Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu HD1500 Dump Truck Shop Manual A30001 & UP – PDF DOWNLOAD
Original price was: $52.95.$34.95Current price is: $34.95.
Komatsu HD1500 Dump Truck Shop Manual
SERIAL NUMBERS A30001 & UP
Book Code: CEBM016105
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu HD1500 Dump Truck Shop Manual
FILE DETAILS:
Komatsu HD1500 Dump Truck Shop Manual
Language : English
Pages : 1304
Downloadable : Yes
File Type : PDF
Size: 29.4
Book Code: CEBM016105
DESCRIPTION:
Komatsu HD1500 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 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...................................................................... 18 Prevention Of Injury By Work Equipment............................................................... 18 Fire Extinguisher And First Aid Kit.................................................................. 18 Precautions For ROPS................................................................................. 18 Precautions For Attachments.......................................................................... 18 HAUL ROADS........................................................................................... 19 PRECAUTIONS DURING OPERATION......................................................................... 19 BEFORE STARTING THE ENGINE....................................................................... 19 Fire Prevention.............................................................................. 20 Preparing For Operation...................................................................... 20 Ventilation In Enclosed Areas................................................................ 20 In Operator’s Cab - Before Starting The Engine............................................... 20 Mirrors, Windows, And Lights................................................................. 20 OPERATING THE MACHINE............................................................................ 21 When Starting The Engine..................................................................... 21 Precautions For Starting Machine............................................................. 21 Truck Operation - General.................................................................... 21 Traveling.................................................................................... 22 Traveling In Reverse......................................................................... 22 Traveling On Slopes.......................................................................... 22 Ensure Good Visibility....................................................................... 22 Operate Carefully On Snow.................................................................... 23 Avoid Damage To Dump Body.................................................................... 23 Driving Near High Voltage Cables............................................................. 23 When Dumping................................................................................. 23 Working On Loose Ground...................................................................... 23 Loading The Body............................................................................. 23 Parking The Machine.......................................................................... 23 TOWING........................................................................................... 24 WORKING NEAR BATTERIES........................................................................... 24 Battery Hazard Prevention.................................................................... 24 Starting With Booster Cables................................................................. 24 MAINTENANCE PRECAUTIONS.............................................................................. 25 Warning Tag...................................................................................... 25 Proper Tools..................................................................................... 25 Stopping The Engine Before Service............................................................... 25 Securing The Dump Body........................................................................... 25 DURING MAINTENANCE............................................................................... 27 Personnel.................................................................................... 27 Attachments.................................................................................. 27 Working Under The Machine.................................................................... 27 Keep The Machine Clean....................................................................... 27 Rules To Follow When Adding Fuel Or Oil...................................................... 27 Radiator Water Level......................................................................... 27 Use Of Lighting.............................................................................. 27 Precautions With The Battery................................................................. 28 Handling High Pressure Hoses................................................................. 28 Precautions With High Pressure Oil........................................................... 28 Precautions When Performing Maintenance Near High Temperature Or High Pressure............... 28 Rotating Fan And Belts....................................................................... 28 Waste Materials.............................................................................. 28 TIRES............................................................................................ 29 Handling Tires............................................................................... 29 Storing Tires After Removal.................................................................. 29 WHEN REPAIRS ARE NECESSARY........................................................................... 30 ADDITIONAL JOB SITE RULES................................................................................ 31 OPERATING INSTRUCTIONS................................................................................... 32 PREPARING FOR OPERATION.............................................................................. 32 Safety Is Thinking Ahead......................................................................... 32 Walk Around Inspection........................................................................... 32 ENGINE START-UP SAFETY PRACTICES..................................................................... 35 Cold Weather Starting............................................................................ 36 Jump Starting.................................................................................... 36 AFTER THE ENGINE HAS STARTED......................................................................... 37 MACHINE OPERATION SAFETY PRECAUTIONS................................................................. 39 LOADING.............................................................................................. 40 HAULING.............................................................................................. 41 RETARDER OPERATION................................................................................... 41 PASSING.............................................................................................. 42 DUMPING.............................................................................................. 42 Raising the Dump Body............................................................................ 43 Lowering The Dump Body........................................................................... 43 SAFE PARKING PROCEDURES.............................................................................. 44 TURNING OFF THE ENGINE............................................................................... 44 SUDDEN LOSS OF ENGINE POWER.......................................................................... 44 Secondary Steering And Braking................................................................... 44 DISABLED TRUCK DUMPING............................................................................... 45 Hookup........................................................................................... 45 Raising the Body................................................................................. 46 Lowering the Body................................................................................ 46 DISABLED TRUCK STEERING AND BRAKING.................................................................. 47 TOWING............................................................................................... 49 SECTION A4 - WARNINGS AND CAUTIONS........................................................................... 52 SECTION A5 - TORQUE TABLES AND CONVERSION CHARTS............................................................ 58 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values..................................... 59 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts.................................... 59 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws....................................... 60 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws................................................... 61 Hardware Tightening Method........................................................................... 69 SECTION A7 - STORAGE PROCEDURES - INDEX ..................................................................... 70 STORAGE AND IDLE MACHINE PREPARATION..................................................................... 72 SHORT TERM IDLE PERIODS.............................................................................. 72 PREPARATION FOR STORAGE.............................................................................. 72 REMOVAL FROM STORAGE................................................................................. 73 RECONDITIONING AN IDLE VEHICLE....................................................................... 75 ENGINE OPERATION..................................................................................... 78 AFTER THE ENGINE HAS STARTED......................................................................... 78 SHORT TERM ENGINE STORAGE............................................................................ 79 Preparing the Engine............................................................................. 79 Removing the Engine from Long Term Storage....................................................... 81 TRANSMISSION PRESERVATION AND STORAGE................................................................ 81 Storage, New Transmission........................................................................ 81 Storage, One Year- Without Oil................................................................... 81 Storage, One Year - With Oil - Normally Installed On The Truck................................... 82 Restoring The Transmission For Service........................................................... 82 SECTION B - STRUCTURES - INDEX .................................................................................. 84 SECTION B2 - STRUCTURAL COMPONENTS - INDEX .................................................................. 86 STRUCTURAL COMPONENTS.................................................................................... 88 PREPARATION.......................................................................................... 88 GRILLE, HOOD AND LADDERS............................................................................. 89 DECKS............................................................................................ 90 CENTER DECK.......................................................................................... 90 Removal.......................................................................................... 90 Installation..................................................................................... 90 RIGHT DECK AND COMPONENTS........................................................................ 90 Removal...................................................................................... 90 Installation................................................................................. 90 LEFT DECK AND CAB................................................................................ 91 Installation................................................................................. 91 SECTION B3 - DUMP BODY - INDEX .............................................................................. 92 DUMP BODY................................................................................................ 94 Removal.............................................................................................. 94 Installation......................................................................................... 96 BODY PADS............................................................................................ 96 Removal.......................................................................................... 96 Installation..................................................................................... 97 Body Pad Adjustment.............................................................................. 97 BODY GUIDE........................................................................................... 99 BODY-UP RETENTION CABLE.............................................................................. 100 ROCK EJECTORS........................................................................................ 100 Inspection....................................................................................... 100 SECTION B4 - FUEL TANK - INDEX .............................................................................. 102 FUEL TANK................................................................................................ 104 Removal.............................................................................................. 104 Cleaning............................................................................................. 105 Repair............................................................................................... 105 Installation......................................................................................... 105 FUEL GAUGE AND SENDING UNIT.......................................................................... 106 Removal.......................................................................................... 106 Installation..................................................................................... 106 WIGGINS QUICK FILL FUEL SYSTEM....................................................................... 106 FUEL RECEIVER.................................................................................... 106 FUEL TANK BREATHER............................................................................... 107 Removal...................................................................................... 107 Installation................................................................................. 107 Disassembly.................................................................................. 107 Assembly..................................................................................... 107 LEFT SIDE FILL................................................................................... 108 SECTION C - ENGINE - INDEX ...................................................................................... 110 SECTION C3 - COOLING SYSTEM - INDEX ......................................................................... 112 COOLING SYSTEM........................................................................................... 114 DESCRIPTION.......................................................................................... 114 LEAKS AND CONTAMINATION.............................................................................. 115 RADIATOR FILL PROCEDURE.............................................................................. 115 RADIATOR REMOVAL..................................................................................... 116 RADIATOR REPAIR...................................................................................... 118 Internal Inspection.............................................................................. 118 External Cleaning................................................................................ 118 Disassembly...................................................................................... 