Komatsu HD1500-7 Dump Truck Shop Manual CEBM021004 PDF

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM021004 – PDF DOWNLOAD

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Komatsu HD1500-7 Dump Truck Shop Manual CEBM021004 – PDF DOWNLOAD 

Language : English
Pages : 1391
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM021004 – PDF DOWNLOAD 

FOREWORD:

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

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

TABLE OF CONTENTS:

Komatsu HD1500-7 Dump Truck Shop Manual CEBM021004 – PDF DOWNLOAD 

SERIAL NUMBERS
A30049-A30055, A30058-A30064,
A30067-A30070, A30073-A30075,
A30078-A30080, A30085-A30090,
A30095-A30108
With SDA12V160 Engine

COVER 1
FOREWORD 4
TABLE OF CONTENTS 6
SECTION A – GENERAL INFORMATION – INDEX 8
SECTION A2 – MAJOR COMPONENTS AND SPECIFICATIONS 10
SECTION A3 – GENERAL SAFETY AND OPERATION – INDEX 14
GENERAL SAFETY AND OPERATION 16
Safety Rules 16
Safety Features 16
Clothing And Personal Items 16
Unauthorized Modification 16
Leaving The Operator’s Seat 16
Mounting And Dismounting 17
Fire Prevention For Fuel And Oil 17
Precautions With High Temperature Fluids 17
Asbestos Dust Hazard Prevention 17
Prevention Of Injury By Work Equipment 18
Fire Extinguisher And First Aid Kit 18
Precautions For ROPS 18
Precautions For Attachments 18
HAUL ROADS 19
PRECAUTIONS DURING OPERATION 19
BEFORE STARTING THE ENGINE 19
Fire Prevention 20
Preparing For Operation 20
Ventilation In Enclosed Areas 20
In Operator’s Cab – Before Starting The Engine 20
Mirrors, Windows, And Lights 20
OPERATING THE MACHINE 21
When Starting The Engine 21
Precautions For Starting Machine 21
Truck Operation – General 21
Traveling 22
Traveling In Reverse 22
Traveling On Slopes 22
Ensure Good Visibility 22
Operate Carefully On Snow 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 23
When Dumping 23
Working On Loose Ground 23
Loading The Body 23
Parking The Machine 23
TOWING 24
WORKING NEAR BATTERIES 24
Battery Hazard Prevention 24
Starting With Booster Cables 24
MAINTENANCE PRECAUTIONS 25
Warning Tag 25
Proper Tools 25
Stopping The Engine Before Service 25
Securing The Dump Body 25
DURING MAINTENANCE 27
Personnel 27
Attachments 27
Working Under The Machine 27
Keep The Machine Clean 27
Rules To Follow When Adding Fuel Or Oil 27
Radiator Water Level 27
Use Of Lighting 27
Precautions With The Battery 28
Handling High Pressure Hoses 28
Precautions With High Pressure Oil 28
Precautions When Performing Maintenance Near High Temperature Or High Pressure 28
Rotating Fan And Belts 28
Waste Materials 28
TIRES 29
Handling Tires 29
Storing Tires After Removal 29
WHEN REPAIRS ARE NECESSARY 30
ADDITIONAL JOB SITE RULES 31
OPERATING INSTRUCTIONS 32
PREPARING FOR OPERATION 32
Safety Is Thinking Ahead 32
Walk Around Inspection 32
Cold Weather Heating System 35
ENGINE START-UP SAFETY PRACTICES 36
Cold Weather Starting 36
Jump Starting 37
AFTER THE ENGINE HAS STARTED 37
MACHINE OPERATION SAFETY PRECAUTIONS 40
LOADING 41
HAULING 41
RETARDER OPERATION 42
PASSING 42
DUMPING 43
Raising the Dump Body 43
Lowering The Dump Body 44
SAFE PARKING PROCEDURES 44
TURNING OFF THE ENGINE 45
SUDDEN LOSS OF ENGINE POWER 45
Secondary Steering And Braking 45
DISABLED TRUCK DUMPING 46
Hookup 46
Raising the Body 47
Lowering the Body 47
DISABLED TRUCK STEERING AND BRAKING 48
TOWING 50
SECTION A4 – WARNINGS AND CAUTIONS 52
SECTION A5 – TORQUE TABLES AND CONVERSION CHARTS 58
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 59
STANDARD TIGHTENING TORQUES For Class 10 9 Cap screws & Class 10 Nuts 59
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws 60
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws 61
Hardware Tightening Method 69
SECTION A7 – STORAGE PROCEDURES – INDEX 70
STORAGE AND IDLE MACHINE PREPARATION 72
SHORT TERM IDLE PERIODS 72
PREPARATION FOR STORAGE 72
REMOVAL FROM STORAGE 73
RECONDITIONING AN IDLE VEHICLE 75
ENGINE OPERATION 78
AFTER THE ENGINE HAS STARTED 78
SHORT TERM ENGINE STORAGE 79
Preparing the Engine 79
Removing the Engine from Long Term Storage 81
TRANSMISSION PRESERVATION AND STORAGE 81
Storage, New Transmission 81
Storage, One Year- Without Oil 81
Storage, One Year – With Oil – Normally Installed On The Truck 82
Restoring The Transmission For Service 82
SECTION B – STRUCTURES – INDEX 84
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 86
STRUCTURAL COMPONENTS 88
PREPARATION 88
GRILLE, HOOD AND LADDERS 89
DECKS 90
CENTER DECK 90
Removal 90
Installation 90
RIGHT DECK AND COMPONENTS 90
Removal 90
Installation 90
LEFT DECK AND CAB 91
Installation 91
SECTION B3 – DUMP BODY – INDEX 92
DUMP BODY 94
Removal 94
Installation 96
BODY PADS 96
Removal 96
Installation 97
Body Pad Adjustment 97
BODY GUIDE 99
BODY-UP RETENTION CABLE 100
ROCK EJECTORS 100
Inspection 100
SECTION B4 – FUEL TANK – INDEX 102
FUEL TANK 104
Removal 104
Cleaning 105
Repair 105
Installation 105
FUEL GAUGE AND SENDING UNIT 106
Removal 106
Installation 106
WIGGINS QUICK FILL FUEL SYSTEM 106
FUEL RECEIVER 106
FUEL TANK BREATHER 107
Removal 107
Installation 107
Disassembly 107
Assembly 107
LEFT SIDE FILL 108
SECTION C – ENGINE – INDEX 110
SECTION C3 – COOLING SYSTEM – INDEX 112
COOLING SYSTEM 114
DESCRIPTION 114
LEAKS AND CONTAMINATION 115
RADIATOR FILL PROCEDURE 115
RADIATOR REMOVAL 116
RADIATOR REPAIR 118
Internal Inspection 118
External Cleaning 118
