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Komatsu HD1500-7 Dump Truck Shop Manual SL NO A30091-A30094, A30099-A30103 – PDF DOWNLOAD
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Komatsu HD1500-7 Dump Truck Shop Manual
SERIAL NUMBERS : A30091-A30094, A30099-A30103
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Description
Komatsu HD1500-7 Dump Truck Shop Manual
FILE DETAILS:
Komatsu HD1500-7 Dump Truck Shop Manual
Language : English
Pages : 1321
Downloadable : Yes
File Type : PDF
Size: 44.7 MB
Book Code: CEBM022303
KOMATSU HD1500-7 DUMP TRUCK SHOP MANUAL SL NO A30091-A30094, A30099-A30103 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu HD1500-7 Dump Truck Shop Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
- This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW.
- GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
Komatsu HD1500-7 Dump Truck Shop Manual
COVER ........................................................................................................... 1 FOREWORD......................................................................................................... 4 TABLE OF CONTENTS................................................................................................ 6 SECTION A GENERAL INFORMATION INDEX.............................................................................. 8 SECTION A2 - MAJOR COMPONENTS AND SPECIFICATIONS............................................................ 10 SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX ........................................................... 14 GENERAL SAFETY AND OPERATION............................................................................. 16 Safety Rules......................................................................................... 16 Safety Features...................................................................................... 16 Clothing And Personal Items.......................................................................... 16 Unauthorized Modification............................................................................ 16 Leaving The Operator’s Seat.......................................................................... 16 Mounting And Dismounting............................................................................. 17 Fire Prevention For Fuel And Oil..................................................................... 17 Precautions With High Temperature Fluids............................................................. 17 Asbestos Dust Hazard Prevention...................................................................... 17 Prevention Of Injury By Work Equipment............................................................... 18 Fire Extinguisher And First Aid Kit.................................................................. 18 Precautions For ROPS................................................................................. 18 Precautions For Attachments.......................................................................... 18 HAUL ROADS........................................................................................... 19 PRECAUTIONS DURING OPERATION......................................................................... 19 BEFORE STARTING THE ENGINE....................................................................... 19 Fire Prevention.............................................................................. 20 Preparing For Operation...................................................................... 20 Ventilation In Enclosed Areas................................................................ 20 In Operator’s Cab - Before Starting The Engine............................................... 20 Mirrors, Windows, And Lights................................................................. 20 OPERATING THE MACHINE............................................................................ 21 When Starting The Engine..................................................................... 21 Precautions For Starting Machine............................................................. 21 Truck Operation - General.................................................................... 21 Traveling.................................................................................... 22 Traveling In Reverse......................................................................... 22 Traveling On Slopes.......................................................................... 22 Ensure Good Visibility....................................................................... 22 Operate Carefully On Snow.................................................................... 23 Avoid Damage To Dump Body.................................................................... 23 Driving Near High Voltage Cables............................................................. 23 When Dumping................................................................................. 23 Working On Loose Ground...................................................................... 23 Loading The Body............................................................................. 23 Parking The Machine.......................................................................... 23 TOWING........................................................................................... 24 WORKING NEAR BATTERIES........................................................................... 24 Battery Hazard Prevention.................................................................... 24 Starting With Booster Cables................................................................. 24 MAINTENANCE PRECAUTIONS.............................................................................. 25 Warning Tag...................................................................................... 25 Proper Tools..................................................................................... 25 Stopping The Engine Before Service............................................................... 25 Securing The Dump Body........................................................................... 25 DURING MAINTENANCE............................................................................... 27 Personnel.................................................................................... 27 Attachments.................................................................................. 27 Working Under The Machine.................................................................... 27 Keep The Machine Clean....................................................................... 27 Rules To Follow When Adding Fuel Or Oil...................................................... 27 Radiator Water Level......................................................................... 27 Use Of Lighting.............................................................................. 27 Precautions With The Battery................................................................. 28 Handling High Pressure Hoses................................................................. 28 Precautions With High Pressure Oil........................................................... 28 Precautions When Performing Maintenance Near High Temperature Or High Pressure............... 28 Rotating Fan And Belts....................................................................... 28 Waste Materials.............................................................................. 28 TIRES............................................................................................ 29 Handling Tires............................................................................... 29 Storing Tires After Removal.................................................................. 29 WHEN REPAIRS ARE NECESSARY........................................................................... 30 ADDITIONAL JOB SITE RULES................................................................................ 31 OPERATING INSTRUCTIONS................................................................................... 32 PREPARING FOR OPERATION.............................................................................. 32 Safety Is Thinking Ahead......................................................................... 32 Walk Around Inspection........................................................................... 32 Cold Weather Heating System...................................................................... 35 ENGINE START-UP SAFETY PRACTICES..................................................................... 36 Cold Weather Starting............................................................................ 36 Jump Starting.................................................................................... 37 AFTER THE ENGINE HAS STARTED......................................................................... 37 MACHINE OPERATION SAFETY PRECAUTIONS................................................................. 40 LOADING.............................................................................................. 41 HAULING.............................................................................................. 41 RETARDER OPERATION................................................................................... 42 PASSING.............................................................................................. 42 DUMPING.............................................................................................. 43 Raising the Dump Body............................................................................ 43 Lowering The Dump Body........................................................................... 44 SAFE PARKING PROCEDURES.............................................................................. 44 TURNING OFF THE ENGINE............................................................................... 45 SUDDEN LOSS OF ENGINE POWER.......................................................................... 45 Secondary Steering And Braking................................................................... 45 DISABLED TRUCK DUMPING............................................................................... 46 Hookup........................................................................................... 46 Raising the Body................................................................................. 47 Lowering the Body................................................................................ 47 DISABLED TRUCK STEERING AND BRAKING.................................................................. 48 TOWING............................................................................................... 50 SECTION A4 - WARNINGS AND CAUTIONS.......................................................................... 52 SECTION A5 - TORQUE TABLES AND CONVERSION CHARTS............................................................ 58 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values..................................... 59 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts.................................... 59 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws....................................... 60 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws................................................... 61 Hardware Tightening Method........................................................................... 69 SECTION A7 - STORAGE PROCEDURES - INDEX ..................................................................... 70 STORAGE AND IDLE MACHINE PREPARATION..................................................................... 72 SHORT TERM IDLE PERIODS.............................................................................. 72 PREPARATION FOR STORAGE.............................................................................. 72 REMOVAL FROM STORAGE................................................................................. 73 RECONDITIONING AN IDLE VEHICLE....................................................................... 75 ENGINE OPERATION..................................................................................... 78 AFTER THE ENGINE HAS STARTED......................................................................... 78 SHORT TERM ENGINE STORAGE............................................................................ 79 Preparing the Engine............................................................................. 79 Removing the Engine from Long Term Storage....................................................... 81 TRANSMISSION PRESERVATION AND STORAGE................................................................ 81 Storage, New Transmission........................................................................ 81 Storage, One Year- Without Oil................................................................... 81 Storage, One Year - With Oil - Normally Installed On The Truck................................... 82 Restoring The Transmission For Service........................................................... 82 SECTION B - STRUCTURES - INDEX .................................................................................. 84 SECTION B2 - STRUCTURAL COMPONENTS - INDEX .................................................................. 86 STRUCTURAL COMPONENTS.................................................................................... 88 PREPARATION.......................................................................................... 88 GRILLE, HOOD AND LADDERS............................................................................. 89 DECKS............................................................................................ 90 CENTER DECK.......................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 90 RIGHT DECK AND COMPONENTS........................................................................ 90 Removal...................................................................................... 90 Installation................................................................................. 90 LEFT DECK AND CAB................................................................................ 91 Installation................................................................................. 91 SECTION B3 - DUMP BODY - INDEX .............................................................................. 92 DUMP BODY................................................................................................ 94 Removal.............................................................................................. 94 Installation......................................................................................... 96 BODY PADS............................................................................................ 96 Removal.......................................................................................... 96 Installation..................................................................................... 97 Body Pad Adjustment.............................................................................. 97 BODY GUIDE........................................................................................... 99 BODY-UP RETENTION CABLE.............................................................................. 100 ROCK EJECTORS........................................................................................ 100 Inspection....................................................................................... 100 SECTION B4 - FUEL TANK - INDEX .............................................................................. 102 FUEL TANK................................................................................................ 104 Removal.............................................................................................. 104 Cleaning............................................................................................. 105 Repair............................................................................................... 105 Installation......................................................................................... 105 FUEL GAUGE AND SENDING UNIT.......................................................................... 106 Removal.......................................................................................... 106 Installation..................................................................................... 106 WIGGINS QUICK FILL FUEL SYSTEM....................................................................... 106 FUEL RECEIVER.................................................................................... 106 FUEL TANK BREATHER............................................................................... 107 Removal...................................................................................... 