119 Cleaning and Inspection.......................................................................... 120 Assembly......................................................................................... 120 Pressure Testing................................................................................. 121 Additional Service Information................................................................... 121 RADIATOR INSTALLATION................................................................................ 122 TRANSMISSION AND BRAKE COOLERS....................................................................... 123 Removal.......................................................................................... 124 Disassembly...................................................................................... 124 Cleaning And Inspection.......................................................................... 125 Assembly......................................................................................... 125 Inspection....................................................................................... 126 Installation..................................................................................... 127 SECTION C4 - ENGINE - INDEX ................................................................................. 128 ENGINE................................................................................................... 130 Removal.............................................................................................. 130 Inspection........................................................................................... 133 Installation......................................................................................... 134 DRIVE LINE ADAPTER................................................................................... 135 Removal.......................................................................................... 136 Disassembly...................................................................................... 137 Cleaning and Inspection.......................................................................... 139 Assembly......................................................................................... 141 Installation..................................................................................... 145 Bearing Tools.................................................................................... 146 SECTION C5 - AIR FILTRATION SYSTEM - INDEX .................................................................. 148 AIR FILTRATION SYSTEM.................................................................................... 150 AIR CLEANER.......................................................................................... 150 Operation........................................................................................ 150 General Maintenance.............................................................................. 150 FILTER SERVICE INDICATOR......................................................................... 152 MAIN FILTER ELEMENT.............................................................................. 152 Removal...................................................................................... 152 Installation................................................................................. 152 SAFETY FILTER ELEMENT............................................................................ 152 Removal...................................................................................... 152 Installation................................................................................. 152 MAIN FILTER CLEANING............................................................................. 153 PRECLEANER CLEANING.............................................................................. 154 AIR INTAKE GUIDELINES............................................................................ 155 Installation................................................................................. 155 AIR INTAKE TROUBLESHOOTING........................................................................... 156 SECTION C7 - FAN DRIVE CLUTCH - INDEX ....................................................................... 158 FAN DRIVE CLUTCH......................................................................................... 160 DISASSEMBLY.......................................................................................... 160 ASSEMBLY............................................................................................. 167 INSPECTION OF PARTS...................................................................................... 178 REBUILD TOOLS........................................................................................ 182 SECTION D - ELECTRICAL SYSTEM - INDEX ........................................................................... 184 SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX .......................................................... 186 BATTERIES AND STARTING SYSTEM............................................................................ 188 BATTERIES............................................................................................ 188 MAINTENANCE AND SERVICE.......................................................................... 188 Electrolyte Levels........................................................................... 188 Cleaning..................................................................................... 188 Other Maintenance............................................................................ 189 PRELUB™ SYSTEM....................................................................................... 191 OPERATION........................................................................................ 191 Oil Pressure Switch.......................................................................... 192 Check Valve.................................................................................. 192 TROUBLESHOOTING.................................................................................. 193 STARTING SYSTEM...................................................................................... 195 CRANKING MOTORS.................................................................................. 195 Removal...................................................................................... 195 Disassembly.................................................................................. 196 Cleaning and Inspection...................................................................... 196 Armature Servicing........................................................................... 196 Field Coil Checks............................................................................ 197 Field Coil Removal........................................................................... 197 Solenoid Checks.............................................................................. 199 Assembly..................................................................................... 200 Installation................................................................................. 202 TROUBLESHOOTING.................................................................................. 202 Preliminary Inspection....................................................................... 202 No-Load Test................................................................................. 202 Interpreting The Results of The Tests........................................................ 203 MAGNETIC SWITCH.................................................................................. 204 Removal...................................................................................... 204 Installation................................................................................. 204 Coil Test.................................................................................... 204 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX ........................................................... 206 ELECTRICAL SYSTEM COMPONENTS............................................................................. 208 CAB MOUNTED COMPONENTS............................................................................... 208 CIRCUIT BREAKERS................................................................................. 210 RELAY CENTER..................................................................................... 211 FUSE PANEL....................................................................................... 216 EXTERIOR COMPONENTS.................................................................................. 220 BATTERY BOX...................................................................................... 220 BATTERY DISCONNECT SWITCH........................................................................ 220 GROUND LEVEL SHUT OFF SWITCH..................................................................... 220 CONTROL POWER RELAYS............................................................................. 220 CIRCUIT BREAKERS................................................................................. 220 BATTERY EQUALIZER................................................................................ 220 Test......................................................................................... 220 BODY POSITION SWITCHES........................................................................... 222 Proximity Switch Operation................................................................... 222 Body-Up Switch Adjustment.................................................................... 223 Hoist Limit Switch Adjustment................................................................ 223 SPEED SENSORS.................................................................................... 225 Sensor Adjustment............................................................................ 226 GENERAL TROUBLESHOOTING.............................................................................. 226 SECTION D10 - CHARGING SYSTEM - INDEX ....................................................................... 228 CHARGING SYSTEM.......................................................................................... 230 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION........................................................ 230 Excessive heat................................................................................... 230 Dirt and dust.................................................................................... 230 Vibration........................................................................................ 230 PREVENTIVE MAINTENANCE PROCEDURES.................................................................... 231 Alternator Cleanliness........................................................................... 231 Alternator Mounting.............................................................................. 231 Belt Tension And Condition....................................................................... 231 TROUBLESHOOTING...................................................................................... 231 ALTERNATOR PERFORMANCE TEST...................................................................... 231 ALTERNATOR CABLE TEST............................................................................ 232 VOLTAGE REGULATOR ADJUSTMENT......................................................................... 233 ALTERNATOR........................................................................................... 234 Removal.......................................................................................... 234 Installation..................................................................................... 235 SECTION D11 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX .................................................... 238 AUTOMATIC TRANSMISSION CONTROLLER........................................................................ 240 GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES........................................... 241 TRANSMISSION OPERATING MODES......................................................................... 242 NETWORK DATA......................................................................................... 242 SHIFT LOGIC.......................................................................................... 244 Shift Lever Position D, Up-Shifting.............................................................. 244 Shift Lever Position D, Down-Shifting............................................................ 244 Shift Lever Positions 6, 5, 4, 3, 2, L........................................................... 244 Shift Lever Positions R.......................................................................... 244 Shift Lever Position N........................................................................... 244 Gear Shift Time Delay............................................................................ 244 SAFETY FUNCTIONALITY............................................................................. 245 Down-Shift Inhibitor Function................................................................ 245 Neutral Safety Function...................................................................... 245 Directional Inhibit Function................................................................. 245 Powertrain Overrun Prevention................................................................ 245 Reverse Safety (Dump Body Raised)............................................................ 245 Speed Range Limit Function (Dump Body Raised)................................................ 245 Self-diagnostic function..................................................................... 245 ATC REAL TIME MONITORING............................................................................. 246 LIMP HOME MODE....................................................................................... 246 Limp Home Procedure 1............................................................................ 249 Limp Home Procedure 2............................................................................ 249 Limp Home Procedure 3............................................................................ 249 Limp Home Procedure 4............................................................................ 249 Limp Home Procedure 5............................................................................ 249 Limp Home Procedure 6............................................................................ 249 Limp Home Procedure 7............................................................................ 249 SECTION D15 - MACHINE MONITOR - INDEX ....................................................................... 250 MACHINE MONITOR.......................................................................................... 252 CHARACTER DISPLAY.................................................................................... 252 Mode Select Switches 1 & 2....................................................................... 253 Service Meter.................................................................................... 253 Odometer......................................................................................... 253 Operation Information............................................................................ 253 Reverse Travel Odometer.......................................................................... 254 Filter And Oil Change Display.................................................................... 254 Display Items.................................................................................... 255 Resetting The Filter/Oil Replacement Meter....................................................... 255 Inputting Telephone Numbers...................................................................... 256 Selecting A Language............................................................................. 256 ACTION CODE DISPLAYS................................................................................. 257 E03 Codes........................................................................................ 257 E02 Codes........................................................................................ 258 E01 Codes........................................................................................ 258 REAL TIME MONITOR.................................................................................... 