Disassembly 119
Cleaning and Inspection 120
Assembly 120
Pressure Testing 121
Additional Service Information 121
RADIATOR INSTALLATION 122
TRANSMISSION AND BRAKE COOLERS 123
Removal 124
Disassembly 124
Cleaning And Inspection 125
Assembly 125
Inspection 126
Installation 127
SECTION C4 – ENGINE – INDEX 128
ENGINE 130
Removal 130
Inspection 133
Installation 134
DRIVE LINE ADAPTER 135
Removal 136
Disassembly 137
Cleaning and Inspection 139
Assembly 141
Installation 145
Bearing Tools 146
SECTION C5 – AIR FILTRATION SYSTEM – INDEX 148
AIR FILTRATION SYSTEM 150
AIR CLEANER 150
Operation 150
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 CLUTCH – INDEX 158
FAN CLUTCH 160
REMOVAL & INSTALLATION TOOLING 160
FAN CLUTCH – DISASSEMBLY 163
CLEANING AND INSPECTION 173
ASSEMBLY – FAN CLUTCH 177
TEST PROCEDURE 191
SECTION D – ELECTRICAL SYSTEM – INDEX 192
SECTION D2 – BATTERIES AND STARTING SYSTEM – INDEX 194
BATTERIES AND STARTING SYSTEM 196
BATTERIES 196
MAINTENANCE AND SERVICE 196
Electrolyte Levels 196
Cleaning 196
Other Maintenance 197
ENGINE PRELUB™ SYSTEM 199
OPERATION 199
Oil Pressure Switch 201
Check Valve 201
Timer Solenoid 201
MAINTENANCE 201
Prelub™ System Operation 201
Prelub Pump 201
Check Valve 202
Timer Solenoid 202
PRELUB CIRCUIT TROUBLESHOOTING 203
STARTING SYSTEM 205
CRANKING MOTORS 205
Removal 205
Disassembly 206
Cleaning and Inspection 206
Armature Servicing 206
Field Coil Checks 207
Field Coil Removal 207
Solenoid Checks 209
Assembly 210
Installation 212
TROUBLESHOOTING 212
Preliminary Inspection 212
No-Load Test 212
Interpreting The Results of The Tests 213
MAGNETIC SWITCH 214
Removal 214
Installation 214
Coil Test 214
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 216
ELECTRICAL SYSTEM COMPONENTS 218
CAB MOUNTED COMPONENTS 218
CIRCUIT BREAKERS 220
RELAY CENTER 221
FUSE PANEL 226
EXTERIOR COMPONENTS 230
BATTERY BOX 230
BATTERY DISCONNECT SWITCH 230
GROUND LEVEL SHUT OFF SWITCH 230
CONTROL POWER RELAYS 230
CIRCUIT BREAKERS 230
BATTERY EQUALIZER 230
Test 230
BODY POSITION SWITCHES 232
Proximity Switch Operation 232
Body-Up Switch Adjustment 233
Hoist Limit Switch Adjustment 233
SPEED SENSORS 235
Sensor Adjustment 236
GENERAL TROUBLESHOOTING 236
SECTION D10 – CHARGING SYSTEM – IND EX 238
CHARGING SYSTEM 240
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 240
Excessive heat 240
Dirt and dust 240
Vibration 240
PREVENTIVE MAINTENANCE PROCEDURES 241
Alternator Cleanliness 241
Alternator Mounting 241
Belt Tension And Condition 241
TROUBLESHOOTING 241
ALTERNATOR PERFORMANCE TEST 241
ALTERNATOR CABLE TEST 242
VOLTAGE REGULATOR ADJUSTMENT 243
ALTERNATOR 244
Removal 244
Installation 245
SECTION D11 – AUTOMATIC TRANSMISSION CONTROLLER – INDEX 248
AUTOMATIC TRANSMISSION CONTROLLER 250
GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES 251
TRANSMISSION OPERATING MODES 252
NETWORK DATA 252
SHIFT LOGIC 254
Shift Lever Position D, Up-Shifting 254
Shift Lever Position D, Down-Shifting 254
Shift Lever Positions 6, 5, 4, 3, 2, L 254
Shift Lever Positions R 254
Shift Lever Position N 254
Gear Shift Time Delay 254
SAFETY FUNCTIONALITY 255
Down-Shift Inhibitor Function 255
Neutral Safety Function 255
Directional Inhibit Function 255
Powertrain Overrun Prevention 255
Reverse Safety (Dump Body Raised) 255
Speed Range Limit Function (Dump Body Raised) 255
Self-diagnostic function 255
ATC REAL TIME MONITORING 256
LIMP HOME MODE 256
Limp Home Procedure 1 259
Limp Home Procedure 2 259
Limp Home Procedure 3 259
Limp Home Procedure 4 259
Limp Home Procedure 5 259
Limp Home Procedure 6 259
Limp Home Procedure 7 259
SECTION D15 – MACHINE MONITOR – INDEX 260
MACHINE MONITOR 262
CHARACTER DISPLAY 262
Mode Select Switches 1 & 2 263
Service Meter 263
Odometer 263
Operation Information 263
Reverse Travel Odometer 264
Filter And Oil Change Display 264
Display Items 265
Resetting The Filter/Oil Replacement Meter 265
Inputting Telephone Numbers 266
Selecting A Language 266
ACTION CODE DISPLAYS 267
E03 Codes 267
E02 Codes 268
E01 Codes 268
REAL TIME MONITOR 269
USING REAL TIME MONITOR 269
Viewing Two Streams of Data At Once 270
Real Time Monitoring Codes 271
MACHINE MONITOR FLOW CHART 275
SECTION D20 – FAILURE CODES – INDEX 280
FAILURE CODES 282
ACTION CODE DISPLAYS 282
CHECKING FAILURE CODES 283
LIMP HOME MODE 284
FAILURE CODE TABLE 285
SECTION D21 – TROUBLESHOOTING 302
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES 302
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION 303
FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR 305
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR 305
FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR 306
FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING 307
FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR 309
FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING 311
FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING 313
FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING 315
FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING 317
FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING 319
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 321
FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION 323
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 325
FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION 329
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 331
FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION 335
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 337
FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION 341
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 343
FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION 347
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 349
FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION 353
FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION 355
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 356
FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION 359
FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING 361
FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION 363
FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION 364
FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE 365
FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR 366
FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE 367
FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE 368
FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE 369
FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION 370
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED 371
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION 372
FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE 373
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 374
FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW 375
FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING 376
FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING 377
FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING 378
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING 379
FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION 380
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION 381
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION 382
FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION 383
FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR 385
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW 389
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW 390
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR 391
FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR 392
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR 393
FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT 394
FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT 395
FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR 396
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR 397
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION 398
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW 399
FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR 400
FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR 401
FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR 403
FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR 404
FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT 405
FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE 407
FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT 409
FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT 410
FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT 411
FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT 412
FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT 413
FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT 415
FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT 417
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT 419
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT 421
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT 423
FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT 425
FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT 427
FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT 429
FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT 433
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 436
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND 437
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT 438
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND 439
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT 440
FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT 441
FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND 442
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 443
FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 444
FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 445
FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 446
FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 447
FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 448
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 449
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE 450
FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION 451
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE 452
FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION 453
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT 454
FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE 455
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT 456
FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE 457
FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE 459
FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION 460
FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT 461
FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION 462
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 463
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION 464
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT 465
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION 466
FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION 467
FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION 468
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 469
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 470
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 471
FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 472
FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 473
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 474
FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT 475
FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT 476
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 477
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 478
FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE 479
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT 480
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON) 481
FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT 482
FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT 483
FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER 484
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 485
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 487
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT 489
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT 490
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER 491
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 492
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 493
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 495
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 496
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER 497
FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION 498
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION 499
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 501
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 502
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER 503
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 504
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 505
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 506
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 507
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 509
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 511
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 513
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 517
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 519
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 521
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 525
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 527
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 529
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 533
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 535
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 537
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 541
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 543
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 545
FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 549
FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 551
FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 553
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 557
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 559
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 561
SECTION D30 – VHMS INITIALIZATION – INDEX 564
INITIALIZATION OF VHMS CONTROLLER 566
Executing Quick PM 577
Downloading Existing VHMS Setting Data 582
Confirmation of Downloaded Data 583
Disconnecting the PC 583
Reporting to Komatsu 583
REPLACING THE VHMS CONTROLLER 585
Prior to Removing VHMS Controller 585
Confirming and Saving VHMS Controller Settings (Versions older than 3 5 2 1) 585
Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3 5 2 1) 589
Confirming and Saving VHMS Controller Settings (Version 3 5 2 1 or newer) 591
Loading Saved VHMS Settings To New VHMS Controller (Version 3 5 2 1 or newer) 592
FINAL VHMS PROCEDURES-POST INSTALLATION 593
Correct the Load Weight Calculation 595
SECTION D31 – VEHICLE HEALTH MONITORING SYSTEM (VHMS) – INDEX 604
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 606
VHMS DOWNLOADING 607
PAYLOAD METER 608
NORMAL OPERATION DISPLAY 609
EXTERNAL DISPLAY LAMPS 610
PREDICTED LOAD DISPLAY 610
CALIBRATING PLM 611
DATA STORED IN PAYLOAD METER 612
PLM DOWNLOADING 613
Downloading From Inside Of The Cab 613
Downloading From Ground Level Box 613
SETTING THE MACHINE ID AND OPEN ID 614
PAYLOAD – CYCLE DATA ITEM 615
ADDITIONAL FUNCTIONS 615
Other Settings 615
SECTION F – TRANSMISSION / TORQUE CONVERTER – INDEX 616
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 618
TORQUE CONVERTER AND TRANSMISSION 620
TORQUE CONVERTER 621
MAIN RELIEF VALVE 623
Function 623
Operation 623
TORQUE CONVERTER RELIEF VALVE 623
Function 623
Operation 623
TORQUE CONVERTER REGULATOR VALVE 625
Operation 625
LOCK-UP CLUTCH 626
Lock-up Clutch Accumulator 626
HYDRAULIC PUMP 627
TORQUE CONVERTER STALL CHECK 628
TRANSMISSION 629