107 Installation................................................................................. 107 Disassembly.................................................................................. 107 Assembly..................................................................................... 107 LEFT SIDE FILL................................................................................... 108 SECTION C - ENGINE - INDEX ...................................................................................... 110 SECTION C3 - COOLING SYSTEM - INDEX ......................................................................... 112 COOLING SYSTEM........................................................................................... 114 DESCRIPTION.......................................................................................... 114 LEAKS AND CONTAMINATION.............................................................................. 115 RADIATOR FILL PROCEDURE.............................................................................. 115 RADIATOR REMOVAL..................................................................................... 116 RADIATOR REPAIR.................................................................................. 118 Internal Inspection.......................................................................... 118 External Cleaning............................................................................ 118 Disassembly.................................................................................. 119 Cleaning and Inspection...................................................................... 120 Assembly..................................................................................... 120 Pressure Testing............................................................................. 121 Additional Service Information............................................................... 121 RADIATOR INSTALLATION................................................................................ 122 TRANSMISSION AND BRAKE COOLERS................................................................... 123 Removal...................................................................................... 124 Disassembly.................................................................................. 124 Cleaning And Inspection...................................................................... 125 Assembly..................................................................................... 125 Inspection................................................................................... 126 Installation................................................................................. 127 SECTION C4 - ENGINE - INDEX ................................................................................. 128 ENGINE................................................................................................... 130 Removal.............................................................................................. 130 Inspection........................................................................................... 133 Installation......................................................................................... 134 DRIVE LINE ADAPTER................................................................................... 135 Removal.......................................................................................... 136 Disassembly...................................................................................... 137 Cleaning and Inspection.......................................................................... 139 Assembly......................................................................................... 141 Installation..................................................................................... 145 Bearing Tools.................................................................................... 146 SECTION C5 - AIR FILTRATION SYSTEM - INDEX .................................................................. 148 AIR FILTRATION SYSTEM.................................................................................... 150 AIR CLEANER.......................................................................................... 150 Operation........................................................................................ 150 AIR CLEANER MAINTENANCE.......................................................................... 150 Filter Service Indicator..................................................................... 152 Replacing The Elements....................................................................... 152 MAIN FILTER CLEANING............................................................................. 153 PRECLEANER CLEANING.............................................................................. 154 AIR INTAKE GUIDELINES............................................................................ 155 Installation................................................................................. 155 AIR INTAKE TROUBLESHOOTING........................................................................... 156 SECTION C7 - FAN CLUTCH - INDEX ............................................................................. 158 FAN CLUTCH............................................................................................... 160 REMOVAL & INSTALLATION TOOLING....................................................................... 160 FAN CLUTCH - DISASSEMBLY............................................................................. 163 CLEANING AND INSPECTION.............................................................................. 173 ASSEMBLY - FAN CLUTCH................................................................................ 177 TEST PROCEDURE....................................................................................... 191 SECTION D - ELECTRICAL SYSTEM - INDEX ........................................................................... 192 SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX .......................................................... 194 BATTERIES AND STARTING SYSTEM............................................................................ 196 BATTERIES............................................................................................ 196 MAINTENANCE AND SERVICE.......................................................................... 196 Electrolyte Levels........................................................................... 196 Cleaning..................................................................................... 196 Other Maintenance............................................................................ 197 ENGINE PRELUB™ SYSTEM................................................................................ 199 OPERATION........................................................................................ 199 Oil Pressure Switch.......................................................................... 201 Check Valve.................................................................................. 201 Timer Solenoid............................................................................... 201 MAINTENANCE...................................................................................... 201 Prelub™ System Operation..................................................................... 201 Prelub Pump.................................................................................. 201 Check Valve.................................................................................. 202 Timer Solenoid............................................................................... 202 PRELUB CIRCUIT TROUBLESHOOTING................................................................... 203 STARTING SYSTEM...................................................................................... 205 CRANKING MOTORS.................................................................................. 205 Removal...................................................................................... 205 Disassembly.................................................................................. 206 Cleaning and Inspection...................................................................... 206 Armature Servicing........................................................................... 206 Field Coil Checks............................................................................ 207 Field Coil Removal........................................................................... 207 Solenoid Checks.............................................................................. 209 Assembly..................................................................................... 210 Installation................................................................................. 212 TROUBLESHOOTING.................................................................................. 212 Preliminary Inspection....................................................................... 212 No-Load Test................................................................................. 212 Interpreting The Results of The Tests........................................................ 213 MAGNETIC SWITCH.................................................................................. 214 Removal...................................................................................... 214 Installation................................................................................. 214 Coil Test.................................................................................... 214 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX ........................................................... 216 ELECTRICAL SYSTEM COMPONENTS............................................................................. 218 CAB MOUNTED COMPONENTS............................................................................... 218 CIRCUIT BREAKERS................................................................................. 220 RELAY CENTER..................................................................................... 221 FUSE PANEL....................................................................................... 226 EXTERIOR COMPONENTS.................................................................................. 230 BATTERY BOX...................................................................................... 230 BATTERY DISCONNECT SWITCH........................................................................ 230 GROUND LEVEL SHUT OFF SWITCH..................................................................... 230 CONTROL POWER RELAYS............................................................................. 230 CIRCUIT BREAKERS................................................................................. 230 BATTERY EQUALIZER................................................................................ 230 Test......................................................................................... 230 BODY POSITION SWITCHES........................................................................... 232 Proximity Switch Operation................................................................... 232 Body-Up Switch Adjustment.................................................................... 233 Hoist Limit Switch Adjustment................................................................ 233 SPEED SENSORS.................................................................................... 235 Sensor Adjustment............................................................................ 236 GENERAL TROUBLESHOOTING.............................................................................. 236 SECTION D10 - CHARGING SYSTEM - INDEX ....................................................................... 238 CHARGING SYSTEM.......................................................................................... 240 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION........................................................ 240 Excessive heat................................................................................... 240 Dirt and dust.................................................................................... 240 Vibration........................................................................................ 240 PREVENTIVE MAINTENANCE PROCEDURES.................................................................... 241 Alternator Cleanliness........................................................................... 241 Alternator Mounting.............................................................................. 241 Belt Tension And Condition....................................................................... 241 TROUBLESHOOTING...................................................................................... 241 ALTERNATOR PERFORMANCE TEST...................................................................... 241 ALTERNATOR CABLE TEST............................................................................ 242 VOLTAGE REGULATOR ADJUSTMENT......................................................................... 243 ALTERNATOR........................................................................................... 244 Removal.......................................................................................... 244 Installation..................................................................................... 245 SECTION D11 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX ..................................................... 248 AUTOMATIC TRANSMISSION CONTROLLER........................................................................ 250 GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES........................................... 251 TRANSMISSION OPERATING MODES......................................................................... 252 NETWORK DATA......................................................................................... 252 SHIFT LOGIC.......................................................................................... 254 Shift Lever Position D, Up-Shifting.............................................................. 254 Shift Lever Position D, Down-Shifting............................................................ 254 Shift Lever Positions 6, 5, 4, 3, 2, L........................................................... 254 Shift Lever Positions R.......................................................................... 254 Shift Lever Position N........................................................................... 254 Gear Shift Time Delay............................................................................ 254 SAFETY FUNCTIONALITY............................................................................. 255 Down-Shift Inhibitor Function................................................................ 255 Neutral Safety Function...................................................................... 255 Directional Inhibit Function................................................................. 255 Powertrain Overrun Prevention................................................................ 255 Reverse Safety (Dump Body Raised)............................................................ 255 Speed Range Limit Function (Dump Body Raised)................................................ 255 Self-diagnostic function..................................................................... 255 ATC REAL TIME MONITORING............................................................................. 256 LIMP HOME MODE....................................................................................... 256 Limp Home Procedure 1............................................................................ 259 Limp Home Procedure 2............................................................................ 259 Limp Home Procedure 3............................................................................ 259 Limp Home Procedure 4............................................................................ 259 Limp Home Procedure 5............................................................................ 259 Limp Home Procedure 6............................................................................ 259 Limp Home Procedure 7............................................................................ 259 SECTION D15 - MACHINE MONITOR - INDEX ....................................................................... 260 MACHINE MONITOR.......................................................................................... 262 CHARACTER DISPLAY.................................................................................... 262 Mode Select Switches 1 & 2....................................................................... 