259 USING REAL TIME MONITOR.......................................................................... 259 Viewing Two Streams of Data At Once.......................................................... 260 Real Time Monitoring Codes................................................................... 261 MACHINE MONITOR FLOW CHART....................................................................... 265 SECTION D20 - FAILURE CODES - INDEX ......................................................................... 270 FAILURE CODES............................................................................................ 272 ACTION CODE DISPLAYS................................................................................. 272 CHECKING FAILURE CODES............................................................................... 273 LIMP HOME MODE....................................................................................... 274 FAILURE CODE TABLE................................................................................... 275 SECTION D21 - TROUBLESHOOTING............................................................................... 292 FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES........................................................ 292 FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION............................................... 293 FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR............................................ 295 FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR............................................ 295 FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 296 FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING........................................................... 297 FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR.......................................... 299 FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING.............................................................. 301 FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING............................................................... 303 FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING............................................................... 305 FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING............................................................... 307 FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING............................................................... 309 FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF................................. 311 FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION.......................................................... 313 FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF.............................. 315 FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION...................................................... 319 FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 321 FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION....................................................... 325 FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 327 FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION....................................................... 331 FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 333 FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION....................................................... 337 FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 339 FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION....................................................... 343 FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION.................................................... 345 FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF............................... 346 FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION....................................................... 349 FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING............................................................... 351 FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION........................................................... 353 FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION..................................................... 354 FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE...................................................... 355 FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR............................................. 356 FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE.................................................. 357 FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE........................................... 358 FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE........................................... 359 FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION...................................................... 360 FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED...................................... 361 FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION............................................................ 362 FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE................................................ 363 FAILURE CODE [B@BCNS] ENGINE: OVERHEAT................................................................... 364 FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW........................................................ 365 FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING............................................. 366 FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING........................................ 367 FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING......................................... 368 FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING.................................................. 369 FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION...................................... 370 FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION.................................... 371 FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION.................................... 372 FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION................................................... 373 FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR............................................... 375 FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW.................................. 379 FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW........................... 380 FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR..................................... 381 FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR....................................... 382 FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR...................................... 383 FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT............................................ 384 FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT.......................................... 385 FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR........................................................ 386 FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR........................... 387 FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION............................. 388 FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW................ 389 FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR......................................... 390 FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR........................................... 391 FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR.......................................... 393 FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR.......................................................... 394 FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT................................................ 395 FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE............................................. 397 FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT.......................................................... 399 FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT......................................................... 400 FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT....................................................... 401 FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT...................................................... 402 FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT................................................ 403 FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT.............................................. 405 FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 407 FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 409 FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 411 FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 413 FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT........................................... 415 FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT............................................... 417 FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT.......................................................... 419 FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT......................................................... 423 FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE..................... 426 FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND...................... 427 FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT................ 428 FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND....................... 429 FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT................. 430 FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT............... 431 FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND..................... 432 FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE................. 433 FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 434 FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE............................... 435 FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 436 FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 437 FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................ 438 FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE................................. 439 FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE........................... 440 FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION............................ 441 FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE.......................... 442 FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION........................... 443 FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT.................................................... 444 FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE............................................. 445 FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT......................................... 446 FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE......................................... 447 FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE................................................... 449 FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION............................................ 450 FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT.................................................. 451 FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION................................................... 452 FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT................................ 453 FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION................................. 454 FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT......................... 455 FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION.......................... 456 FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION......................................... 457 FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION.......................................... 458 FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 459 FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 460 FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT............................... 461 FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 462 FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION................................ 463 FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL.... 464 FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT........................................ 465 FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT......................................... 466 FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT.................................... 467 FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT................................... 468 FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE.............................................. 469 FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT.............................. 470 FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)........................................ 471 FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT........................................................ 472 FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT....................................................... 473 FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER...................................................... 474 FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................................ 475 FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)....................... 477 FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT....................................... 479 FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT...................................... 480 FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER..................................... 481 FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)............... 482 FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)........................ 483 FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT........................................ 485 FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT....................................... 486 FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER...................................... 487 FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION......................................... 488 FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION..................................... 489 FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT......................................... 491 FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT........................................ 492 FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER....................................... 493 FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)................. 494 FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT.................................... 495 FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT................................... 496 FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................. 497 FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT...................................... 499 FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT..................................... 501 FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER.................................... 503 FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 507 FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 509 FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 511 FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 515 FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 517 FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 519 FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 523 FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 525 FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 527 FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 531 FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 533 FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 535 FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT......................................... 539 FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT........................................ 541 FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER....................................... 543 FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT....................................... 547 FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT...................................... 549 FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER..................................... 551 SECTION D30 - VHMS INITIALIZATION - INDEX ................................................................... 