LUBRICATION RELIEF VALVE 631
Function 631
TRANSMISSION CONTROL VALVE 632
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 634
Pressure Control Valve 635
Flow Sensor Valve 635
ECMV and Proportional Solenoid 635
ECMV and Fill Switch 635
ECMV Operation 636
ECMV REPAIR 639
Preparation 639
Filter Replacement Procedure 639
ECMV Identification 640
ECMV Removal 640
Disassembly 640
Assembly 642
Installation 642
TRANSMISSION FILTERS 644
Service 644
Installation 644
TRANSMISSION SPEED SENSORS 645
Adjustment Procedure 645
TRANSMISSION OIL LEVEL CHECK 646
TRANSMISSION OIL PRESSURE CHECK 647
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 649
Preliminary Checks 649
TRANSMISSION REMOVAL 653
TRANSMISSION INSTALLATION 654
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION (-40°C) – INDEX 658
TORQUE CONVERTER AND TRANSMISSION (-40°C) 660
TORQUE CONVERTER 661
MAIN RELIEF VALVE 663
Function 663
Operation 663
TORQUE CONVERTER RELIEF VALVE 663
Function 663
Operation 663
TORQUE CONVERTER REGULATOR VALVE 665
Operation 665
COLD RELIEF VALVE 666
Operation 666
LOCK-UP CLUTCH 666
Lock-up Clutch Accumulator 667
HYDRAULIC PUMP 668
TORQUE CONVERTER STALL CHECK 669
TRANSMISSION 670
LUBRICATION RELIEF VALVE 672
Function 672
TRANSMISSION CONTROL VALVE 673
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 675
Pressure Control Valve 676
Flow Sensor Valve 676
ECMV and Proportional Solenoid 676
ECMV and Fill Switch 676
ECMV Operation 677
ECMV REPAIR 680
Preparation 680
Filter Replacement Procedure 680
ECMV Identification 681
ECMV Removal 681
Disassembly 681
Assembly 683
Installation 683
TRANSMISSION FILTERS 685
Service 685
Installation 685
COLD OIL FILTER RELIEF VALVE 686
TRANSMISSION SPEED SENSORS 686
Adjustment Procedure 687
TRANSMISSION OIL LEVEL CHECK 687
TRANSMISSION OIL PRESSURE CHECK 688
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 690
Preliminary Checks 690
TRANSMISSION REMOVAL 694
TRANSMISSION INSTALLATION 695
SECTION F3 – TRANSMISSION OIL COOLER & STRAINERS – INDEX 698
TRANSMISSION OIL COOLER & STRAINERS 700
TRANSMISSION OIL COOLER 700
Removal and Installation 700
Repair 700
TRANSMISSION OIL STRAINER 700
Removal 701
Inspection 701
Installation 701
SECTION F5 – DRIVE SHAFTS – INDEX 702
DRIVE SHAFTS 704
FRONT DRIVE SHAFT 704
Removal 704
Disassembly 704
Assembly 704
Installation 705
FRONT DRIVE SHAFT ALIGNMENT 706
REAR DRIVE SHAFT 709
Removal 709
Disassembly 710
Assembly 710
Installation 710
SECTION F8 – TORQUE CONVERTER REBUILD – INDEX 712
TORQUE CONVERTER REBUILD 714
REMOVAL 714
INSTALLATION 716
DISASSEMBLY 718
PTO COVER DISASSEMBLY 726
CLEANING & INSPECTION 727
TABLE I COMPONENT WEAR LIMITS 728
TABLE II Gear Backlash 728
ASSEMBLY 729
ONE-WAY CLUTCH ASSEMBLY 730
STATOR BEARING PRE-LOAD ADJUSTMENT 732
PTO DRIVE ASSEMBLY 736
SPECIAL TOOLS 741
SECTION F8 – TORQUE CONVERTER REBUILD (-40°C) – INDEX 744
TORQUE CONVERTER REBUILD (-40°C) 746
REMOVAL 746
INSTALLATION 749
DISASSEMBLY 751
PTO COVER DISASSEMBLY 759
CLEANING & INSPECTION 760
TABLE I COMPONENT WEAR LIMITS 761
TABLE II Gear Backlash 761
ASSEMBLY 762
ONE-WAY CLUTCH ASSEMBLY 763
STATOR BEARING PRE-LOAD ADJUSTMENT 765
PTO DRIVE ASSEMBLY 769
SPECIAL TOOLS 775
SECTION F9 – TRANSMISSION REBUILD – INDEX 776
TRANSMISSION REBUILD 778
TRANSMISSION DISASSEMBLY 778
Number One Clutch Housing Disassembly 782
Bearing Cage & Cover Disassembly 785
Number Four Carrier Disassembly 786
Output Shaft Cover Disassembly 787
Rear Case Bearing Removal 787
Output Shaft Removal 788
Output Shaft Disassembly 788
Number Five/Six Carrier Disassembly 788
CLEANING AND INSPECTION 790
INSPECTION TABLE INDEX 790
TRANSMISSION ASSEMBLY 796
GENERAL INSTRUCTIONS 796
Number Five/Six Carrier Assembly 796
Output Shaft Assembly 797
Number Seven Clutch Assembly 798
Rear Case Assembly 799
Rear Case & Carrier Assembly 799
Number Six Clutch Assembly 801
Number Four Carrier Assembly 802
Number Four Carrier Bearing Cage Assembly 803
Number Five Clutch Assembly 803
Number Four Clutch Assembly 804
Number Three Clutch Assembly 804
Clutch Test 805
Number Two Clutch Ring Gear Installation 805
Number Three Carrier & Number Two Clutch Assembly 806
Number One Carrier Assembly 806
Number One Clutch Assembly 809
Checks Prior to Final Assembly 811
Final Assembly 811
Input Shaft Installation 812
External Components 814
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 816
SECTION G2 – TIRES AND RIMS – INDEX 818
TIRES AND RIMS 820
GENERAL INFORMATION 820
FRONT TIRES AND RIMS 821
Removal 821
Installation 822
REAR TIRE AND RIM 822
Removal 822
Installation 824
TIRE MATCHING 825
RIM 825
Tire Removal From Rim 825
Tire Installation On Rim 826
FRONT WHEEL STUD INSTALLATION 827
REAR WHEEL STUD INSTALLATION 828
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 830
FRONT WHEEL HUB AND SPINDLE 832
OIL SAMPLE ANALYSIS 832
Oil Sampling Guidelines 832
Guidelines For Obtaining A Sample 832
FRONT WHEEL HUB 833
Removal 833
Disassembly 833
Inspection 833
Assembly 834
Installation 836
Front Wheel Hub Bearing Adjustment 836
FRONT SPINDLE 837
A-ARM 837
Removal 837
Inspection 837
Installation 837
CENTER TIE ROD PIVOT 838
Removal 838
Inspection 838
Installation 838
TOE IN ADJUSTMENT 839
Adjustment Procedure 839
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 844
REAR AXLE ATTACHMENTS 846
CENTER LINK AND LOWER LINKS 846
Removal 846
Inspection 847
Spherical Bearing Replacement 847