263 Service Meter.................................................................................... 263 Odometer......................................................................................... 263 Operation Information............................................................................ 263 Reverse Travel Odometer.......................................................................... 264 Filter And Oil Change Display.................................................................... 264 Display Items.................................................................................... 265 Resetting The Filter/Oil Replacement Meter....................................................... 265 Inputting Telephone Numbers...................................................................... 266 Selecting A Language............................................................................. 266 ACTION CODE DISPLAYS................................................................................. 267 E03 Codes........................................................................................ 267 E02 Codes........................................................................................ 268 E01 Codes........................................................................................ 268 REAL TIME MONITOR.................................................................................... 269 USING REAL TIME MONITOR.......................................................................... 269 Viewing Two Streams of Data At Once.......................................................... 270 Real Time Monitoring Codes................................................................... 271 MACHINE MONITOR FLOW CHART....................................................................... 275 SECTION D20 - FAILURE CODES - INDEX ......................................................................... 280 FAILURE CODES............................................................................................ 282 ACTION CODE DISPLAYS................................................................................. 282 CHECKING FAILURE CODES............................................................................... 283 LIMP HOME MODE....................................................................................... 284 FAILURE CODE TABLE................................................................................... 285 SECTION D21 - TROUBLESHOOTING............................................................................... 302 FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES........................................................ 302 FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION............................................... 303 FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR............................................ 305 FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR............................................ 305 FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 306 FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING........................................................... 307 FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 309 FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING.............................................................. 311 FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING............................................................... 313 FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING............................................................... 315 FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING............................................................... 317 FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING............................................................... 319 FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF................................. 321 FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION.......................................................... 323 FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF.............................. 325 FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION...................................................... 329 FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 331 FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION....................................................... 335 FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 337 FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION....................................................... 341 FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 343 FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION....................................................... 347 FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 349 FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION....................................................... 353 FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION.................................................... 355 FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 356 FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION....................................................... 359 FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING............................................................... 361 FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION........................................................... 363 FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION..................................................... 364 FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE...................................................... 365 FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR............................................. 366 FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE.................................................. 367 FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE........................................... 368 FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE........................................... 369 FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION...................................................... 370 FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED...................................... 371 FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION............................................................ 372 FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE................................................ 373 FAILURE CODE [B@BCNS] ENGINE: OVERHEAT................................................................... 374 FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW........................................................ 375 FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING............................................. 376 FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING........................................ 377 FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING......................................... 378 FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING.................................................. 379 FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION...................................... 380 FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION.................................... 381 FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION.................................... 382 FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION................................................... 383 FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR............................................... 385 FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW.................................. 389 FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW........................... 390 FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR..................................... 391 FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR....................................... 392 FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR...................................... 393 FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT............................................ 394 FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT.......................................... 395 FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR........................................................ 396 FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR........................... 397 FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION............................. 398 FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW................ 399 FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR......................................... 400 FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR........................................... 401 FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR.......................................... 403 FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR.......................................................... 404 FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT................................................ 405 FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE............................................. 407 FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT.......................................................... 409 FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT......................................................... 410 FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT....................................................... 411 FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT...................................................... 412 FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT................................................ 413 FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT.............................................. 415 FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 417 FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 419 FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 421 FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 423 FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT........................................... 425 FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 427 FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT.......................................................... 429 FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT......................................................... 433 FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE..................... 436 FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND...................... 437 FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT................ 438 FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND....................... 439 FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT................. 440 FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT............... 441 FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND..................... 442 FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE................. 443 FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 444 FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 445 FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 446 FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 447 FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 448 FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................. 449 FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE........................... 450 FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION............................ 451 FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE.......................... 452 FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION........................... 453 FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT.................................................... 454 FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE............................................. 455 FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT......................................... 456 FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE......................................... 457 FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE................................................... 459 FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION............................................ 460 FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT.................................................. 461 FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION................................................... 462 FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT................................ 463 FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION................................. 464 FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT......................... 465 FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION.......................... 466 FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION......................................... 467 FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION.......................................... 468 FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 469 FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 470 FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 471 FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 472 FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 473 FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL.... 474 FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT........................................ 475 FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT......................................... 476 FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT.................................... 477 FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT................................... 478 FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE.............................................. 479 FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT.............................. 480 FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)........................................ 481 FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT........................................................ 482 FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT....................................................... 483 FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER...................................................... 484 FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................................ 485 FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)....................... 487 FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT....................................... 489 FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT...................................... 490 FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER..................................... 491 FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)............... 492 FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)........................ 493 FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT........................................ 495 FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT....................................... 496 FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER...................................... 497 FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION......................................... 498 FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION..................................... 499 FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT......................................... 501 FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT........................................ 502 FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER....................................... 503 FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................. 504 FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT.................................... 505 FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT................................... 506 FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................. 507 FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT...................................... 509 FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT..................................... 511 FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................... 