554 INITIALIZATION OF VHMS CONTROLLER........................................................................ 556 Executing Quick PM................................................................................... 567 Downloading Existing VHMS Setting Data............................................................... 572 Confirmation of Downloaded Data...................................................................... 573 Disconnecting the PC................................................................................. 573 Reporting to Komatsu................................................................................. 573 REPLACING THE VHMS CONTROLLER............................................................................ 575 Prior to Removing VHMS Controller.................................................................... 575 Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)......................... 575 Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)..................... 579 Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)............................ 581 Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)........................ 582 FINAL VHMS PROCEDURES-POST INSTALLATION.................................................................. 583 Correct the Load Weight Calculation.................................................................. 585 SECTION D31 - VEHICLE HEALTH MONITORING SYSTEM (VHMS) - INDEX ............................................... 594 VEHICLE HEALTH MONITORING SYSTEM (VHMS).................................................................. 596 VHMS DOWNLOADING..................................................................................... 597 PAYLOAD METER........................................................................................ 598 NORMAL OPERATION DISPLAY......................................................................... 599 EXTERNAL DISPLAY LAMPS........................................................................... 600 PREDICTED LOAD DISPLAY........................................................................... 600 CALIBRATING PLM.................................................................................. 601 DATA STORED IN PAYLOAD METER..................................................................... 602 PLM DOWNLOADING.................................................................................. 603 Downloading From Inside Of The Cab........................................................... 603 Downloading From Ground Level Box............................................................ 603 SETTING THE MACHINE ID AND OPEN ID............................................................... 604 PAYLOAD - CYCLE DATA ITEM........................................................................ 605 ADDITIONAL FUNCTIONS............................................................................. 605 Other Settings............................................................................... 605 SECTION F - TRANSMISSION/TORQUE CONVERTER - INDEX ............................................................... 606 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX ...................................................... 608 TORQUE CONVERTER AND TRANSMISSION........................................................................ 610 TORQUE CONVERTER..................................................................................... 611 MAIN RELIEF VALVE................................................................................ 613 Function..................................................................................... 613 Operation.................................................................................... 613 TORQUE CONVERTER RELIEF VALVE.................................................................... 613 Function..................................................................................... 613 Operation.................................................................................... 613 TORQUE CONVERTER REGULATOR VALVE................................................................. 615 Operation.................................................................................... 615 LOCK-UP CLUTCH................................................................................... 616 Lock-up Clutch Accumulator................................................................... 616 HYDRAULIC PUMP................................................................................... 617 TORQUE CONVERTER STALL CHECK..................................................................... 618 TRANSMISSION......................................................................................... 619 LUBRICATION RELIEF VALVE......................................................................... 621 Function..................................................................................... 621 TRANSMISSION CONTROL VALVE....................................................................... 622 ELECTRONIC CONTROL MODULATION VALVE (ECMV)....................................................... 624 Pressure Control Valve....................................................................... 625 Flow Sensor Valve............................................................................ 625 ECMV and Proportional Solenoid............................................................... 625 ECMV and Fill Switch......................................................................... 625 ECMV Operation............................................................................... 626 ECMV REPAIR...................................................................................... 629 Preparation.................................................................................. 629 Filter Replacement Procedure................................................................. 629 ECMV Identification.......................................................................... 630 ECMV Removal................................................................................. 630 Disassembly.................................................................................. 630 Assembly..................................................................................... 632 Installation................................................................................. 632 TRANSMISSION FILTERS............................................................................. 634 Service...................................................................................... 634 Installation................................................................................. 634 TRANSMISSION SPEED SENSORS....................................................................... 635 Adjustment Procedure......................................................................... 635 TRANSMISSION OIL LEVEL CHECK..................................................................... 636 TRANSMISSION OIL PRESSURE CHECK.................................................................. 637 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING.................................................... 639 Preliminary Checks............................................................................... 639 TRANSMISSION REMOVAL............................................................................. 643 TRANSMISSION INSTALLATION........................................................................ 644 SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX .................................................... 648 TRANSMISSION OIL COOLER & STRAINERS...................................................................... 650 TRANSMISSION OIL COOLER.............................................................................. 650 Removal and Installation......................................................................... 650 Repair........................................................................................... 650 TRANSMISSION OIL STRAINER............................................................................ 650 Removal.......................................................................................... 651 Inspection....................................................................................... 651 Installation..................................................................................... 651 SECTION F5 - DRIVE SHAFTS - INDEX ........................................................................... 652 DRIVE SHAFTS............................................................................................. 654 FRONT DRIVE SHAFT.................................................................................... 654 Removal.......................................................................................... 654 Disassembly...................................................................................... 654 Assembly......................................................................................... 654 Installation..................................................................................... 655 FRONT DRIVE SHAFT ALIGNMENT...................................................................... 656 REAR DRIVE SHAFT..................................................................................... 659 Removal.......................................................................................... 659 Disassembly...................................................................................... 660 Assembly......................................................................................... 660 Installation..................................................................................... 660 SECTION F8 - TORQUE CONVERTER REBUILD - INDEX ............................................................... 662 TORQUE CONVERTER REBUILD................................................................................. 664 REMOVAL.............................................................................................. 664 INSTALLATION......................................................................................... 666 DISASSEMBLY.......................................................................................... 668 PTO COVER DISASSEMBLY............................................................................ 676 CLEANING & INSPECTION................................................................................ 677 TABLE I. COMPONENT WEAR LIMITS................................................................... 678 TABLE II. Gear Backlash.......................................................................... 678 ASSEMBLY............................................................................................. 679 ONE-WAY CLUTCH ASSEMBLY.......................................................................... 680 STATOR BEARING PRE-LOAD ADJUSTMENT............................................................... 682 PTO DRIVE ASSEMBLY............................................................................... 686 SPECIAL TOOLS........................................................................................ 691 SECTION F9 - TRANSMISSION REBUILD - INDEX ................................................................... 694 TRANSMISSION REBUILD..................................................................................... 696 TRANSMISSION DISASSEMBLY............................................................................. 696 Number One Clutch Housing Disassembly............................................................ 700 Bearing Cage & Cover Disassembly................................................................. 703 Number Four Carrier Disassembly.................................................................. 704 Output Shaft Cover Disassembly................................................................... 705 Rear Case Bearing Removal........................................................................ 705 Output Shaft Removal............................................................................. 706 Output Shaft Disassembly......................................................................... 706 Number Five/Six Carrier Disassembly.............................................................. 706 CLEANING AND INSPECTION.............................................................................. 708 INSPECTION TABLE INDEX........................................................................... 708 TRANSMISSION ASSEMBLY................................................................................ 714 GENERAL INSTRUCTIONS............................................................................. 714 Number Five/Six Carrier Assembly............................................................. 714 Output Shaft Assembly........................................................................ 715 Number Seven Clutch Assembly................................................................. 716 Rear Case Assembly........................................................................... 717 Rear Case & Carrier Assembly................................................................. 717 Number Six Clutch Assembly................................................................... 719 Number Four Carrier Assembly................................................................. 720 Number Four Carrier Bearing Cage Assembly.................................................... 721 Number Five Clutch Assembly.................................................................. 721 Number Four Clutch Assembly.................................................................. 722 Number Three Clutch Assembly................................................................. 722 Clutch Test.................................................................................. 723 Number Two Clutch Ring Gear Installation..................................................... 723 Number Three Carrier & Number Two Clutch Assembly............................................ 724 Number One Carrier Assembly.................................................................. 724 Number One Clutch Assembly................................................................... 727 Checks Prior to Final Assembly............................................................... 729 Final Assembly............................................................................... 729 Input Shaft Installation..................................................................... 730 External Components.......................................................................... 732 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX ............................................................. 734 SECTION G2 - TIRES AND RIMS - INDEX ......................................................................... 736 TIRES AND RIMS........................................................................................... 738 GENERAL INFORMATION.................................................................................. 738 FRONT TIRES AND RIMS................................................................................. 739 Removal.......................................................................................... 739 Installation..................................................................................... 740 REAR TIRE AND RIM.................................................................................... 740 Removal.......................................................................................... 740 Installation..................................................................................... 742 TIRE MATCHING........................................................................................ 743 RIM.................................................................................................. 743 Tire Removal From Rim............................................................................ 743 Tire Installation On Rim......................................................................... 744 FRONT WHEEL STUD INSTALLATION........................................................................ 