Installation 847
PANHARD ROD (DIAGONAL LINK) 848
Removal 848
Inspection 849
Installation 849
SECTION G5 – REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 850
REAR AXLE & FINAL DRIVE ASSEMBLY 852
DIFFERENTIAL OPERATION 852
Straight-away-travel 852
Turning 852
REAR AXLE ASSEMBLY 853
Removal 853
Installation 853
DIFFERENTIAL OIL LEVEL CHECK 854
DIFFERENTIAL ASSEMBLY 855
Removal 855
Installation 856
Disassembly 856
Pinion Carrier Assembly 859
Differential Gear Unit 859
Differential Gear Unit 860
Cleaning and Inspection 863
Assembly 863
Differential Bearing 863
Assembly Of Differential Gear Assembly 863
Installation Of Differential Assembly 865
Input Pinion and Carrier Assembly 866
Adjusting Tooth Contact, Backlash 870
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 874
FINAL DRIVE PLANETARIES AND WHEEL HUBS 876
FINAL DRIVE 876
Oil Level Check 877
FINAL DRIVE CARRIER ASSEMBLY 877
Removal 877
Installation 878
Disassembly 878
Assembly 879
FINAL DRIVE ASSEMBLY 880
Disassembly 880
Assembly 882
SECTION H – SUSPENSIONS – INDEX 884
SECTION H2 – FRONT SUSPENSION – INDEX 886
FRONT SUSPENSION 888
Removal 890
Installation 891
Disassembly 892
Cleaning and Inspection 894
Assembly 894
Pressure Tests 895
DAMPING VALVE REPAIR 896
Disassembly 896
Assembly 897
SECTION H3 – REAR SUSPENSION – INDEX 898
REAR SUSPENSION 900
Operation 901
Removal 902
Installation 902
Disassembly 902
Cleaning and Inspection 906
Assembly 906
LEAK TESTING 907
SPHERICAL BEARINGS 907
Removal 907
Inspection 907
Installation 907
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 908
SUSPENSION OILING AND CHARGING 910
GENERAL INFORMATION 910
Equipment List 910
FRONT SUSPENSION 912
Front Suspension Oiling 912
Front Suspension Nitrogen Charging 915
REAR SUSPENSION 917
GENERAL INFORMATION 917
Rear Suspension Oiling 917
Rear Suspension Nitrogen Charging 921
FRONT AND REAR CYLINDER LENGTH ADJUSTMENT 921
SECTION J – BRAKE SYSTEM – INDEX 924
SECTION J2 – BRAKE SYSTEM OPERATION – INDEX 926
BRAKE SYSTEM OPERATION 928
DESCRIPTION 928
SERVICE BRAKE OPERATION 929
SECONDARY BRAKING AND AUTOMATIC APPLY 929
BRAKE SYSTEM COMPONENTS 931
BRAKE MANIFOLD CARTRIDGE VALVES 933
SERVICE BRAKE CIRCUIT 937
RETARDING CIRCUIT 939
PARKING BRAKE CIRCUIT 941
AUTO APPLY 943
AUXILIARY BRAKE CIRCUIT 945
BRAKE LOCK CIRCUIT 947
AUTOMATIC SPIN REGULATOR 949
BRAKE COOLING CIRCUIT 951
BRAKE COOLING VALVE 952
COLD OIL DIVERTER VALVES 955
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 956
BRAKE CIRCUIT COMPONENT SERVICE 958
BRAKE VALVE 959
Rebuild Criteria 959
Removal 959
Installation 960
Disassembly 961
Cleaning and Inspection 962
Assembly 964
Actuator Base Threaded Inserts 964
Boot and Cap 964
Valve Body Seal Installation 964
Regulator Sleeve O-Ring Installation 964
Actuator Plunger O-ring Installation 965
Assembly of Valve 966
BENCH TEST AND ADJUSTMENT 967
Test Bench Only 967
Test Set Up Procedure 967
Brake Valve Output Pressure Adjustment 969
Final Test and Adjustment 970
Proximity Switch Installation and Adjustment 972
Installation Of Brake Pedal Actuator Assembly to Brake Valve 972
BRAKE ACCUMULATORS 973
Removal 974
Installation 974
Disassembly 974
Cleaning and Inspection 976
Assembly 976
Leak Testing 978
ACCUMULATOR CHARGING 979
Temperature During Precharge 981
ACCUMULATOR STORAGE 982
Installation 982
BRAKE COOLING VALVE (BCV) 983
RETARDER CONTROL LEVER 984
Removal 984
Installation 984
Disassembly and Adjustment 984
Potentiometer Check 986
Assembly 986
Retard Lever Calibration 987
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 988
BRAKE CIRCUIT CHECK-OUT 990
REQUIRED EQUIPMENT 990
PREPARATION 990
BRAKE CIRCUIT TESTING 991
Initial System Setup 991
Parking Brake 992
Brake Lock 993
Low-Brake Pressure and Auto-Apply 993
Validation 994
Retarding 994
BRAKE SYSTEM DATA SHEET 995
BRAKE CIRCUIT TROUBLESHOOTING 998
SECTION J5 – FRONT WET DISC BRAKES – INDEX 1002
FRONT WET DISC BRAKES 1004
BRAKE MAINTENANCE 1005
Checking Disc Wear 1005
FRONT BRAKE ASSEMBLY 1007
Removal 1007
Installation 1007
Disassembly 1007
Cleaning and Inspection 1008
Assembly 1009
Floating Seal Installation 1012
BRAKE BLEEDING 1015
SECTION J6 – REAR WET DISC BRAKES – INDEX 1016
REAR WET DISC BRAKES 1018
DESCRIPTION 1018
OPERATION 1018
MAINTENANCE 1019
Checking Brake Disc Wear 1019
REMOVAL 1020
INSTALLATION 1021
BRAKE REBUILD 1023
Disassembly 1023
Cleaning and Inspection 1024
Assembly 1024
Floating Seal Installation 1026
WET DISC BRAKE BLEEDING 1029
SECTION J7 – PARKING BRAKE – INDEX 1030
PARKING BRAKE 1032
Description 1032
Parking Brake Service Criteria 1032
Removal 1033
Installation 1033
PARKING BRAKE SPRING CYLINDER REPLACEMENT 1035
Removal 1035
Installation 1035
AUTOMATIC SLACK ADJUSTER 1035
Adjustment Procedure 1035
PARKING BRAKE CHECK-OUT 1036
SECTION L – HYDRAULIC SYSTEM – INDEX 1038
SECTION L2 – HYDRAULIC SYSTEM OVERVIEW – INDEX 1040
HYDRAULIC SYSTEM OVERVIEW 1042
SYSTEM COMPONENTS 1042
HYDRAULIC TANK 1042
BLEED-DOWN MANIFOLD 1044
HOIST VALVE 1044
HOIST PUMP 1044
BRAKE COOLING PUMP 1045
BRAKE CONTROL VALVE (BCV) 1045
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 1046
HYDRAULIC COMPONENT REPAIR 1048
HYDRAULIC TANK 1048
FILLING INSTRUCTIONS 1048
MAINTENANCE 1048
Removal 1049
Installation 1051
Gap Measurement – Hydraulic Tank Mounting 1051
STRAINERS AND DIFFUSERS 1052
Removal 1052
Cleaning and Inspection 1052
Installation 1053
HYDRAULIC TANK BREATHER 1053