513 FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 517 FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 519 FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 521 FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 525 FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 527 FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 529 FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 533 FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 535 FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 537 FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 541 FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 543 FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 545 FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT......................................... 549 FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT........................................ 551 FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER....................................... 553 FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 557 FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 559 FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 561 SECTION D30 - VHMS INITIALIZATION - INDEX................................................................... 564 INITIALIZATION OF VHMS CONTROLLER........................................................................ 566 Executing Quick PM................................................................................... 577 Downloading Existing VHMS Setting Data............................................................... 582 Confirmation of Downloaded Data...................................................................... 583 Disconnecting the PC................................................................................. 583 Reporting to Komatsu................................................................................. 583 REPLACING THE VHMS CONTROLLER............................................................................ 585 Prior to Removing VHMS Controller.................................................................... 585 Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)......................... 585 Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)..................... 589 Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)............................ 591 Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)........................ 592 FINAL VHMS PROCEDURES-POST INSTALLATION.................................................................. 593 Correct the Load Weight Calculation.................................................................. 595 SECTION D31 - VEHICLE HEALTH MONITORING SYSTEM (VHMS) - INDEX ............................................... 604 VEHICLE HEALTH MONITORING SYSTEM (VHMS).................................................................. 606 VHMS DOWNLOADING..................................................................................... 607 PAYLOAD METER........................................................................................ 608 NORMAL OPERATION DISPLAY......................................................................... 609 EXTERNAL DISPLAY LAMPS........................................................................... 610 PREDICTED LOAD DISPLAY........................................................................... 610 CALIBRATING PLM.................................................................................. 611 DATA STORED IN PAYLOAD METER..................................................................... 612 PLM DOWNLOADING.................................................................................. 613 Downloading From Inside Of The Cab........................................................... 613 Downloading From Ground Level Box............................................................ 613 SETTING THE MACHINE ID AND OPEN ID............................................................... 614 PAYLOAD - CYCLE DATA ITEM........................................................................ 615 ADDITIONAL FUNCTIONS............................................................................. 615 Other Settings............................................................................... 615 SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX ............................................................. 616 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX ...................................................... 618 TORQUE CONVERTER AND TRANSMISSION........................................................................ 620 TORQUE CONVERTER..................................................................................... 621 MAIN RELIEF VALVE................................................................................ 623 Function..................................................................................... 623 Operation.................................................................................... 623 TORQUE CONVERTER RELIEF VALVE.................................................................... 623 Function..................................................................................... 623 Operation.................................................................................... 623 TORQUE CONVERTER REGULATOR VALVE................................................................. 625 Operation.................................................................................... 625 LOCK-UP CLUTCH................................................................................... 626 Lock-up Clutch Accumulator................................................................... 626 HYDRAULIC PUMP................................................................................... 627 TORQUE CONVERTER STALL CHECK..................................................................... 628 TRANSMISSION......................................................................................... 629 LUBRICATION RELIEF VALVE......................................................................... 631 Function..................................................................................... 631 TRANSMISSION CONTROL VALVE....................................................................... 632 ELECTRONIC CONTROL MODULATION VALVE (ECMV)....................................................... 634 Pressure Control Valve....................................................................... 635 Flow Sensor Valve............................................................................ 635 ECMV and Proportional Solenoid............................................................... 635 ECMV and Fill Switch......................................................................... 635 ECMV Operation............................................................................... 636 ECMV REPAIR...................................................................................... 639 Preparation.................................................................................. 639 Filter Replacement Procedure................................................................. 639 ECMV Identification.......................................................................... 640 ECMV Removal................................................................................. 640 Disassembly.................................................................................. 640 Assembly..................................................................................... 642 Installation................................................................................. 642 TRANSMISSION FILTERS............................................................................. 644 Service...................................................................................... 644 Installation................................................................................. 644 TRANSMISSION SPEED SENSORS....................................................................... 645 Adjustment Procedure......................................................................... 645 TRANSMISSION OIL LEVEL CHECK..................................................................... 646 TRANSMISSION OIL PRESSURE CHECK.................................................................. 647 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING.................................................... 649 Preliminary Checks............................................................................... 649 TRANSMISSION REMOVAL............................................................................. 653 TRANSMISSION INSTALLATION........................................................................ 654 SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX .................................................... 658 TRANSMISSION OIL COOLER & STRAINERS...................................................................... 660 TRANSMISSION OIL COOLER.............................................................................. 660 Removal and Installation......................................................................... 660 Repair........................................................................................... 660 TRANSMISSION OIL STRAINER............................................................................ 660 Removal.......................................................................................... 661 Inspection....................................................................................... 661 Installation..................................................................................... 661 SECTION F5 - DRIVE SHAFTS - INDEX ........................................................................... 662 DRIVE SHAFTS............................................................................................. 664 FRONT DRIVE SHAFT.................................................................................... 664 Removal.......................................................................................... 664 Disassembly...................................................................................... 664 Assembly......................................................................................... 664 Installation..................................................................................... 665 FRONT DRIVE SHAFT ALIGNMENT...................................................................... 666 REAR DRIVE SHAFT..................................................................................... 669 Removal.......................................................................................... 669 Disassembly...................................................................................... 670 Assembly......................................................................................... 670 Installation..................................................................................... 670 SECTION F8 - TORQUE CONVERTER REBUILD - INDEX ............................................................... 672 TORQUE CONVERTER REBUILD................................................................................. 674 REMOVAL.............................................................................................. 674 INSTALLATION......................................................................................... 676 DISASSEMBLY.......................................................................................... 678 PTO COVER DISASSEMBLY............................................................................ 686 CLEANING & INSPECTION................................................................................ 687 TABLE I. COMPONENT WEAR LIMITS................................................................... 688 TABLE II. Gear Backlash.......................................................................... 688 ASSEMBLY............................................................................................. 689 ONE-WAY CLUTCH ASSEMBLY.......................................................................... 690 STATOR BEARING PRE-LOAD ADJUSTMENT............................................................... 692 PTO DRIVE ASSEMBLY............................................................................... 696 SPECIAL TOOLS........................................................................................ 701 SECTION F9 - TRANSMISSION REBUILD - INDEX ................................................................... 704 TRANSMISSION REBUILD..................................................................................... 706 TRANSMISSION DISASSEMBLY............................................................................. 706 Number One Clutch Housing Disassembly............................................................ 710 Bearing Cage & Cover Disassembly................................................................. 713 Number Four Carrier Disassembly.................................................................. 714 Output Shaft Cover Disassembly................................................................... 715 Rear Case Bearing Removal........................................................................ 715 Output Shaft Removal............................................................................. 716 Output Shaft Disassembly......................................................................... 716 Number Five/Six Carrier Disassembly.............................................................. 716 CLEANING AND INSPECTION.............................................................................. 718 INSPECTION TABLE INDEX........................................................................... 718 TRANSMISSION ASSEMBLY................................................................................ 724 GENERAL INSTRUCTIONS............................................................................. 724 Number Five/Six Carrier Assembly............................................................. 724 Output Shaft Assembly........................................................................ 725 Number Seven Clutch Assembly................................................................. 726 Rear Case Assembly........................................................................... 727 Rear Case & Carrier Assembly................................................................. 727 Number Six Clutch Assembly................................................................... 729 Number Four Carrier Assembly................................................................. 730 Number Four Carrier Bearing Cage Assembly.................................................... 731 Number Five Clutch Assembly.................................................................. 731 Number Four Clutch Assembly.................................................................. 732 Number Three Clutch Assembly................................................................. 732 Clutch Test.................................................................................. 733 Number Two Clutch Ring Gear Installation..................................................... 733 Number Three Carrier & Number Two Clutch Assembly............................................ 734 Number One Carrier Assembly.................................................................. 734 Number One Clutch Assembly................................................................... 737 Checks Prior to Final Assembly............................................................... 739 Final Assembly............................................................................... 739 Input Shaft Installation..................................................................... 740 External Components.......................................................................... 742 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX ............................................................. 744 SECTION G2 - TIRES AND RIMS - INDEX ......................................................................... 746 TIRES AND RIMS........................................................................................... 748 GENERAL INFORMATION.................................................................................. 748 FRONT TIRES AND RIMS................................................................................. 749 Removal.......................................................................................... 749 Installation..................................................................................... 750 REAR TIRE AND RIM.................................................................................... 750 Removal.......................................................................................... 750 Installation..................................................................................... 752 TIRE MATCHING........................................................................................ 