745 REAR WHEEL STUD INSTALLATION......................................................................... 746 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX ............................................................ 748 FRONT WHEEL HUB AND SPINDLE.............................................................................. 750 OIL SAMPLE ANALYSIS.................................................................................. 750 Oil Sampling Guidelines.......................................................................... 750 Guidelines For Obtaining A Sample................................................................ 750 FRONT WHEEL HUB...................................................................................... 751 Removal.......................................................................................... 751 Disassembly...................................................................................... 751 Inspection....................................................................................... 751 Assembly......................................................................................... 752 Installation..................................................................................... 754 Front Wheel Hub Bearing Adjustment............................................................... 754 FRONT SPINDLE........................................................................................ 755 A-ARM................................................................................................ 755 Removal.......................................................................................... 755 Inspection....................................................................................... 755 Installation..................................................................................... 755 CENTER TIE ROD PIVOT................................................................................. 756 Removal.......................................................................................... 756 Inspection....................................................................................... 756 Installation..................................................................................... 756 TOE IN ADJUSTMENT.................................................................................... 757 Adjustment Procedure............................................................................. 757 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX .................................................................. 762 REAR AXLE ATTACHMENTS.................................................................................... 764 CENTER LINK AND LOWER LINKS.......................................................................... 764 Removal.......................................................................................... 764 Inspection....................................................................................... 765 Spherical Bearing Replacement.................................................................... 765 Installation..................................................................................... 765 PANHARD ROD (DIAGONAL LINK).......................................................................... 766 Removal.......................................................................................... 766 Inspection....................................................................................... 767 Installation..................................................................................... 767 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX ..................................................... 768 REAR AXLE & FINAL DRIVE ASSEMBLY......................................................................... 770 DIFFERENTIAL OPERATION............................................................................... 770 Straight-away-travel............................................................................. 770 Turning.......................................................................................... 770 REAR AXLE ASSEMBLY............................................................................... 771 Removal...................................................................................... 771 Installation................................................................................. 771 DIFFERENTIAL OIL LEVEL CHECK..................................................................... 772 DIFFERENTIAL ASSEMBLY............................................................................ 773 Removal...................................................................................... 773 Installation................................................................................. 774 Disassembly.................................................................................. 774 Pinion Carrier Assembly...................................................................... 777 Differential Gear Unit....................................................................... 777 Differential Gear Unit....................................................................... 778 Cleaning and Inspection...................................................................... 781 Assembly..................................................................................... 781 Differential Bearing......................................................................... 781 Assembly Of Differential Gear Assembly....................................................... 781 Installation Of Differential Assembly........................................................ 783 Input Pinion and Carrier Assembly............................................................ 784 Adjusting Tooth Contact, Backlash............................................................ 788 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX ................................................. 792 FINAL DRIVE PLANETARIES AND WHEEL HUBS................................................................... 794 FINAL DRIVE.......................................................................................... 794 Oil Level Check.................................................................................. 795 FINAL DRIVE CARRIER ASSEMBLY..................................................................... 795 Removal...................................................................................... 795 Installation................................................................................. 796 Disassembly.................................................................................. 796 Assembly..................................................................................... 797 FINAL DRIVE ASSEMBLY............................................................................. 798 Disassembly.................................................................................. 798 Assembly..................................................................................... 800 SECTION H - SUSPENSIONS - INDEX ................................................................................. 802 SECTION H2 - FRONT SUSPENSION - INDEX ....................................................................... 804 FRONT SUSPENSION......................................................................................... 806 Removal.............................................................................................. 808 Installation......................................................................................... 809 Disassembly.......................................................................................... 810 Cleaning and Inspection.............................................................................. 812 Assembly............................................................................................. 812 Pressure Tests....................................................................................... 813 DAMPING VALVE REPAIR................................................................................. 814 Disassembly...................................................................................... 814 Assembly......................................................................................... 815 SECTION H3 - REAR SUSPENSION - INDEX ........................................................................ 816 REAR SUSPENSION.......................................................................................... 818 Operation............................................................................................ 819 Removal.............................................................................................. 820 Installation......................................................................................... 820 Disassembly.......................................................................................... 820 Cleaning and Inspection.............................................................................. 824 Assembly............................................................................................. 824 LEAK TESTING......................................................................................... 825 SPHERICAL BEARINGS................................................................................... 825 Removal.......................................................................................... 825 Inspection....................................................................................... 825 Installation..................................................................................... 825 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX ......................................................... 826 SUSPENSION OILING AND CHARGING........................................................................... 828 GENERAL INFORMATION.................................................................................. 828 Equipment List................................................................................... 828 FRONT SUSPENSION..................................................................................... 830 Front Suspension Oiling.......................................................................... 830 Front Suspension Nitrogen Charging............................................................... 833 REAR SUSPENSION...................................................................................... 835 GENERAL INFORMATION.............................................................................. 835 Rear Suspension Oiling....................................................................... 835 Rear Suspension Nitrogen Charging............................................................ 839 FRONT AND REAR CYLINDER LENGTH ADJUSTMENT............................................................ 839 SECTION J - BRAKE SYSTEM - INDEX ................................................................................ 842 SECTION J2 - BRAKE SYSTEM OPERATION - INDEX ................................................................. 844 BRAKE SYSTEM OPERATION................................................................................... 846 DESCRIPTION.......................................................................................... 846 SERVICE BRAKE OPERATION.............................................................................. 847 SECONDARY BRAKING AND AUTOMATIC APPLY................................................................ 847 BRAKE SYSTEM COMPONENTS.............................................................................. 849 BRAKE MANIFOLD CARTRIDGE VALVES...................................................................... 851 SERVICE BRAKE CIRCUIT................................................................................ 855 RETARDING CIRCUIT................................................................................ 857 PARKING BRAKE CIRCUIT............................................................................ 859 AUTO APPLY....................................................................................... 861 AUXILIARY BRAKE CIRCUIT.......................................................................... 863 BRAKE LOCK CIRCUIT............................................................................... 865 AUTOMATIC SPIN REGULATOR......................................................................... 867 BRAKE COOLING CIRCUIT................................................................................ 869 BRAKE COOLING VALVE.............................................................................. 870 COLD OIL DIVERTER VALVES......................................................................... 873 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX ........................................................ 874 BRAKE CIRCUIT COMPONENT SERVICE.......................................................................... 876 BRAKE VALVE.......................................................................................... 877 Rebuild Criteria................................................................................. 877 Removal.......................................................................................... 877 Installation..................................................................................... 878 Disassembly...................................................................................... 879 Cleaning and Inspection.......................................................................... 880 Assembly......................................................................................... 882 Actuator Base Threaded Inserts................................................................... 882 Boot and Cap..................................................................................... 882 Valve Body Seal Installation..................................................................... 882 Regulator Sleeve O-Ring Installation............................................................. 882 Actuator Plunger O-ring Installation............................................................. 883 Assembly of Valve................................................................................ 884 BENCH TEST AND ADJUSTMENT............................................................................ 885 Test Bench Only.................................................................................. 885 Test Set Up Procedure............................................................................ 885 Brake Valve Output Pressure Adjustment........................................................... 887 Final Test and Adjustment........................................................................ 888 Proximity Switch Installation and Adjustment..................................................... 890 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................................... 890 BRAKE ACCUMULATORS................................................................................... 891 Removal.......................................................................................... 892 Installation..................................................................................... 892 Disassembly...................................................................................... 892 Cleaning and Inspection.......................................................................... 894 Assembly......................................................................................... 894 Leak Testing..................................................................................... 896 ACCUMULATOR CHARGING................................................................................. 897 Temperature During Precharge..................................................................... 899 ACCUMULATOR STORAGE.................................................................................. 900 Installation..................................................................................... 900 BRAKE COOLING VALVE (BCV)............................................................................ 901 RETARDER CONTROL LEVER............................................................................... 902 Removal.......................................................................................... 902 Installation..................................................................................... 