Service 1054
HYDRAULIC SYSTEM FLUSHING 1054
HYDRAULIC PUMPS 1055
Removal 1055
Installation 1056
PUMP REBUILD 1057
Disassembly 1057
Inspection Of Parts 1060
Assembly 1060
Bearing Replacement 1063
Seal Replacement 1063
TROUBLESHOOTING GUIDE 1066
SECTION L4 – STEERING CIRCUIT – INDEX 1068
STEERING CIRCUIT 1070
OPERATION 1070
COMPONENT DESCRIPTION 1070
Steering Control Valve 1070
Bleed-down Manifold 1070
Bleed-down Solenoid 1071
Accumulators 1072
Flow Amplifier 1072
High Pressure Filter 1072
Warning Devices 1072
FLOW AMPLIFIER OPERATION 1074
STEERING/BRAKE PUMP 1082
COMPONENTS 1082
OPERATION 1084
SECTION L5 – STEERING CONTROL UNIT – INDEX 1086
STEERING CONTROL UNIT 1088
Removal 1088
Installation 1088
REBUILD PROCEDURE 1089
Disassembly 1090
Cleaning and Inspection 1091
Assembly 1093
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 1098
STEERING CIRCUIT COMPONENT REPAIR 1100
BLEED-DOWN MANIFOLD 1100
Removal 1100
Adjusting Relief Valve 1100
Testing and Adjustment 1101
FLOW AMPLIFIER 1102
Removal 1102
Installation 1102
Disassembly 1102
Assembly 1105
ACCUMULATORS 1106
Removal 1106
Installation 1107
Disassembly 1108
Cleaning and Inspection 1108
Assembly 1108
Leak Testing 1109
STEERING ACCUMULATOR CHARGING 1111
Temperature During Precharge 1114
ACCUMULATOR STORAGE 1114
Installation 1115
STEERING CYLINDER 1116
Removal 1116
Installation 1116
STEERING CYLINDER REBUILD 1117
Disassembly 1117
Cleaning and Inspection 1117
Assembly 1118
Testing 1118
STEERING/BRAKE PUMP 1118
Removal 1118
Installation 1119
PUMP REBUILD 1120
Disassembly 1120
Control Group 1121
Valve Plate Group 1122
Rotating Group 1122
Drive Shaft Group 1123
Swashblock Group 1123
Inspection 1123
Control Group 1123
Valve Plate Group 1124
Rotating Group 1124
Swashblock Group 1125
Drive Shaft Group 1125
Assembly 1125
Swashblock Group 1125
Drive Shaft Group 1126
Rotating Group 1126
Valve Plate Group 1127
Control Group 1128
STEERING CIRCUIT FILTER 1129
Removal 1129
Installation 1129
TROUBLESHOOTING CHART 1130
SECTION L7 – HOIST CIRCUIT – INDEX 1132
HOIST CIRCUIT 1134
HOIST CIRCUIT OPERATION 1134
COMPONENT DESCRIPTION 1135
Hydraulic Tank 1135
Hoist Pump 1135
Hoist Valve 1135
Hoist Pilot Valve 1136
Power Up Solenoid 1137
Pilot Operated Check Valve 1137
Power Down Spool Limit Solenoid 1137
HOIST CIRCUIT HYDRAULIC FLOW 1138
POWER UP 1140
HOLD 1142
POWER DOWN 1144
FLOAT 1146
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1148
HOIST CIRCUIT COMPONENT REPAIR 1150
HOIST VALVE 1150
Removal 1150
Installation 1150
O-Ring Replacement 1151
INLET SECTION 1152
Disassembly 1152
Cleaning and Inspection 1153
Assembly 1153
SPOOL SECTION 1153
Disassembly 1153
Cleaning and Inspection 1154
Assembly 1156
HOIST PILOT VALVE 1157
Removal 1157
Installation 1157
Disassembly 1158
Cleaning and Inspection 1159
Assembly 1159
HOIST CYLINDERS 1160
Removal 1160
Installation 1162
Disassembly 1162
Cleaning and Inspection 1164
Assembly – Quill And Cylinder 1165
Quill Installation 1165
Installation Of Check Balls And Plugs In Quill 1166
Assembly of Cylinder 1167
Pressure Testing 1168
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1170
HYDRAULIC SYSTEM FILTERS 1172
HIGH PRESSURE FILTER 1172
Removal 1172
Installation 1173
LOW PRESSURE FILTERS 1173
BRAKE COOLING & HOIST FILTERS 1173
TRANSMISSION FILTER 1173
Removal 1174
Installation 1174
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 1176
HYDRAULIC CHECK-OUT PROCEDURE 1178
GENERAL INFORMATION 1178
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1178
Equipment Requirements 1179
Installation Of Gauges 1179
Initial Startup And Flushing 1179
Component Checkout And Adjustment 1180
CHECKING HOIST SYSTEM PRESSURES 1182
Equipment Requirements 1182
Steering Components Leakage Test 1184
HYDRAULIC SYSTEM CHECKOUT DATA SHEET 1185
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1186
SECTION M7 – HOT START SYSTEM – INDEX 1188
HOT START SYSTEM 1190
SYSTEM OPERATION 1190
HEATER INFORMATION 1191
TROUBLESHOOTING GUIDELINES 1193
SECTION M8 – SPECIAL TOOLS 1194
SECTION N – OPERATOR CAB – INDEX 1198
SECTION N2 – OPERATOR CAB – INDEX 1200
OPERATOR CAB 1202
Removal 1203
Installation 1205
CAB DOORS 1205
Removal 1205
Installation 1206
Door Striker Adjustment 1206
Door Handle Plunger Adjustment 1207
DOOR PANEL 1208
Removal 1208
Installation 1208
DOOR WINDOW 1209
Removal 1209
Installation 1211
WINDOW REGULATOR 1213
Removal 1213
Installation 1213
DOOR HANDLE AND DOOR LATCH 1213
Removal 1213
Installation 1213
DOOR SEALS 1214
Removal 1214
Installation 1214
DOOR OPENING SEAL 1214
Removal 1214
Installation 1214
GLASS REPLACEMENT 1215
Replacement 1215
WINDSHIELD AND REAR GLASS 1216
Removal 1216
Installation 1217
SECTION N3 – CAB COMPONENTS – INDEX 1218
CAB COMPONENTS 1220
WIPER MOTOR 1220
Removal 1220
Installation 1220
WIPER ARM 1221
Removal 1221
Installation 1221
WIPER LINKAGE 1222
Removal 1222
Installation 1222
WINDSHIELD WASHER 1222
Operation 1222
Service 1222
OPERATOR SEAT 1223
Adjustment 1223
Seat Removal 1224
Seat Installation 1224
Seat Belt Replacement 1224
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX 1226
HEATING AND AIR CONDITIONING 1228
HEATER/AIR CONDITIONER UNIT 1228
Fan Speed Control Knob 1228
Temperature Control Knob 1228
Air Flow Directional Knob 1228
Heater/Air Conditioner Vents 1229
COMPONENTS 1229
Fuse 1229
Relays 1229
Heater Core 1229
Fan Motor And Speed Control 1230
