................................................................1008 Disassembly..................................................................................1008 Cleaning and Inspection......................................................................1008 Assembly.....................................................................................1009 STEERING/BRAKE PUMP..............................................................................1009 Removal......................................................................................1009 Installation.................................................................................1010 PUMP REBUILD.....................................................................................1011 Disassembly..................................................................................1011 Control Group................................................................................1012 Valve Plate Group............................................................................1013 Rotating Group...............................................................................1013 Drive Shaft Group............................................................................1014 Swashblock Group.............................................................................1014 Inspection...................................................................................1014 Control Group................................................................................1014 Valve Plate Group............................................................................1015 Rotating Group...............................................................................1015 Swashblock Group.............................................................................1016 Drive Shaft Group............................................................................1016 Assembly.....................................................................................1016 Swashblock Group.............................................................................1016 Drive Shaft Group............................................................................1017 Rotating Group...............................................................................1017 Valve Plate Group............................................................................1018 Control Group................................................................................1019 STEERING CIRCUIT FILTER..........................................................................1020 Removal......................................................................................1020 Installation.................................................................................1020 TROUBLESHOOTING CHART................................................................................1021 SECTION L7 - HOIST CIRCUIT - INDEX...........................................................................1023 HOIST CIRCUIT............................................................................................1025 HOIST CIRCUIT OPERATION..............................................................................1025 COMPONENT DESCRIPTION............................................................................1026 Hydraulic Tank...............................................................................1026 Hoist Pump...................................................................................1026 Hoist Valve..................................................................................1026 Hoist Pilot Valve............................................................................1027 Power Up Solenoid............................................................................1028 Pilot Operated Check Valve...................................................................1028 Power Down Spool Limit Solenoid..............................................................1028 HOIST CIRCUIT HYDRAULIC FLOW.....................................................................1029 POWER UP.....................................................................................1031 HOLD.........................................................................................1033 POWER DOWN...................................................................................1035 FLOAT........................................................................................1037 SECTION L8 - HOIST CIRCUIT COMPONET REPAIR - INDEX...........................................................1039 HOIST CIRCUIT COMPONENT REPAIR...........................................................................1041 HOIST VALVE..........................................................................................1041 Removal..........................................................................................1041 Installation.....................................................................................1041 O-Ring Replacement...............................................................................1042 INLET SECTION....................................................................................1043 Disassembly..................................................................................1043 Cleaning and Inspection......................................................................1044 Assembly.....................................................................................1044 SPOOL SECTION....................................................................................1044 Disassembly..................................................................................1044 Cleaning and Inspection......................................................................1045 Assembly.....................................................................................1047 HOIST PILOT VALVE....................................................................................1048 Removal..........................................................................................1048 Installation.....................................................................................1048 Disassembly......................................................................................1049 Cleaning and Inspection..........................................................................1050 Assembly.........................................................................................1050 HOIST CYLINDERS......................................................................................1051 Removal..........................................................................................1051 Installation.....................................................................................1053 Disassembly......................................................................................1053 Cleaning and Inspection..........................................................................1055 Assembly - Quill And Cylinder....................................................................1056 Quill Installation...............................................................................1056 Installation Of Check Balls And Plugs In Quill...................................................1057 Assembly of Cylinder.............................................................................1058 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX................................................................1059 HYDRAULIC SYSTEM FILTERS.................................................................................1061 HIGH PRESSURE FILTER.................................................................................1061 Removal..........................................................................................1061 Installation.....................................................................................1062 LOW PRESSURE FILTERS.................................................................................1062 BRAKE COOLING & HOIST FILTERS....................................................................1062 TRANSMISSION FILTER..............................................................................1062 Removal......................................................................................1063 Installation.................................................................................1063 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX..........................................................1065 HYDRAULIC CHECK-OUT PROCEDURE............................................................................1067 GENERAL INFORMATION..................................................................................1067 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................................................1067 Equipment Requirements...........................................................................1068 Installation Of