753 RIM.................................................................................................. 753 Tire Removal From Rim............................................................................ 753 Tire Installation On Rim......................................................................... 754 FRONT WHEEL STUD INSTALLATION........................................................................ 755 REAR WHEEL STUD INSTALLATION......................................................................... 756 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX ............................................................ 758 FRONT WHEEL HUB AND SPINDLE.............................................................................. 760 OIL SAMPLE ANALYSIS.................................................................................. 760 Oil Sampling Guidelines.......................................................................... 760 Guidelines For Obtaining A Sample................................................................ 760 FRONT WHEEL HUB...................................................................................... 761 Removal.......................................................................................... 761 Disassembly...................................................................................... 761 Inspection....................................................................................... 761 Assembly......................................................................................... 762 Installation..................................................................................... 764 Front Wheel Hub Bearing Adjustment............................................................... 764 FRONT SPINDLE........................................................................................ 765 A-ARM................................................................................................ 765 Removal.......................................................................................... 765 Inspection....................................................................................... 765 Installation..................................................................................... 765 CENTER TIE ROD PIVOT................................................................................. 766 Removal.......................................................................................... 766 Inspection....................................................................................... 766 Installation..................................................................................... 766 TOE IN ADJUSTMENT.................................................................................... 767 Adjustment Procedure............................................................................. 767 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX .................................................................. 772 REAR AXLE ATTACHMENTS.................................................................................... 774 CENTER LINK AND LOWER LINKS.......................................................................... 774 Removal.......................................................................................... 774 Inspection....................................................................................... 775 Spherical Bearing Replacement.................................................................... 775 Installation..................................................................................... 775 PANHARD ROD (DIAGONAL LINK).......................................................................... 776 Removal.......................................................................................... 776 Inspection....................................................................................... 777 Installation..................................................................................... 777 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX ..................................................... 778 REAR AXLE & FINAL DRIVE ASSEMBLY......................................................................... 780 DIFFERENTIAL OPERATION............................................................................... 780 Straight-away-travel............................................................................. 780 Turning.......................................................................................... 780 REAR AXLE ASSEMBLY............................................................................... 781 Removal...................................................................................... 781 Installation................................................................................. 781 DIFFERENTIAL OIL LEVEL CHECK..................................................................... 782 DIFFERENTIAL ASSEMBLY............................................................................ 783 Removal...................................................................................... 783 Installation................................................................................. 784 Disassembly.................................................................................. 784 Pinion Carrier Assembly...................................................................... 787 Differential Gear Unit....................................................................... 787 Differential Gear Unit....................................................................... 788 Cleaning and Inspection...................................................................... 791 Assembly..................................................................................... 791 Differential Bearing......................................................................... 791 Assembly Of Differential Gear Assembly....................................................... 791 Installation Of Differential Assembly........................................................ 793 Input Pinion and Carrier Assembly............................................................ 794 Adjusting Tooth Contact, Backlash............................................................ 798 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX ................................................. 802 FINAL DRIVE PLANETARIES AND WHEEL HUBS................................................................... 804 FINAL DRIVE.......................................................................................... 804 Oil Level Check.................................................................................. 805 FINAL DRIVE CARRIER ASSEMBLY..................................................................... 805 Removal...................................................................................... 805 Installation................................................................................. 806 Disassembly.................................................................................. 806 Assembly..................................................................................... 807 FINAL DRIVE ASSEMBLY............................................................................. 808 Disassembly.................................................................................. 808 Assembly..................................................................................... 810 SECTION H - SUSPENSIONS - INDEX ................................................................................. 812 SECTION H2 - FRONT SUSPENSION - INDEX ....................................................................... 814 FRONT SUSPENSION......................................................................................... 816 Removal.............................................................................................. 818 Installation......................................................................................... 819 Disassembly.......................................................................................... 820 Cleaning and Inspection.............................................................................. 822 Assembly............................................................................................. 822 Pressure Tests....................................................................................... 823 DAMPING VALVE REPAIR................................................................................. 824 Disassembly...................................................................................... 824 Assembly......................................................................................... 825 SECTION H3 - REAR SUSPENSION - INDEX ........................................................................ 826 REAR SUSPENSION.......................................................................................... 828 Operation............................................................................................ 829 Removal.............................................................................................. 830 Installation......................................................................................... 830 Disassembly.......................................................................................... 830 Cleaning and Inspection.............................................................................. 834 Assembly............................................................................................. 834 LEAK TESTING......................................................................................... 835 SPHERICAL BEARINGS................................................................................... 835 Removal.......................................................................................... 835 Inspection....................................................................................... 835 Installation..................................................................................... 835 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX ......................................................... 836 SUSPENSION OILING AND CHARGING........................................................................... 838 GENERAL INFORMATION.................................................................................. 838 Equipment List................................................................................... 838 FRONT SUSPENSION..................................................................................... 840 Front Suspension Oiling.......................................................................... 840 Front Suspension Nitrogen Charging............................................................... 843 REAR SUSPENSION...................................................................................... 845 GENERAL INFORMATION.............................................................................. 845 Rear Suspension Oiling....................................................................... 845 Rear Suspension Nitrogen Charging............................................................ 849 FRONT AND REAR CYLINDER LENGTH ADJUSTMENT............................................................ 849 SECTION J - BRAKE SYSTEM - INDEX ................................................................................ 852 SECTION J2 - BRAKE SYSTEM OPERATION - INDEX ................................................................. 854 BRAKE SYSTEM OPERATION................................................................................... 856 DESCRIPTION.......................................................................................... 856 SERVICE BRAKE OPERATION.............................................................................. 857 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 857 BRAKE SYSTEM COMPONENTS.............................................................................. 859 BRAKE MANIFOLD CARTRIDGE VALVES...................................................................... 861 SERVICE BRAKE CIRCUIT................................................................................ 865 RETARDING CIRCUIT................................................................................ 867 PARKING BRAKE CIRCUIT............................................................................ 869 AUTO APPLY....................................................................................... 871 AUXILIARY BRAKE CIRCUIT.......................................................................... 873 BRAKE LOCK CIRCUIT............................................................................... 875 AUTOMATIC SPIN REGULATOR......................................................................... 877 BRAKE COOLING CIRCUIT................................................................................ 879 BRAKE COOLING VALVE.............................................................................. 880 COLD OIL DIVERTER VALVES......................................................................... 883 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX ........................................................ 884 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 886 BRAKE VALVE.......................................................................................... 887 Rebuild Criteria................................................................................. 887 Removal.......................................................................................... 887 Installation..................................................................................... 888 Disassembly...................................................................................... 889 Cleaning and Inspection.......................................................................... 890 Assembly......................................................................................... 892 Actuator Base Threaded Inserts................................................................... 892 Boot and Cap..................................................................................... 892 Valve Body Seal Installation..................................................................... 892 Regulator Sleeve O-Ring Installation............................................................. 892 Actuator Plunger O-ring Installation............................................................. 893 Assembly of Valve................................................................................ 894 BENCH TEST AND ADJUSTMENT............................................................................ 895 Test Bench Only.................................................................................. 895 Test Set Up Procedure............................................................................ 895 Brake Valve Output Pressure Adjustment........................................................... 897 Final Test and Adjustment........................................................................ 898 Proximity Switch Installation and Adjustment..................................................... 900 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 900 BRAKE ACCUMULATORS................................................................................... 901 Removal.......................................................................................... 902 Installation..................................................................................... 902 Disassembly...................................................................................... 902 Cleaning and Inspection.......................................................................... 904 Assembly......................................................................................... 904 Leak Testing..................................................................................... 906 ACCUMULATOR CHARGING................................................................................. 907 Temperature During Precharge..................................................................... 909 ACCUMULATOR STORAGE.................................................................................. 910 Installation..................................................................................... 910 BRAKE COOLING VALVE (BCV)............................................................................ 911 RETARDER CONTROL LEVER............................................................................... 912 Removal.......................................................................................... 912 Installation..................................................................................... 912 Disassembly and Adjustment....................................................................... 