902 Disassembly and Adjustment....................................................................... 902 Potentiometer Check.............................................................................. 904 Assembly......................................................................................... 904 Retard Lever Calibration......................................................................... 905 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX ................................................................. 906 BRAKE CIRCUIT CHECK-OUT.................................................................................. 908 REQUIRED EQUIPMENT................................................................................... 908 PREPARATION.......................................................................................... 908 BRAKE CIRCUIT TESTING................................................................................ 909 Initial System Setup............................................................................. 909 Parking Brake.................................................................................... 910 Brake Lock....................................................................................... 911 Low-Brake Pressure and Auto-Apply................................................................ 911 Validation....................................................................................... 912 Retarding........................................................................................ 912 BRAKE SYSTEM DATA SHEET.............................................................................. 913 BRAKE CIRCUIT TROUBLESHOOTING........................................................................ 916 SECTION J5 - FRONT WET DISC BRAKES - INDEX .................................................................. 920 FRONT WET DISC BRAKES.................................................................................... 922 BRAKE MAINTENANCE.................................................................................... 923 Checking Disc Wear............................................................................... 923 FRONT BRAKE ASSEMBLY................................................................................. 925 Removal.......................................................................................... 925 Installation..................................................................................... 925 Disassembly...................................................................................... 925 Cleaning and Inspection.......................................................................... 926 Assembly......................................................................................... 927 Floating Seal Installation....................................................................... 930 BRAKE BLEEDING....................................................................................... 933 SECTION J6 - REAR WET DISC BRAKES - INDEX ................................................................... 934 REAR WET DISC BRAKES..................................................................................... 936 DESCRIPTION.......................................................................................... 936 OPERATION............................................................................................ 936 MAINTENANCE.......................................................................................... 937 Checking Brake Disc Wear......................................................................... 937 REMOVAL.......................................................................................... 938 INSTALLATION..................................................................................... 939 BRAKE REBUILD.................................................................................... 941 Disassembly.................................................................................. 941 Cleaning and Inspection...................................................................... 942 Assembly..................................................................................... 942 Floating Seal Installation................................................................... 944 WET DISC BRAKE BLEEDING.......................................................................... 947 SECTION J7 - PARKING BRAKE - INDEX .......................................................................... 948 PARKING BRAKE............................................................................................ 950 Description.......................................................................................... 950 Parking Brake Service Criteria....................................................................... 950 Removal.............................................................................................. 951 Installation......................................................................................... 951 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................................ 953 Removal.......................................................................................... 953 Installation..................................................................................... 953 AUTOMATIC SLACK ADJUSTER............................................................................. 953 Adjustment Procedure............................................................................. 953 PARKING BRAKE CHECK-OUT.............................................................................. 954 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................................ 956 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX .............................................................. 958 HYDRAULIC SYSTEM OVERVIEW................................................................................ 960 SYSTEM COMPONENTS.................................................................................... 960 HYDRAULIC TANK................................................................................... 960 BLEED-DOWN MANIFOLD.............................................................................. 962 HOIST VALVE...................................................................................... 962 HOIST PUMP....................................................................................... 962 BRAKE COOLING PUMP............................................................................... 963 BRAKE CONTROL VALVE (BCV)........................................................................ 963 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX ...................................................... 964 HYDRAULIC COMPONENT REPAIR............................................................................... 966 HYDRAULIC TANK....................................................................................... 966 FILLING INSTRUCTIONS............................................................................. 966 MAINTENANCE...................................................................................... 966 Removal...................................................................................... 967 Installation................................................................................. 969 Gap Measurement - Hydraulic Tank Mounting.................................................... 969 STRAINERS AND DIFFUSERS.......................................................................... 970 Removal...................................................................................... 970 Cleaning and Inspection...................................................................... 970 Installation................................................................................. 971 HYDRAULIC TANK BREATHER.............................................................................. 971 Service.......................................................................................... 972 HYDRAULIC SYSTEM FLUSHING............................................................................ 972 HYDRAULIC PUMPS...................................................................................... 973 Removal.......................................................................................... 973 Installation..................................................................................... 974 PUMP REBUILD..................................................................................... 975 Disassembly.................................................................................. 975 Inspection Of Parts.......................................................................... 978 Assembly..................................................................................... 978 Bearing Replacement.......................................................................... 981 Seal Replacement............................................................................. 981 TROUBLESHOOTING GUIDE............................................................................ 984 SECTION L4 - STEERING CIRCUIT - INDEX ....................................................................... 986 STEERING CIRCUIT......................................................................................... 988 OPERATION............................................................................................ 988 COMPONENT DESCRIPTION................................................................................ 988 Steering Control Valve........................................................................... 988 Bleed-down Manifold.............................................................................. 988 Bleed-down Solenoid.............................................................................. 989 Accumulators..................................................................................... 990 Flow Amplifier................................................................................... 990 High Pressure Filter............................................................................. 990 Warning Devices.................................................................................. 990 FLOW AMPLIFIER OPERATION............................................................................. 992 STEERING/BRAKE PUMP..................................................................................1000 COMPONENTS.......................................................................................1000 OPERATION........................................................................................1002 SECTION L5 - STEERING CONTROL UNIT - INDEX .................................................................1004 STEERING CONTROL UNIT....................................................................................1006 Removal..............................................................................................1006 Installation.........................................................................................1006 REBUILD PROCEDURE....................................................................................1007 Disassembly......................................................................................1008 Cleaning and Inspection..........................................................................1009 Assembly.........................................................................................1011 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX ......................................................1016 STEERING CIRCUIT COMPONENT REPAIR........................................................................1018 BLEED-DOWN MANIFOLD..................................................................................1018 Removal..........................................................................................1018 Adjusting Relief Valve...........................................................................1018 Testing and Adjustment...........................................................................1019 FLOW AMPLIFIER...................................................................................1020 Removal......................................................................................1020 Installation.................................................................................1020 Disassembly..................................................................................1020 Assembly.....................................................................................1023 ACCUMULATORS.....................................................................................1024 Removal......................................................................................1024 Installation.................................................................................1025 Disassembly..................................................................................1026 Cleaning and Inspection......................................................................1026 Assembly.....................................................................................1026 Leak Testing.................................................................................1027 STEERING ACCUMULATOR CHARGING....................................................................1029 Temperature During Precharge.................................................................1032 ACCUMULATOR STORAGE..............................................................................1032 Installation.................................................................................1033 STEERING CYLINDER................................................................................1034 Removal......................................................................................1034 Installation.................................................................................1034 STEERING CYLINDER REBUILD........................................................................1035 Disassembly..................................................................................1035 Cleaning and Inspection......................................................................1035 Assembly.....................................................................................1036 Testing......................................................................................1036 STEERING/BRAKE PUMP..............................................................................1036 Removal......................................................................................1036 Installation.................................................................................1037 PUMP REBUILD.....................................................................................1038 Disassembly..................................................................................1038 Control Group................................................................................1039 Valve Plate Group............................................................................1040 Rotating Group...............................................................................1040 Drive Shaft Group............................................................................1041 Swashblock Group.............................................................................1041 Inspection...................................................................................1041 Control Group................................................................................1041 Valve Plate Group............................................................................1042 Rotating Group...............................................................................1042 Swashblock Group.............................................................................1043 Drive Shaft Group............................................................................1043 Assembly.....................................................................................1043 Swashblock Group.............................................................................1043 Drive Shaft Group............................................................................1044 Rotating Group...............................................................................1044 Valve Plate Group............................................................................1045 Control Group................................................................................1046 STEERING CIRCUIT