Gauges...........................................................................1068 Initial Startup And Flushing.....................................................................1068 Component Checkout And Adjustment................................................................1069 CHECKING HOIST SYSTEM PRESSURES......................................................................1071 Equipment Requirements...........................................................................1071 Steering Components Leakage Test.................................................................1073 HYDRAULIC SYSTEM CHECKOUT DATA SHEET.................................................................1074 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX....................................................................1075 SECTION M7 HOT START SYSTEM INDEX............................................................................1077 HOT START SYSTEM.........................................................................................1079 SYSTEM OPERATION.....................................................................................1079 HEATER INFORMATION...................................................................................1080 TROUBLESHOOTING GUIDELINES...........................................................................1082 SECTION M8 - SPECIAL TOOLS...................................................................................1083 SECTION N - OPERATOR CAB - INDEX.................................................................................1085 SECTION N2 - OPERATOR CAB - INDEX............................................................................1087 OPERATOR CAB.............................................................................................1089 Removal..............................................................................................1090 Installation.........................................................................................1092 CAB DOORS............................................................................................1092 Removal..........................................................................................1092 Installation.....................................................................................1093 Door Striker Adjustment..........................................................................1093 Door Handle Plunger Adjustment...................................................................1094 DOOR PANEL.......................................................................................1095 Removal......................................................................................1095 Installation.................................................................................1095 DOOR WINDOW......................................................................................1096 Removal......................................................................................1096 Installation.................................................................................1098 WINDOW REGULATOR.................................................................................1100 Removal......................................................................................1100 Installation.................................................................................1100 DOOR HANDLE AND DOOR LATCH.......................................................................1100 Removal......................................................................................1100 Installation.................................................................................1100 DOOR SEALS...........................................................................................1101 Removal..........................................................................................1101 Installation.....................................................................................1101 DOOR OPENING SEAL....................................................................................1101 Removal..........................................................................................1101 Installation.....................................................................................1101 GLASS REPLACEMENT....................................................................................1102 Replacement......................................................................................1102 WINDSHIELD AND REAR GLASS........................................................................1103 Removal......................................................................................1103 Installation.................................................................................1104 SECTION N3 CAB COMPONENTS INDEX..............................................................................1105 CAB COMPONENTS...........................................................................................1107 WINDSHIELD WIPERS....................................................................................1107 WIPER MOTOR......................................................................................1107 Removal......................................................................................1107 Installation.................................................................................1107 WIPER ARM........................................................................................1107 Removal......................................................................................1107 Installation.................................................................................1108 WIPER LINKAGE....................................................................................1108 Removal......................................................................................1108 Installation.................................................................................1108 WINDSHIELD WASHER....................................................................................1109 Operation........................................................................................1109 Service..........................................................................................1109 OPERATOR SEAT........................................................................................1110 Adjustment Controls..............................................................................1110 Seat Removal.....................................................................................1111 Seat Installation................................................................................1111 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX............................................................1113 HEATING AND AIR CONDITIONING.............................................................................1115 HEATER/AIR CONDITIONER UNIT..........................................................................1115 Fan Speed Control Knob...........................................................................1115 Temperature Control Knob.........................................................................1115 Air Flow Directional Knob........................................................................1115 Heater/Air Conditioner Vents.....................................................................1116 COMPONENTS...........................................................................................1116 Fuse.............................................................................................1116 Relays...........................................................................................1116 Heater Core......................................................................................1116 Fan Motor And Speed Control......................................................................1117 Actuators........................................................................................1117 Cab Air Filter...................................................................................1117 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.............................................................1120 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................1120 PRINCIPLES OF REFRIGERATION..........................................................................1120 Air Conditioning.................................................................................1120 Refrigeration - The Act Of Cooling...............................................................1121 The Refrigeration Cycle..........................................................................1121 AIR CONDITIONER SYSTEM COMPONENTS....................................................................1122 Compressor (Refrigerant Pump)....................................................................1122 Service