912 Potentiometer Check.............................................................................. 914 Assembly......................................................................................... 914 Retard Lever Calibration......................................................................... 915 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX ................................................................. 916 BRAKE CIRCUIT CHECK-OUT.................................................................................. 918 REQUIRED EQUIPMENT................................................................................... 918 PREPARATION.......................................................................................... 918 BRAKE CIRCUIT TESTING................................................................................ 919 Initial System Setup............................................................................. 919 Parking Brake.................................................................................... 920 Brake Lock....................................................................................... 921 Low-Brake Pressure and Auto-Apply................................................................ 921 Validation....................................................................................... 922 Retarding........................................................................................ 922 BRAKE SYSTEM DATA SHEET.............................................................................. 923 BRAKE CIRCUIT TROUBLESHOOTING........................................................................ 926 SECTION J5 - FRONT WET DISC BRAKES - INDEX .................................................................. 930 FRONT WET DISC BRAKES.................................................................................... 932 BRAKE MAINTENANCE.................................................................................... 933 Checking Disc Wear............................................................................... 933 FRONT BRAKE ASSEMBLY................................................................................. 935 Removal.......................................................................................... 935 Installation..................................................................................... 935 Disassembly...................................................................................... 935 Cleaning and Inspection.......................................................................... 936 Assembly......................................................................................... 937 Floating Seal Installation....................................................................... 940 BRAKE BLEEDING....................................................................................... 943 SECTION J6 - REAR WET DISC BRAKES - INDEX ................................................................... 944 REAR WET DISC BRAKES..................................................................................... 946 DESCRIPTION.......................................................................................... 946 OPERATION............................................................................................ 946 MAINTENANCE.......................................................................................... 947 Checking Brake Disc Wear......................................................................... 947 REMOVAL.......................................................................................... 948 INSTALLATION..................................................................................... 949 BRAKE REBUILD.................................................................................... 951 Disassembly.................................................................................. 951 Cleaning and Inspection...................................................................... 952 Assembly..................................................................................... 952 Floating Seal Installation................................................................... 954 WET DISC BRAKE BLEEDING.......................................................................... 957 SECTION J7 - PARKING BRAKE - INDEX .......................................................................... 958 PARKING BRAKE............................................................................................ 960 Description.......................................................................................... 960 Parking Brake Service Criteria....................................................................... 960 Removal.............................................................................................. 961 Installation......................................................................................... 961 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................................ 963 Removal.......................................................................................... 963 Installation..................................................................................... 963 AUTOMATIC SLACK ADJUSTER............................................................................. 963 Adjustment Procedure............................................................................. 963 PARKING BRAKE CHECK-OUT.............................................................................. 964 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................ 966 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX.............................................................. 968 HYDRAULIC SYSTEM OVERVIEW................................................................................ 970 SYSTEM COMPONENTS.................................................................................... 970 HYDRAULIC TANK................................................................................... 970 BLEED-DOWN MANIFOLD.............................................................................. 972 HOIST VALVE...................................................................................... 972 HOIST PUMP....................................................................................... 972 BRAKE COOLING PUMP............................................................................... 973 BRAKE CONTROL VALVE (BCV)........................................................................ 973 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX ...................................................... 974 HYDRAULIC COMPONENT REPAIR............................................................................... 976 HYDRAULIC TANK....................................................................................... 976 FILLING INSTRUCTIONS............................................................................. 976 MAINTENANCE...................................................................................... 976 Removal...................................................................................... 977 Installation................................................................................. 979 Gap Measurement - Hydraulic Tank Mounting.................................................... 979 STRAINERS AND DIFFUSERS.......................................................................... 980 Removal...................................................................................... 980 Cleaning and Inspection...................................................................... 980 Installation................................................................................. 981 HYDRAULIC TANK BREATHER.............................................................................. 981 Service.......................................................................................... 982 HYDRAULIC SYSTEM FLUSHING............................................................................ 982 HYDRAULIC PUMPS...................................................................................... 983 Removal.......................................................................................... 983 Installation..................................................................................... 984 PUMP REBUILD..................................................................................... 985 Disassembly.................................................................................. 985 Inspection Of Parts.......................................................................... 988 Assembly..................................................................................... 988 Bearing Replacement.......................................................................... 991 Seal Replacement............................................................................. 991 TROUBLESHOOTING GUIDE............................................................................ 994 SECTION L4 - STEERING CIRCUIT - INDEX ....................................................................... 996 STEERING CIRCUIT......................................................................................... 998 OPERATION............................................................................................ 998 COMPONENT DESCRIPTION................................................................................ 998 Steering Control Valve........................................................................... 998 Bleed-down Manifold.............................................................................. 998 Bleed-down Solenoid.............................................................................. 999 Accumulators.....................................................................................1000 Flow Amplifier...................................................................................1000 High Pressure Filter.............................................................................1000 Warning Devices..................................................................................1000 FLOW AMPLIFIER OPERATION.............................................................................1002 STEERING/BRAKE PUMP..................................................................................1010 COMPONENTS.......................................................................................1010 OPERATION........................................................................................1012 SECTION L5 - STEERING CONTROL UNIT - INDEX ..................................................................1014 STEERING CONTROL UNIT....................................................................................1016 Removal..............................................................................................1016 Installation.........................................................................................1016 REBUILD PROCEDURE....................................................................................1017 Disassembly......................................................................................1018 Cleaning and Inspection..........................................................................1019 Assembly.........................................................................................1021 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX ......................................................1026 STEERING CIRCUIT COMPONENT REPAIR........................................................................1028 BLEED-DOWN MANIFOLD..................................................................................1028 Removal..........................................................................................1028 Adjusting Relief Valve...........................................................................1028 Testing and Adjustment...........................................................................1029 FLOW AMPLIFIER...................................................................................1030 Removal......................................................................................1030 Installation.................................................................................1030 Disassembly..................................................................................1030 Assembly.....................................................................................1033 ACCUMULATORS.....................................................................................1034 Removal......................................................................................1034 Installation.................................................................................1035 Disassembly..................................................................................1036 Cleaning and Inspection......................................................................1036 Assembly.....................................................................................1036 Leak Testing.................................................................................1037 STEERING ACCUMULATOR CHARGING....................................................................1039 Temperature During Precharge.................................................................1042 ACCUMULATOR STORAGE..............................................................................1042 Installation.................................................................................1043 STEERING CYLINDER................................................................................1044 Removal......................................................................................1044 Installation.................................................................................1044 STEERING CYLINDER REBUILD........................................................................1045 Disassembly..................................................................................1045 Cleaning and Inspection......................................................................1045 Assembly.....................................................................................1046 Testing......................................................................................1046 STEERING/BRAKE PUMP..............................................................................1046 Removal......................................................................................1046 Installation.................................................................................1047 PUMP REBUILD.....................................................................................1048 Disassembly..................................................................................1048 Control Group................................................................................1049 Valve Plate Group............................................................................1050 Rotating Group...............................................................................1050 Drive Shaft Group............................................................................1051 Swashblock Group.............................................................................1051 Inspection...................................................................................1051 Control Group................................................................................1051 Valve Plate Group............................................................................1052 Rotating Group...............................................................................1052 Swashblock Group.............................................................................1053 Drive Shaft Group............................................................................1053 Assembly.....................................................................................1053 Swashblock Group.............................................................................1053 Drive Shaft Group............................................................................1054 Rotating Group...............................................................................1054 Valve Plate Group............................................................................1055 Control Group................................................................................1056 STEERING CIRCUIT FILTER..........................................................................1057 Removal......................................................................................1057 Installation.................................................................................1057 TROUBLESHOOTING