FILTER..........................................................................1047 Removal......................................................................................1047 Installation.................................................................................1047 TROUBLESHOOTING CHART....................................................................................1048 SECTION L7 - HOIST CIRCUIT - INDEX ..........................................................................1050 HOIST CIRCUIT............................................................................................1052 HOIST CIRCUIT OPERATION..............................................................................1052 COMPONENT DESCRIPTION............................................................................1053 Hydraulic Tank...............................................................................1053 Hoist Pump...................................................................................1053 Hoist Valve..................................................................................1053 Hoist Pilot Valve............................................................................1054 Power Up Solenoid............................................................................1055 Pilot Operated Check Valve...................................................................1055 Power Down Spool Limit Solenoid..............................................................1055 HOIST CIRCUIT HYDRAULIC FLOW.....................................................................1056 POWER UP.....................................................................................1058 HOLD.........................................................................................1060 POWER DOWN...................................................................................1062 FLOAT........................................................................................1064 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX .........................................................1066 HOIST CIRCUIT COMPONENT REPAIR...........................................................................1068 HOIST VALVE..........................................................................................1068 Removal..........................................................................................1068 Installation.....................................................................................1068 O-Ring Replacement...............................................................................1069 INLET SECTION....................................................................................1070 Disassembly..................................................................................1070 Cleaning and Inspection......................................................................1071 Assembly.....................................................................................1071 SPOOL SECTION....................................................................................1071 Disassembly..................................................................................1071 Cleaning and Inspection......................................................................1072 Assembly.....................................................................................1074 HOIST PILOT VALVE....................................................................................1075 Removal..........................................................................................1075 Installation.....................................................................................1075 Disassembly......................................................................................1076 Cleaning and Inspection..........................................................................1077 Assembly.........................................................................................1077 HOIST CYLINDERS......................................................................................1078 Removal..........................................................................................1078 Installation.....................................................................................1080 Disassembly......................................................................................1080 Cleaning and Inspection..........................................................................1082 Assembly - Quill And Cylinder....................................................................1083 Quill Installation...............................................................................1083 Installation Of Check Balls And Plugs In Quill...................................................1084 Assembly of Cylinder.............................................................................1085 Pressure Testing.................................................................................1086 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX ...............................................................1088 HYDRAULIC SYSTEM FILTERS.................................................................................1090 HIGH PRESSURE FILTER.................................................................................1090 Removal..........................................................................................1090 Installation.....................................................................................1091 LOW PRESSURE FILTERS.................................................................................1091 BRAKE COOLING & HOIST FILTERS....................................................................1091 TRANSMISSION FILTER..............................................................................1091 Removal......................................................................................1092 Installation.................................................................................1092 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX .........................................................1094 HYDRAULIC CHECK-OUT PROCEDURE............................................................................1096 GENERAL INFORMATION..................................................................................1096 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................................................1096 Equipment Requirements...........................................................................1097 Installation Of Gauges...........................................................................1097 Initial Startup And Flushing.....................................................................1097 Component Checkout And Adjustment................................................................1098 CHECKING HOIST SYSTEM PRESSURES......................................................................1100 Equipment Requirements...........................................................................1100 Steering Components Leakage Test.................................................................1102 HYDRAULIC SYSTEM CHECKOUT DATA SHEET.................................................................1103 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX ...................................................................1104 SECTION M7 - HOT START SYSTEM - INDEX.......................................................................1106 HOT START SYSTEM.........................................................................................1108 SYSTEM OPERATION.....................................................................................1108 HEATER INFORMATION...................................................................................1109 TROUBLESHOOTING GUIDELINES...........................................................................1111 SECTION M8 - SPECIAL TOOLS..................................................................................1112 SECTION N - OPERATOR CAB - INDEX ................................................................................1116 SECTION N2 - OPERATOR CAB - INDEX ...........................................................................1118 OPERATOR CAB.............................................................................................1120 Removal..............................................................................................1121 Installation.........................................................................................1123 CAB DOORS............................................................................................1123 Removal..........................................................................................1123 Installation.....................................................................................1124 Door Striker Adjustment..........................................................................1124 Door Handle Plunger Adjustment...................................................................1125 DOOR PANEL.......................................................................................1126 Removal......................................................................................1126 Installation.................................................................................1126 DOOR WINDOW......................................................................................1127 Removal......................................................................................1127 Installation.................................................................................1129 WINDOW REGULATOR.................................................................................1131 Removal......................................................................................1131 Installation.................................................................................1131 DOOR HANDLE AND DOOR LATCH.......................................................................1131 Removal......................................................................................1131 Installation.................................................................................1131 DOOR SEALS...........................................................................................1132 Removal..........................................................................................1132 Installation.....................................................................................1132 DOOR OPENING SEAL....................................................................................1132 Removal..........................................................................................1132 Installation.....................................................................................1132 GLASS REPLACEMENT....................................................................................1133 Replacement......................................................................................1133 WINDSHIELD AND REAR GLASS........................................................................1134 Removal......................................................................................1134 Installation.................................................................................1135 SECTION N3 - CAB COMPONENTS - INDEX .........................................................................1136 CAB COMPONENTS...........................................................................................1138 WIPER MOTOR..........................................................................................1138 Removal..........................................................................................1138 Installation.....................................................................................1138 WIPER ARM............................................................................................1139 Removal..........................................................................................1139 Installation.....................................................................................1139 WIPER LINKAGE........................................................................................1140 Removal..........................................................................................1140 Installation.....................................................................................1140 WINDSHIELD WASHER....................................................................................1140 Operation........................................................................................1140 Service..........................................................................................1140 OPERATOR SEAT........................................................................................1141 Adjustment.......................................................................................1141 Seat Removal.....................................................................................1142 Seat Installation................................................................................1142 Seat Belt Replacement............................................................................1142 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX ...........................................................1144 HEATING AND AIR CONDITIONING.............................................................................1146 OPERATION............................................................................................1146 Fan Control Knob.................................................................................1146 Temperature Control Knob.........................................................................1146 Directional Control Knob.........................................................................1146 Heater Vents.....................................................................................1146 COMPONENTS...........................................................................................1147 Fuse and Circuit Breaker.........................................................................1147 Relays...........................................................................................1147 Heater Core......................................................................................1147 Fan Motor And Speed Control......................................................................1148 Actuators........................................................................................1148 Cab Air Filter...................................................................................1148 ENVIRONMENTAL IMPACT OF AIR CONDITIONING.............................................................1151 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................................1151 PRINCIPLES OF REFRIGERATION..........................................................................1151 Air Conditioning.................................................................................1152 The Refrigeration Cycle..........................................................................1152 AIR CONDITIONER SYSTEM COMPONENTS....................................................................1153 Compressor (Refrigerant Pump)....................................................................1153 Service Valves...................................................................................1153 Condenser........................................................................................1153 Receiver-Drier...................................................................................1153 Expansion Block Valve............................................................................1154 Accumulator......................................................................................1154 Evaporator.......................................................................................1155 ELECTRICAL CIRCUIT...............................................................................1155 Thermostat...................................................................................1155 Compressor Clutch............................................................................1156 Trinary™ Switch..............................................................................1156 AIR CONDITIONING SYSTEM SERVICING WARNINGS.......................................................1157 SERVICE TOOLS AND EQUIPMENT......................................................................1158 