Valves...................................................................................1122 Condenser........................................................................................1122 Receiver-Drier...................................................................................1122 Expansion Block Valve............................................................................1123 Accumulator......................................................................................1123 Evaporator.......................................................................................1123 ELECTRICAL CIRCUIT...................................................................................1124 Thermostat.......................................................................................1124 Compressor Clutch................................................................................1124 Trinary™ Switch..................................................................................1125 SYSTEM SERVICING.....................................................................................1126 SERVICE TOOLS AND EQUIPMENT..........................................................................1127 Recovery/Recycle Station.........................................................................1127 Leak Detector....................................................................................1127 Service Valves...................................................................................1128 Vacuum Pump......................................................................................1128 Manifold Gauge Set...............................................................................1129 Installing Manifold Gauge Set....................................................................1130 Purging Air From Service Hoses...................................................................1130 SYSTEM PERFORMANCE TEST..............................................................................1131 SYSTEM OIL...........................................................................................1132 Handling and Reusing PAG Oil.....................................................................1132 Oil Quantity.....................................................................................1132 Checking System Oil..............................................................................1132 REFRIGERANT..........................................................................................1133 Recycled Refrigerant.............................................................................1133 Reclaimed Refrigerant............................................................................1133 Refrigerant Quantity.............................................................................1133 R-134a Refrigerant Containers....................................................................1134 SYSTEM LEAK TESTING..................................................................................1134 Electronic Leak Detector.........................................................................1135 Tracer Dyes......................................................................................1135 Soap and Water...................................................................................1135 RECOVERING AND RECYCLING THE REFRIGERANT.............................................................1135 Draining Oil from the Previous Recovery Cycle....................................................1135 Performing the Recovery Cycle....................................................................1135 Performing the Recycling Procedure...............................................................1136 Evacuating and Charging the A/C System...........................................................1136 SYSTEM REPAIR........................................................................................1136 System Flushing..................................................................................1136 A/C DRIVE BELT CHECKOUT PROCEDURE....................................................................1137 Pulley Alignment.................................................................................1137 Belt Tension Check...............................................................................1137 COMPONENT REPLACEMENT................................................................................1139 Hoses and Fittings...............................................................................1139 Lines............................................................................................1139 Expansion Valve..................................................................................1139 Receiver-Drier...................................................................................1139 Thermostat.......................................................................................1139 Compressor.......................................................................................1140 Accumulator......................................................................................1140 Clutch...........................................................................................1140 Servicing the Compressor Clutch..................................................................1141 Pulley Removal...................................................................................1143 Clutch Coil Check................................................................................1144 Pulley Installation..............................................................................1144 Clutch Assembly Installation.....................................................................1144 EVACUATING THE SYSTEM................................................................................1146 CHARGING THE A/C SYSTEM..............................................................................1148 TROUBLESHOOTING..........................................................................................1149 Preliminary Checks...................................................................................1149 Diagnosis Of Gauge Readings And System Performance...................................................1149 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...........................................................1150 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...........................................................1156 SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX...............................................................1157 OPERATOR CAB AND CONTROLS................................................................................1159 STEERING WHEEL AND CONTROLS..........................................................................1160 Horn Button......................................................................................1160 ARSC Set Lever...................................................................................1160 Telescoping/Tilt Wheel Lever.....................................................................1160 Multi-Function Turn Signal Lever.................................................................1161 RETARDER CONTROL LEVER...............................................................................1161 STEERING WHEEL.......................................................................................1162 Removal..........................................................................................1162 Installation.....................................................................................1162 SERVICE BRAKE PEDAL..................................................................................1162 ACCELERATOR PEDAL....................................................................................1163 INSTRUMENT PANEL.....................................................................................1163 HEATER / AIR CONDITIONER CONTROLS....................................................................1163 RETARDING CAPACITY CHART.............................................................................1163 RADIO SPEAKERS.......................................................................................1164 AIR CLEANER VACUUM GAUGES............................................................................1164 WARNING ALARM BUZZER.................................................................................1164 AM/FM RADIO / CD PLAYER..............................................................................1164 CENTER CONSOLE.......................................................................................1165 Hoist Control Lever..............................................................................1166 Transmission Shift Lever.........................................................................1166 Parking Brake Switch.............................................................................1167 