Actuators 1230
Cab Air Filter 1230
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1233
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1233
PRINCIPLES OF REFRIGERATION 1233
Air Conditioning 1233
Refrigeration – The Act Of Cooling 1234
The Refrigeration Cycle 1234
AIR CONDITIONER SYSTEM COMPONENTS 1235
Compressor (Refrigerant Pump) 1235
Service Valves 1235
Condenser 1235
Receiver-Drier 1235
Expansion Block Valve 1236
Accumulator 1236
Evaporator 1236
ELECTRICAL CIRCUIT 1237
Thermostat 1237
Compressor Clutch 1237
Trinary™ Switch 1238
SYSTEM SERVICING 1239
SERVICE TOOLS AND EQUIPMENT 1240
Recovery/Recycle Station 1240
Leak Detector 1240
Service Valves 1241
Vacuum Pump 1241
Manifold Gauge Set 1242
Installing Manifold Gauge Set 1243
Purging Air From Service Hoses 1243
SYSTEM PERFORMANCE TEST 1244
SYSTEM OIL 1245
Handling and Reusing PAG Oil 1245
Oil Quantity 1245
Checking System Oil 1245
REFRIGERANT 1246
Recycled Refrigerant 1246
Reclaimed Refrigerant 1246
Refrigerant Quantity 1246
R-134a Refrigerant Containers 1247
SYSTEM LEAK TESTING 1247
Electronic Leak Detector 1248
Tracer Dyes 1248
Soap and Water 1248
RECOVERING AND RECYCLING THE REFRIGERANT 1248
Draining Oil from the Previous Recovery Cycle 1248
Performing the Recovery Cycle 1248
Performing the Recycling Procedure 1249
Evacuating and Charging the A/C System 1249
SYSTEM REPAIR 1249
System Flushing 1249
A/C DRIVE BELT CHECKOUT PROCEDURE 1250
Pulley Alignment 1250
Belt Tension Check 1250
COMPONENT REPLACEMENT 1252
Hoses and Fittings 1252
Lines 1252
Expansion Valve 1252
Receiver-Drier 1252
Thermostat 1252
Compressor 1253
Accumulator 1253
Clutch 1253
Servicing the Compressor Clutch 1254
Pulley Removal 1256
Clutch Coil Check 1257
Pulley Installation 1257
Clutch Assembly Installation 1257
EVACUATING THE SYSTEM 1259
CHARGING THE A/C SYSTEM 1261
TROUBLESHOOTING 1262
Preliminary Checks 1262
Diagnosis Of Gauge Readings And System Performance 1262
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1263
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1269
SECTION N5 – OPERATOR CAB AND CONTROLS – INDEX 1270
OPERATOR CAB AND CONTROLS 1272
STEERING WHEEL AND CONTROLS 1273
Horn Button 1273
ARSC Set Lever 1273
Telescoping/Tilt Wheel Lever 1273
Multi-Function Turn Signal Lever 1273
RETARDER CONTROL LEVER 1274
STEERING WHEEL 1275
Removal 1275
Installation 1275
SERVICE BRAKE PEDAL 1275
ACCELERATOR PEDAL 1275
INSTRUMENT PANEL 1275
HEATER / AIR CONDITIONER CONTROLS 1276
RETARDING CAPACITY CHART 1276
RADIO SPEAKERS 1276
AIR CLEANER VACUUM GAUGES 1276
WARNING ALARM BUZZER 1276
AM/FM RADIO / CD PLAYER 1276
CENTER CONSOLE 1277
Hoist Control Lever 1278
Transmission Shift Lever 1278
Parking Brake Switch 1279
LH Window Control Switch 1279
RH Window Control Switch 1279
Auxiliary Power Outlets 1279
INSTRUMENT PANEL AND INDICATORS 1280
UPPER RH SWITCH PANEL 1281
Brake Lock Switch 1281
F1 Start Switch 1281
Hazard Warning Lights Switch 1281
LOWER RH SWITCH PANEL 1282
Key Switch 1282
Ether Starting Aid Switch 1283
ASR Cut Switch 1283
ARSC Switch 1283
Automatic Idle Selector Switch (AISS) 1283
Auxiliary Brake Switch 1284
UPPER LH SWITCH PANEL 1285
Automatic Lubrication System Indicator 1285
LOWER LH SWITCH PANEL 1286
Head Light Switch 1286
Ladder Light Switch 1286
BackUp/Deck Light Switch 1287
Fog Light Switch 1287
Mode Select Switches 1 & 2 1287
Panel Light Dimmer Switch 1287
ELECTRONIC DISPLAY PANEL 1288
PILOT DISPLAY ITEMS 1289
METER DISPLAYS 1291
CAUTION ITEMS 1293
EMERGENCY STOP ITEMS 1295
CHARACTER DISPLAY 1298
REAR ELECTRICAL COMPARTMENT 1299
AUTOMATIC RETARD SPEED CONTROL (ARSC) 1302
AUTOMATIC SPIN REGULATOR (ASR) 1305
SECTION P – LUBRICATION AND SERVICE – INDEX 1308
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1310
LUBRICATION AND SERVICE 1312
COOLANT SPECIFICATIONS 1312
Unacceptable Practices 1312
RADIATOR FILL PROCEDURE 1312
HYDRAULIC TANK SERVICE 1313
Filling Instructions 1313
TRANSMISSION OIL LEVEL CHECK 1313
QUICK FILL SERVICE CENTER 1314
PERIODIC REPLACEMENT OF CRITICAL PARTS 1314
10 HOUR (DAILY) INSPECTION 1316
10 HOUR (DAILY) INSPECTION (continued) 1317
250 HOUR INSPECTION 1318
250 HOUR INSPECTION (continued) 1319
250 HOUR INSPECTION (continued) 1320
500 HOUR INSPECTION 1321
1000 HOUR INSPECTION 1322
2000 HOUR INSPECTION 1323
5000 HOUR INSPECTION 1324
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 1326
AUTOMATIC LUBRICATION SYSTEM 1328
GENERAL DESCRIPTION 1328
SYSTEM COMPONENTS 1332
SYSTEM OPERATION 1334
INJECTOR OPERATION 1335
LUBRICANT PUMP 1336
Pump Housing Oil Level 1336
Pump Pressure Control 1336
INJECTORS (SL-1 Series “H”)) 1337
Injector Specifications 1337
Injector Adjustment 1337
SYSTEM PRIMING 1338
Filter Assembly 1338
SYSTEM CHECK 1339
Lubrication Controller Check 1339
Lubrication Controller Operation 1339
Lubrication Controller Components 1339
Lubrication Controller Adjustment 1339
SYSTEM TROUBLESHOOTING CHART 1341
PREVENTATIVE MAINTENANCE 1343
Daily Lubrication System Inspection 1343
250 Hour Inspection 1343
1000 Hour Inspection 1344
PUMP REBUILD 1345
Disassembly 1345
Cleaning and Inspection 1348
Assembly 1348
SECTION R – SYSTEM SCHEMATICS – INDEX 1350
HYDRAULIC SYSTEM SCHEMATIC 1352
HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40°C) 1353
BRAKE SYSTEM SCHEMATIC 1354
HOOKUP SCHEMATIC 1355
ELECTICAL WIRING SCHEMATIC 1363
HVAC WIRING SCHEMATIC 1386
CONNECTOR LOCATOR 1387

S.V 16/12/24