CHART....................................................................................1058 SECTION L7 - HOIST CIRCUIT - INDEX ..........................................................................1060 HOIST CIRCUIT............................................................................................1062 HOIST CIRCUIT OPERATION..............................................................................1062 COMPONENT DESCRIPTION............................................................................1063 Hydraulic Tank...............................................................................1063 Hoist Pump...................................................................................1063 Hoist Valve..................................................................................1063 Hoist Pilot Valve............................................................................1064 Power Up Solenoid............................................................................1065 Pilot Operated Check Valve...................................................................1065 Power Down Spool Limit Solenoid..............................................................1065 HOIST CIRCUIT HYDRAULIC FLOW.....................................................................1066 POWER UP.....................................................................................1068 HOLD.........................................................................................1070 POWER DOWN...................................................................................1072 FLOAT........................................................................................1074 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX .........................................................1076 HOIST CIRCUIT COMPONENT REPAIR...........................................................................1078 HOIST VALVE..........................................................................................1078 Removal..........................................................................................1078 Installation.....................................................................................1078 O-Ring Replacement...............................................................................1079 INLET SECTION....................................................................................1080 Disassembly..................................................................................1080 Cleaning and Inspection......................................................................1081 Assembly.....................................................................................1081 SPOOL SECTION....................................................................................1081 Disassembly..................................................................................1081 Cleaning and Inspection......................................................................1082 Assembly.....................................................................................1084 HOIST PILOT VALVE....................................................................................1085 Removal..........................................................................................1085 Installation.....................................................................................1085 Disassembly......................................................................................1086 Cleaning and Inspection..........................................................................1087 Assembly.........................................................................................1087 HOIST CYLINDERS......................................................................................1088 Removal..........................................................................................1088 Installation.....................................................................................1090 Disassembly......................................................................................1090 Cleaning and Inspection..........................................................................1092 Assembly - Quill And Cylinder....................................................................1093 Quill Installation...............................................................................1093 Installation Of Check Balls And Plugs In Quill...................................................1094 Assembly of Cylinder.............................................................................1095 Pressure Testing.................................................................................1096 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX ...............................................................1098 HYDRAULIC SYSTEM FILTERS.................................................................................1100 HIGH PRESSURE FILTER.................................................................................1100 Removal..........................................................................................1100 Installation.....................................................................................1101 LOW PRESSURE FILTERS.................................................................................1101 BRAKE COOLING & HOIST FILTERS....................................................................1101 TRANSMISSION FILTER..............................................................................1101 Removal......................................................................................1102 Installation.................................................................................1102 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX .........................................................1104 HYDRAULIC CHECK-OUT PROCEDURE............................................................................1106 GENERAL INFORMATION..................................................................................1106 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................................................1106 Equipment Requirements...........................................................................1107 Installation Of Gauges...........................................................................1107 Initial Startup And Flushing.....................................................................1107 Component Checkout And Adjustment................................................................1108 CHECKING HOIST SYSTEM PRESSURES......................................................................1110 Equipment Requirements...........................................................................1110 Steering Components Leakage Test.................................................................1112 HYDRAULIC SYSTEM CHECKOUT DATA SHEET.................................................................1113 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX ...................................................................1114 SECTION M7 - HOT START SYSTEM - INDEX.......................................................................1116 HOT START SYSTEM.........................................................................................1118 SYSTEM OPERATION.....................................................................................1118 HEATER INFORMATION...................................................................................1119 TROUBLESHOOTING GUIDELINES...........................................................................1121 SECTION M8 - SPECIAL TOOLS..................................................................................1122 SECTION N - OPERATOR CAB - INDEX ................................................................................1126 SECTION N2 - OPERATOR CAB - INDEX ...........................................................................1128 OPERATOR CAB.............................................................................................1130 Removal..............................................................................................1131 Installation.........................................................................................1133 CAB DOORS............................................................................................1133 Removal..........................................................................................1133 Installation.....................................................................................1134 Door Striker Adjustment..........................................................................1134 Door Handle Plunger Adjustment...................................................................1135 DOOR PANEL.......................................................................................1136 Removal......................................................................................1136 Installation.................................................................................1136 DOOR WINDOW......................................................................................1137 Removal......................................................................................1137 Installation.................................................................................1139 WINDOW REGULATOR.................................................................................1141 Removal......................................................................................1141 Installation.................................................................................1141 DOOR HANDLE AND DOOR LATCH.......................................................................1141 Removal......................................................................................1141 Installation.................................................................................1141 DOOR SEALS...........................................................................................1142 Removal..........................................................................................1142 Installation.....................................................................................1142 DOOR OPENING SEAL....................................................................................1142 Removal..........................................................................................1142 Installation.....................................................................................1142 GLASS REPLACEMENT....................................................................................1143 Replacement......................................................................................1143 WINDSHIELD AND REAR GLASS........................................................................1144 Removal......................................................................................1144 Installation.................................................................................1145 SECTION N3 - CAB COMPONENTS - INDEX.........................................................................1146 CAB COMPONENTS...........................................................................................1148 WINDSHIELD WIPERS....................................................................................1148 WIPER MOTOR......................................................................................1148 Removal......................................................................................1148 Installation.................................................................................1148 WIPER ARM........................................................................................1148 Removal......................................................................................1148 Installation.................................................................................1149 WIPER LINKAGE....................................................................................1149 Removal......................................................................................1149 Installation.................................................................................1149 WINDSHIELD WASHER....................................................................................1150 Operation........................................................................................1150 Service..........................................................................................1150 OPERATOR SEAT........................................................................................1151 Adjustment.......................................................................................1151 Inspection.......................................................................................1152 Removal..........................................................................................1152 Installation.....................................................................................1152 SEAT BELT............................................................................................1152 Removal..........................................................................................1152 Installation.....................................................................................1154 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX ...........................................................1156 HEATING AND AIR CONDITIONING.............................................................................1158 HEATER/AIR CONDITIONER UNIT..........................................................................1158 Fan Speed Control Knob...........................................................................1158 Temperature Control Knob.........................................................................1158 Air Flow Directional Knob........................................................................1158 Heater/Air Conditioner Vents.....................................................................1159 COMPONENTS...........................................................................................1159 Fuse.............................................................................................1159 Relays...........................................................................................1159 Heater Core......................................................................................1159 Fan Motor And Speed Control......................................................................1160 Actuators........................................................................................1160 Cab Air Filter...................................................................................1160 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.............................................................1163 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................1163 PRINCIPLES OF REFRIGERATION..........................................................................1163 Air Conditioning.................................................................................1163 Refrigeration - The Act Of Cooling...............................................................1164 The Refrigeration Cycle..........................................................................1164 AIR CONDITIONER SYSTEM COMPONENTS....................................................................1165 Compressor (Refrigerant Pump)....................................................................1165 Service Valves...................................................................................1165 Condenser........................................................................................1165 Receiver-Drier...................................................................................1165 Expansion Block Valve............................................................................1166 Accumulator......................................................................................1166 Evaporator.......................................................................................1166 ELECTRICAL CIRCUIT...................................................................................1167 Thermostat.......................................................................................1167 Compressor Clutch................................................................................1167 Trinary™ Switch..................................................................................1168 SYSTEM SERVICING.....................................................................................1169 SERVICE TOOLS AND EQUIPMENT..........................................................................1170 Recovery/Recycle Station.........................................................................1170 