Komatsu D1500-5 Dump Truck Service Repair Shop Manual (A30039-A30048) - CEBM006203

This complete service repair workshop manual PDF download for the Komatsu Dump Truck D1500-5 (SN: A30039-A30048) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : Komatsu HD1500-5
Serial Numbers : A30039 - A30048


TABLE OF CONTENTS :

- GENERAL INFORMATION
- STRUCTURES
- ENGINE, FUEL, COOLING AND AIR CLEANER
- ELECTRIC SYSTEM (24 VDC. NON-PROPULSION)
- TRANSMISSION AND TORQUE CONVERTER
- DRIVE AXLE, SPINDLES AND WHEELS
- SUSPENSIONS
- BRAKE CIRCUIT
- AIR SYSTEM
- HYDRAULIC SYSTEM
- OPTIONS AND SPECIAL TOOLS
- OPERATOR'S CAB
- LUBRICATION AND SERVICE
- ALPHABETICAL INDEX
- SYSTEM SCHEMATICS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM006203
Total Pages : 1239


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

SECTION A - GENERAL INFORMATION - INDEX
SECTION A2 - MAJOR COMPONENTS AND SPECIFICATIONS
SECTION A3 - SAFETY - INDEX
SAFETY
Safety Rules
Safety Features
Clothing And Personal Items
Unauthorized Modification
Leaving The Operator’s Seat
Mounting And Dismounting
Fire Prevention For Fuel And Oil
Precautions With High Temperature Fluids
Asbestos Dust Hazard Prevention
Prevention Of Injury By Work Equipment
Fire Extinguisher And First Aid Kit
Precautions For ROPS
Precautions For Attachments
PRECAUTIONS DURING OPERATION
Safety Is Thinking Ahead
BEFORE STARTING THE ENGINE
Safety At The Worksite
Fire Prevention
Preparing For Operation
Ventilation In Enclosed Areas
In Operator’s Cab - Before Starting The Engine
Mirrors, Windows, And Lights
OPERATING THE MACHINE
When Starting The Engine
Precautions For Starting Machine
Truck Operation - General
Check When Traveling In Reverse
Traveling
Traveling On Slopes
Ensure Good Visibility
Operate Carefully On Snow
Avoid Damage To Dump Body
Driving Near High Voltage Cables
When Dumping
Working On Loose Ground
When Loading
Parking The Machine
TOWING
WORKING NEAR BATTERIES
Battery Hazard Prevention
Starting With Booster Cables
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
Warning Tag
Proper Tools
Stopping The Engine Before Service
Securing The Dump Body
DURING MAINTENANCE
Personnel
Attachments
Working Under The Machine
Keep The Machine Clean
Rules To Follow When Adding Fuel Or Oil
Radiator Water Level
Use Of Lighting
Precautions With The Battery
Handling High Pressure Hoses
Precautions With High Pressure Oil
Precautions When Performing Maintenance Near High Temperature Or High Pressure
Rotating Fan And Belts
Waste Materials
TIRES
Handling Tires
Storing Tires After Removal
WHEN REPAIRS ARE NECESSARY
ADDITIONAL JOB SITE RULES
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
Safety Is Thinking Ahead
At The Truck - Ground Level Walk Around Inspection
ENGINE START-UP SAFETY PRACTICES
AFTER THE ENGINE HAS STARTED
MACHINE OPERATION SAFETY PRECAUTIONS
LOADING
HAULING
RETARDER OPERATION
PASSING
DUMPING
Raising the Dump Body
Lowering The Dump Body
SAFE PARKING PROCEDURES
SHUTDOWN PROCEDURE
SUDDEN LOSS OF ENGINE POWER
Secondary Steering And Braking
DISABLED TRUCK DUMPING PROCEDURE
Hookup
Raising the Body
Lowering the Body
DISABLED TRUCK STEERING AND BRAKING
TOWING
SECTION A4 - WARNINGS AND CAUTIONS
SECTION A5 - STANDARD TABLES
Sealants and Adhesives
SECTION A7 - STORAGE PROCEDURES - INDEX
STORAGE AND IDLE MACHINE PREPARATION
SHORT TERM IDLE PERIODS
PREPARATION FOR STORAGE
REMOVAL FROM STORAGE
RECONDITIONING AN IDLE VEHICLE
ENGINE OPERATION
AFTER ENGINE HAS STARTED
ENGINE STORAGE
Engine Storage-(Short Term)
Engine Storage- (Long Term)
TRANSMISSION PRESERVATION AND STORAGE
Restoring Transmission to Service