Recovery/Recycle Station.....................................................................1158 Leak Detector................................................................................1159 Manifold Gauge Set...........................................................................1159 Installing Manifold Gauge Set................................................................1160 Purging Air From Service Hoses...............................................................1161 Service Valves...............................................................................1161 Vacuum Pump..................................................................................1162 SYSTEM PERFORMANCE TEST..........................................................................1163 SYSTEM OIL.......................................................................................1164 Handling and Reusing PAG Oil.................................................................1164 Oil Quantity.................................................................................1164 Checking System Oil..........................................................................1164 REFRIGERANT......................................................................................1165 Recycled Refrigerant.........................................................................1165 Reclaimed Refrigerant........................................................................1165 Refrigerant Quantity.........................................................................1166 R-134a Refrigerant Containers................................................................1166 SYSTEM LEAK TESTING..............................................................................1166 Electronic Leak Detector.....................................................................1167 Tracer Dyes..................................................................................1167 Soap and Water...............................................................................1167 RECOVERING AND RECYCLING THE REFRIGERANT.........................................................1167 Draining Oil from the Previous Recovery Cycle................................................1167 Performing the Recovery Cycle................................................................1168 Performing the Recycling Procedure...........................................................1168 Evacuating and Charging the A/C System.......................................................1168 SYSTEM REPAIR....................................................................................1168 System Flushing..............................................................................1169 COMPRESSOR PULLEY AND BELT CHECKS....................................................................1169 Pulley Alignment.................................................................................1169 Belt Tension Check...............................................................................1170 COMPONENT REPLACEMENT............................................................................1172 Hoses and Fittings...........................................................................1172 Lines........................................................................................1172 Receiver-Drier...............................................................................1172 Expansion Valve..............................................................................1172 Thermostat...................................................................................1172 Compressor...................................................................................1173 Accumulator..................................................................................1173 Clutch.......................................................................................1173 Servicing the Compressor Clutch..............................................................1174 Pulley Removal...............................................................................1176 Clutch Coil Check............................................................................1177 Pulley Installation..........................................................................1177 Clutch Assembly Installation.................................................................1178 EVACUATING THE SYSTEM............................................................................1179 CHARGING THE A/C SYSTEM..........................................................................1180 TROUBLESHOOTING..................................................................................1181 Preliminary Checks...........................................................................1181 Diagnosis Of Gauge Readings And System Performance...........................................1181 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...........................................................1182 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...........................................................1188 SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX ..............................................................1190 OPERATOR CAB AND CONTROLS................................................................................1192 STEERING WHEEL AND CONTROLS..........................................................................1193 Horn Button......................................................................................1193 ARSC Set Lever...................................................................................1193 Telescoping/Tilt Wheel Lever.....................................................................1193 Multi-Function Turn Signal Lever.................................................................1193 RETARDER CONTROL LEVER...............................................................................1194 STEERING WHEEL.......................................................................................1195 Removal..........................................................................................1195 Installation.....................................................................................1195 SERVICE BRAKE PEDAL..................................................................................1195 ACCELERATOR PEDAL....................................................................................1195 INSTRUMENT PANEL.....................................................................................1195 HEATER / AIR CONDITIONER CONTROLS....................................................................1196 RETARDING CAPACITY CHART.............................................................................1196 RADIO SPEAKERS.......................................................................................1196 AIR CLEANER VACUUM GAUGES............................................................................1196 WARNING ALARM BUZZER.................................................................................1196 AM/FM RADIO / CD PLAYER..............................................................................1196 CENTER CONSOLE.......................................................................................1197 Hoist Control Lever..............................................................................1198 Transmission Shift Lever.........................................................................1198 Parking Brake Switch.............................................................................1199 LH Window Control Switch.........................................................................1199 RH Window Control Switch.........................................................................1199 Auxiliary Power Outlets..........................................................................1199 INSTRUMENT PANEL AND INDICATORS......................................................................1200 UPPER RH SWITCH PANEL............................................................................1201 Brake Lock Switch............................................................................1201 F1 Start Switch..............................................................................1201 Hazard Warning Lights Switch.................................................................1201 LOWER RH SWITCH PANEL............................................................................1202 Key Switch...................................................................................1202 Ether Starting Aid Switch....................................................................1203 ASR Cut Switch...............................................................................1203 ARSC Switch..................................................................................1203 Automatic Idle Selector Switch (AISS)........................................................1203 Auxiliary Brake Switch.......................................................................1204 UPPER LH SWITCH PANEL............................................................................1205 Automatic Lubrication System Indicator.......................................................1205 LOWER LH SWITCH PANEL............................................................................1206 Head Light Switch............................................................................1206 Ladder Light Switch..........................................................................1206 BackUp/Deck Light Switch.....................................................................1207 Fog Light Switch.............................................................................1207 Mode Select Switches 1 & 2...................................................................1207 Panel Light Dimmer Switch....................................................................1207 ELECTRONIC DISPLAY PANEL.............................................................................1208 PILOT DISPLAY ITEMS..............................................................................1209 METER DISPLAYS...................................................................................1211 CAUTION ITEMS....................................................................................1213 EMERGENCY STOP ITEMS.............................................................................1215 CHARACTER DISPLAY................................................................................1218 REAR ELECTRICAL COMPARTMENT..........................................................................1219 AUTOMATIC RETARD SPEED CONTROL (ARSC)................................................................1222 AUTOMATIC SPIN REGULATOR (ASR).......................................................................1225 SECTION P - LUBRICATION AND SERVICE - INDEX .....................................................................1228 SECTION P2 - LUBRICATION AND SERVICE - INDEX ................................................................1230 LUBRICATION AND SERVICE..................................................................................1232 COOLANT SPECIFICATIONS...............................................................................1232 Unacceptable Practices...........................................................................1232 RADIATOR FILL PROCEDURE..............................................................................1232 HYDRAULIC TANK SERVICE...............................................................................1233 Filling Instructions.............................................................................1233 TRANSMISSION OIL LEVEL CHECK.........................................................................1233 QUICK FILL SERVICE CENTER............................................................................1234 PERIODIC REPLACEMENT OF CRITICAL PARTS...............................................................1234 10 HOUR (DAILY) INSPECTION...........................................................................1236 10 HOUR (DAILY) INSPECTION (continued)...............................................................1237 250 HOUR INSPECTION..................................................................................1238 250 HOUR INSPECTION (continued)......................................................................1239 250 HOUR INSPECTION (continued)......................................................................1240 500 HOUR INSPECTION..................................................................................1241 1000 HOUR INSPECTION.................................................................................1242 2000 HOUR INSPECTION.................................................................................1243 5000 HOUR INSPECTION.................................................................................1244 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX ...........................................................1246 AUTOMATIC LUBRICATION SYSTEM.............................................................................1248 GENERAL DESCRIPTION..................................................................................1248 SYSTEM COMPONENTS....................................................................................1252 SYSTEM OPERATION.....................................................................................1254 INJECTOR OPERATION...................................................................................1255 LUBRICANT PUMP.......................................................................................1256 Pump Housing Oil Level...........................................................................1256 Pump Pressure Control............................................................................1256 INJECTORS (SL-1 Series “H”)).........................................................................1257 Injector Specifications..........................................................................1257 Injector Adjustment..............................................................................1257 SYSTEM PRIMING.......................................................................................1258 Filter Assembly..................................................................................1258 SYSTEM CHECK.........................................................................................1259 Lubrication Controller Check.....................................................................1259 Lubrication Controller Operation.................................................................1259 Lubrication Controller Components................................................................1259 Lubrication Controller Adjustment................................................................1259 SYSTEM TROUBLESHOOTING CHART.........................................................................1261 PREVENTATIVE MAINTENANCE.............................................................................1263 Daily Lubrication System Inspection..............................................................1263 250 Hour Inspection..............................................................................1263 1000 Hour Inspection.............................................................................1264 PUMP REBUILD.........................................................................................1265 Disassembly......................................................................................1265 Cleaning and Inspection..........................................................................1268 Assembly.........................................................................................1268 SECTION R - SYSTEM SCHEMATICS - INDEX ...........................................................................1270 HYDRAULIC SYSTEM SCHEMATIC ..................................................................................1272 BRAKE SYSTEM SCHEMATIC .....................................................................................1273 HOOKUP SCHEMATIC ...........................................................................................1274 ELECTRICAL WIRING SCHEMATIC ................................................................................1282
KOMATSU HD1500 DUMP TRUCK SHOP MANUAL A30001 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
1 review for Komatsu HD1500 Dump Truck Shop Manual A30001 & UP – PDF DOWNLOAD
Add a review
Ryder –