Leak Detector....................................................................................1170 Service Valves...................................................................................1171 Vacuum Pump......................................................................................1171 Manifold Gauge Set...............................................................................1172 Installing Manifold Gauge Set....................................................................1173 Purging Air From Service Hoses...................................................................1173 SYSTEM PERFORMANCE TEST..............................................................................1174 SYSTEM OIL...........................................................................................1175 Handling and Reusing PAG Oil.....................................................................1175 Oil Quantity.....................................................................................1175 Checking System Oil..............................................................................1175 REFRIGERANT..........................................................................................1176 Recycled Refrigerant.............................................................................1176 Reclaimed Refrigerant............................................................................1176 Refrigerant Quantity.............................................................................1176 R-134a Refrigerant Containers....................................................................1177 SYSTEM LEAK TESTING..................................................................................1177 Electronic Leak Detector.........................................................................1178 Tracer Dyes......................................................................................1178 Soap and Water...................................................................................1178 RECOVERING AND RECYCLING THE REFRIGERANT.............................................................1178 Draining Oil from the Previous Recovery Cycle....................................................1178 Performing the Recovery Cycle....................................................................1178 Performing the Recycling Procedure...............................................................1179 Evacuating and Charging the A/C System...........................................................1179 SYSTEM REPAIR........................................................................................1179 System Flushing..................................................................................1179 A/C DRIVE BELT CHECKOUT PROCEDURE....................................................................1180 Pulley Alignment.................................................................................1180 Belt Tension Check...............................................................................1180 COMPONENT REPLACEMENT................................................................................1182 Hoses and Fittings...............................................................................1182 Lines............................................................................................1182 Expansion Valve..................................................................................1182 Receiver-Drier...................................................................................1182 Thermostat.......................................................................................1182 Compressor.......................................................................................1183 Accumulator......................................................................................1183 Clutch...........................................................................................1183 Servicing the Compressor Clutch..................................................................1184 Pulley Removal...................................................................................1186 Clutch Coil Check................................................................................1187 Pulley Installation..............................................................................1187 Clutch Assembly Installation.....................................................................1187 EVACUATING THE SYSTEM................................................................................1189 CHARGING THE A/C SYSTEM..............................................................................1191 TROUBLESHOOTING..........................................................................................1192 Preliminary Checks...................................................................................1192 Diagnosis Of Gauge Readings And System Performance...................................................1192 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...........................................................1193 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...........................................................1199 SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX ..............................................................1200 OPERATOR CAB AND CONTROLS................................................................................1202 STEERING WHEEL AND CONTROLS..........................................................................1203 Horn Button......................................................................................1203 ARSC Set Lever...................................................................................1203 Telescoping/Tilt Wheel Lever.....................................................................1203 Multi-Function Turn Signal Lever.................................................................1203 RETARDER CONTROL LEVER...............................................................................1204 STEERING WHEEL.......................................................................................1205 Removal..........................................................................................1205 Installation.....................................................................................1205 SERVICE BRAKE PEDAL..................................................................................1205 ACCELERATOR PEDAL....................................................................................1205 INSTRUMENT PANEL.....................................................................................1205 HEATER / AIR CONDITIONER CONTROLS....................................................................1206 RETARDING CAPACITY CHART.............................................................................1206 RADIO SPEAKERS.......................................................................................1206 AIR CLEANER VACUUM GAUGES............................................................................1206 WARNING ALARM BUZZER.................................................................................1206 AM/FM RADIO / CD PLAYER..............................................................................1206 CENTER CONSOLE.......................................................................................1207 Hoist Control Lever..............................................................................1208 Transmission Shift Lever.........................................................................1208 Parking Brake Switch.............................................................................1209 LH Window Control Switch.........................................................................1209 RH Window Control Switch.........................................................................1209 Auxiliary Power Outlets..........................................................................1209 INSTRUMENT PANEL AND INDICATORS......................................................................1210 UPPER RH SWITCH PANEL............................................................................1211 Brake Lock Switch............................................................................1211 F1 Start Switch..............................................................................1211 Hazard Warning Lights Switch.................................................................1211 LOWER RH SWITCH PANEL............................................................................1212 Key Switch...................................................................................1212 Ether Starting Aid Switch....................................................................1213 ASR Cut Switch...............................................................................1213 ARSC Switch..................................................................................1213 Automatic Idle Selector Switch (AISS)........................................................1213 Auxiliary Brake Switch.......................................................................1214 UPPER LH SWITCH PANEL............................................................................1215 Automatic Lubrication System Indicator.......................................................1215 LOWER LH SWITCH PANEL............................................................................1216 Head Light Switch............................................................................1216 Ladder Light Switch..........................................................................1216 BackUp/Deck Light Switch.....................................................................1217 Fog Light Switch.............................................................................1217 Mode Select Switches 1 & 2...................................................................1217 Panel Light Dimmer Switch....................................................................1217 ELECTRONIC DISPLAY PANEL.............................................................................1218 PILOT DISPLAY ITEMS..............................................................................1219 METER DISPLAYS...................................................................................1221 CAUTION ITEMS....................................................................................1223 EMERGENCY STOP ITEMS.............................................................................1225 CHARACTER DISPLAY................................................................................1228 REAR ELECTRICAL COMPARTMENT..........................................................................1229 AUTOMATIC RETARD SPEED CONTROL (ARSC)................................................................1232 AUTOMATIC SPIN REGULATOR (ASR).......................................................................1235 SECTION P - LUBRICATION AND SERVICE - INDEX .....................................................................1238 SECTION P2 - LUBRICATION AND SERVICE - INDEX ................................................................1240 LUBRICATION AND SERVICE..................................................................................1242 COOLANT SPECIFICATIONS...............................................................................1242 Unacceptable Practices...........................................................................1242 RADIATOR FILL PROCEDURE..............................................................................1242 HYDRAULIC TANK SERVICE...............................................................................1243 Filling Instructions.............................................................................1243 TRANSMISSION OIL LEVEL CHECK.........................................................................1243 QUICK FILL SERVICE CENTER............................................................................1244 PERIODIC REPLACEMENT OF CRITICAL PARTS...............................................................1244 10 HOUR (DAILY) INSPECTION...........................................................................1246 10 HOUR (DAILY) INSPECTION (continued)...............................................................1247 250 HOUR INSPECTION..................................................................................1248 250 HOUR INSPECTION (continued)......................................................................1249 250 HOUR INSPECTION (continued)......................................................................1250 500 HOUR INSPECTION..................................................................................1251 1000 HOUR INSPECTION.................................................................................1252 2000 HOUR INSPECTION.................................................................................1253 5000 HOUR INSPECTION.................................................................................1254 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX ...........................................................1256 AUTOMATIC LUBRICATION SYSTEM.............................................................................1258 GENERAL DESCRIPTION..................................................................................1258 SYSTEM COMPONENTS....................................................................................1262 SYSTEM OPERATION.....................................................................................1264 INJECTOR OPERATION...................................................................................1265 LUBRICANT PUMP.......................................................................................1266 Pump Housing Oil Level...........................................................................1266 Pump Pressure Control............................................................................1266 INJECTORS (SL-1 Series “H”)).........................................................................1267 Injector Specifications..........................................................................1267 Injector Adjustment..............................................................................1267 SYSTEM PRIMING.......................................................................................1268 Filter Assembly..................................................................................1268 SYSTEM CHECK.........................................................................................1269 Lubrication Controller Check.....................................................................1269 Lubrication Controller Operation.................................................................1269 Lubrication Controller Components................................................................1269 Lubrication Controller Adjustment................................................................1269 SYSTEM TROUBLESHOOTING CHART.........................................................................1271 PREVENTATIVE MAINTENANCE.............................................................................1273 Daily Lubrication System Inspection..............................................................1273 250 Hour Inspection..............................................................................1273 1000 Hour Inspection.............................................................................1274 PUMP REBUILD.........................................................................................1275 Disassembly......................................................................................1275 Cleaning and Inspection..........................................................................1278 Assembly.........................................................................................1278 SECTION R - SYSTEM SCHEMATICS - INDEX ...........................................................................1280 HYDRAULIC SYSTEM SCHEMATIC ..................................................................................1282 HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40° C) ............................................................1283 BRAKE SYSTEM SCHEMATIC......................................................................................1284 HOOKUP SCHEMATIC............................................................................................1285 ELECTRICAL WIRING SCHEMATIC.................................................................................1293 HVAC WIRING SCHEMATIC.......................................................................................1316 CONNECTOR LOCATOR ...........................................................................................1317
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