LH Window Control Switch.........................................................................1167 RH Window Control Switch.........................................................................1167 Auxiliary Power Outlets..........................................................................1167 INSTRUMENT PANEL AND INDICATORS......................................................................1168 UPPER RH SWITCH PANEL............................................................................1169 Brake Lock Switch............................................................................1169 F1 Start Switch..............................................................................1169 Hazard Warning Lights Switch.................................................................1169 LOWER RH SWITCH PANEL............................................................................1170 Key Switch...................................................................................1170 Ether Starting Aid Switch....................................................................1171 ASR Cut Switch...............................................................................1171 ARSC Switch..................................................................................1171 Automatic Idle Selector Switch (AISS)........................................................1171 Auxiliary Brake Switch.......................................................................1172 UPPER LH SWITCH PANEL............................................................................1173 Automatic Lubrication System Indicator.......................................................1173 LOWER LH SWITCH PANEL............................................................................1174 Head Light Switch............................................................................1174 Ladder Light Switch..........................................................................1174 BackUp/Deck Light Switch.....................................................................1175 Fog Light Switch.............................................................................1175 Mode Select Switches 1 & 2...................................................................1175 Panel Light Dimmer Switch....................................................................1175 ELECTRONIC DISPLAY PANEL.............................................................................1176 PILOT DISPLAY ITEMS..............................................................................1177 METER DISPLAYS...................................................................................1179 CAUTION ITEMS....................................................................................1181 EMERGENCY STOP ITEMS.............................................................................1183 CHARACTER DISPLAY................................................................................1186 REAR ELECTRICAL COMPARTMENT..........................................................................1187 AUTOMATIC RETARD SPEED CONTROL (ARSC)................................................................1190 AUTOMATIC SPIN REGULATOR (ASR).......................................................................1193 SECTION P - LUBRICATION AND SERVICE - INDEX......................................................................1195 SECTION P2 - LUBRICATION AND SERVICE - INDEX.................................................................1197 LUBRICATION AND SERVICE..................................................................................1199 RADIATOR FILL PROCEDURE..............................................................................1199 HYDRAULIC TANK SERVICE...............................................................................1200 Filling Instructions.............................................................................1200 TRANSMISSION OIL LEVEL CHECK.........................................................................1200 PERIODIC REPLACEMENT OF CRITICAL PARTS...............................................................1202 10 HOUR (DAILY) INSPECTION...........................................................................1203 10 HOUR (DAILY) INSPECTION (continued)...............................................................1204 250 HOUR INSPECTION..................................................................................1205 250 HOUR INSPECTION (continued)......................................................................1206 500 HOUR INSPECTION..................................................................................1207 1000 HOUR INSPECTION.................................................................................1208 2000 HOUR INSPECTION.................................................................................1209 5000 HOUR INSPECTION.................................................................................1210 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX............................................................1211 AUTOMATIC LUBRICATION SYSTEM.............................................................................1213 GENERAL DESCRIPTION..................................................................................1213 SYSTEM COMPONENTS....................................................................................1217 SYSTEM OPERATION.....................................................................................1219 INJECTOR OPERATION...................................................................................1220 LUBRICANT PUMP.......................................................................................1221 Pump Housing Oil Level...........................................................................1221 Pump Pressure Control............................................................................1221 INJECTORS (SL-1 Series “H”)).........................................................................1222 Injector Specifications..........................................................................1222 Injector Adjustment..............................................................................1222 SYSTEM PRIMING.......................................................................................1223 Filter Assembly..................................................................................1223 SYSTEM CHECK.........................................................................................1224 Lubrication Controller Check.....................................................................1224 Lubrication Controller Operation.................................................................1224 Lubrication Controller Components................................................................1224 Lubrication Controller Adjustment................................................................1224 SYSTEM TROUBLESHOOTING CHART.........................................................................1226 PREVENTATIVE MAINTENANCE.............................................................................1228 Daily Lubrication System Inspection..............................................................1228 250 Hour Inspection..............................................................................1228 1000 Hour Inspection.............................................................................1229 PUMP REBUILD.........................................................................................1230 Disassembly......................................................................................1230 Cleaning and Inspection..........................................................................1233 Assembly.........................................................................................1233 SECTION R - SYSTEM SCHEMATICS - INDEX............................................................................1235 HYDRAULIC SYSTEM SCHEMATIC...................................................................................1237 HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40C)...............................................................1239 BRAKE SCHEMATIC..............................................................................................1241 HOOKUP SCHEMATIC.............................................................................................1243 ELECTRICAL WIRING SCHEMATIC..................................................................................1259 HVAC WIRING SCHEMATIC........................................................................................1305 CONNECTOR LOCATOR............................................................................................1307
DESCRIPTION:
KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SEN05273-05 – PDF DOWNLOAD
- 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 lbs). 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.
S.S 27/12/24