SECTION B - STRUCTURES - INDEX
SECTION B2 - STRUCTURAL COMPONENTS - INDEX
STRUCTURAL COMPONENTS
Preparation
GRILLE, HOOD AND LADDERS
DECKS
RIGHT DECK AND COMPONENTS
Removal
Installation
LEFT DECK AND CAB
Installation
SECTION B3 - DUMP BODY - INDEX
DUMP BODY
Removal
Installation
BODY PADS
Body Pad Adjustment
BODY GUIDE
BODY-UP RETENTION CABLE
ROCK EJECTORS
Inspection
SECTION B4 - FUEL TANK - INDEX
FUEL TANK
Removal
Installation
Cleaning
Repair
FUEL GAUGE SENDER
Removal
Installation
WIGGINS QUICK FILL FUEL SYSTEM
FUEL RECEIVER
TANK BREATHER VALVE
Removal
Installation
Disassembly
Assembly
LEFT SIDE FILL

SECTION C - ENGINE - INDEX
SECTION C3 - COOLING SYSTEM - INDEX
COOLING SYSTEM
DESCRIPTION
RADIATOR
Leaks and Contamination
Radiator Removal
RADIATOR REPAIR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
Additional Service Information
Radiator Installation
HEAT EXCHANGERS (Oil Coolers)
Removal
Disassembly
Cleaning And Inspection
Assembly
Inspection
Installation
SECTION C4 - ENGINE - INDEX
ENGINE
Preparation
Removal
Inspection
Installation
DRIVE LINE ADAPTER
Drive Line Adapter Removal
Drive Line Adapter Installation
Drive Line Adapter Damper Disassembly
Drive Line Adapter Damper Assembly
RECOMMENDED LUBRICANTS
SECTION C5 - AIR FILTRATION SYSTEM - INDEX
AIR FILTRATION SYSTEM
AIR CLEANER
Operation
General Information
FILTER SERVICE INDICATOR
MAIN FILTER ELEMENT
Removal
Installation
SAFETY FILTER ELEMENT
Removal
Installation
AIR INTAKE TROUBLESHOOTING
Main Filter Cleaning
Precleaner Section Cleaning
SECTION C7 - FAN CLUTCH - INDEX
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
FAN CLUTCH - DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY - FAN CLUTCH
TEST PROCEDURE

SECTION D - ELECTRICAL SYSTEM AND POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX
SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX
24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
Maintenance and Service
Troubleshooting
BATTERY CHARGING SYSTEM (Niehoff)
General Description
TROUBLESHOOTING PROCEDURES (On-Truck)
Equipment Required:
Preliminary Checks
Test Setup
Test Procedure
Regulator Bypass Test
ON VEHICLE TROUBLESHOOTING GUIDE
ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:
CHARGE VOLT AND AMP VALUES
DEFINITIONS
ADVANCED SYSTEM TROUBLESHOOTING
Static Test - Engine OFF, Key ON, Battery Switch ON.
Go To Alternator
Go To Regulator (If Required)
Go To Regulator Connector On The Alternator
24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUB)
OPERATION
Pressure Switch
Check Valve
Timer Solenoid
MAINTENANCE
Prelub™ System Operation
Starter/Prelub Pump
Check Valve
Timer Solenoid
TROUBLESHOOTING PRELUB STARTER CIRCUIT
24 VDC ELECTRIC START SYSTEM
CRANKING MOTORS
Operation
Removal
Installation
CRANKING MOTOR TROUBLESHOOTING
Preliminary Inspection
No-Load Test
Interpreting Results of Tests
Disassembly
Cleaning and Inspection
Armature Servicing
Field Coil Checks
Field Coil Removal
Solenoid Checks
Assembly
Magnetic Switch
Removal
Installation
Coil Test
SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX
ELECTRICAL SYSTEM COMPONENTS
GENERAL TROUBLESHOOTING
CAB MOUNTED COMPONENTS
Circuit Breakers
RELAY BOARDS
Relay Boards (With Circuit Breakers)
Preliminary Checks
Service
Relay Board Description
Relay Board RB1
Relay Board RB4
Relay Board RB5
Relay Boards (Without Circuit Breakers)
Truck Inclination Sensors
Payload Meter Inclinometer Sensor
Lateral Inclination Sensor
Lubrication System Timer
ACCELERATOR PEDAL
Operation
AISS Operation
Throttle Pedal Malfunction
ACCELERATOR PEDAL CHECKS
Idle Validation Switch Continuity Check
24V COMPONENTS (Outside Cab)
Battery Box
Battery Disconnect Switch
Ground Level Shutdown Switch
Control Power Relays
Circuit Breakers
Level Sensor
Battery Equalizer
Body Position Sensor Switches
Body-Up Switch Adjustment
Hoist Limit Switch Adjustment
Speed Sensors
Sensor Adjustment
24V/240 AMP ALTERNATOR TEST AND REBUILD
BENCH TEST
TEST 1 - No Load Test
STATIC TESTS
Regulator Tests
Control Box Tests
ALTERNATOR DISASSEMBLY
ASSEMBLY- ALTERNATOR
BF4822 STATOR SERVICE TOOL INSTRUCTIONS
Stator Removal And Replacement
Stator Installation
SECTION D22 - POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX
POWERTRAIN MANAGEMENT CONTROL™ SYSTEM
System Description
Engine (Cummins QSK45)
Transmission
Transmission Controller
Retard Control and Monitor
Powertrain Management Controller
Electronic Display Panel
Payload Meter
Message for Operator and Maintenance Display
Suspension Controller
Data Acquisition Device
Cummins Quantum
Cummins CENSE
PMC SYSTEM TROUBLESHOOTING
Preliminary Troubleshooting Procedures
Emergency Operation
Indication Of A Fault Occurrence
Action Codes
Fault History
System Troubleshooting
EMERGENCY TRUCK OPERATION
PMC SYSTEM FAULT CODES
SECTION D23 - POWERTRAIN MANAGEMENT CONTROLLER - INDEX
POWERTRAIN MANAGEMENT CONTROLLER (PMC)
PMC CONTROLLER FEATURES
LED Display
DIP Switch Settings
NORMAL OPERATION - PMC
Throttle Control
AISS Operation
Retarder Control
COMMUNICATION
S-NET
CENSE
RCM
PLM
“MOM” and “DAD”
Additional Functions
PMC CONTROLLER TROUBLESHOOTING
GENERAL TROUBLESHOOTING PROCEDURES
PMC FAULT CODE TROUBLESHOOTING
PMC CONTROLLER LOGIC
Fault Recovery Classifications
PMC FAULT CODE LOGIC DESCRIPTION
PMC WIRING HARNESS CONNECTORS
SECTION D24 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX
AUTOMATIC TRANSMISSION CONTROLLER (ATC)
ATC CONTROLLER FEATURES
LED Display
Rotary Switch Settings
Shift Control
Range Selector Positions And Automatic Gear Shifting Ranges
Transmission Operation Modes
Braking Mode:
Normal Mode:
Automatic Gear Shifting
Automatic Shifting Sequence
Gearshifting time lag
Shift Skip Logic
Safety Functions
TROUBLESHOOTING - ATC
GENERAL TROUBLESHOOTING PROCEDURES
ATC FAULT CODE TROUBLESHOOTING
ATC FAULT CODE LOGIC DESCRIPTION
TRANSMISSION CONTROLLER HARNESS CONNECTORS
SECTION D25 - ELECTRONIC DISPLAY PANEL - INDEX
ELECTRONIC DISPLAY PANEL
Rotary Switch
Gauges and Indicators
External Indicator Lamps
Display Self-Check Function
Lamp Test
Action Code Display
Cancellation of Action Code
ELECTRONIC DISPLAY PANEL TROUBLESHOOTING
GENERAL TROUBLESHOOTING PROCEDURES
Harness Circuit Tests
Table 1: Continuity checks
Table 2: Short Circuit to Ground Checks
Table 3: Circuit Isolation Checks
EDP WIRING HARNESS CONNECTORS
SECTION D26 - RETARD CONTROL AND MONITOR (RCM) - INDEX
RETARD CONTROL AND MONITOR (RCM)
Description
RCM Calibration
GENERAL TROUBLESHOOTING PROCEDURES
RCM FAULT CODE TROUBLESHOOTING
Description
RCM WIRING HARNESS CONNECTORS
SECTION D27 - AUTOMATIC SUSPENSION SYSTEM - INDEX
AUTOMATIC SUSPENSION SYSTEM
Automatic Suspension Controller
Manifold Valve
Actuator
Steering Sensor
AUTOMATIC MODE SELECTION CONTROL
SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION
d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE
d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE
d015:TRANSMISSION SPEED SIGNAL LOST
d016:STEERING SPEED SIGNAL LOST
d021:SOLENOID OUTPUT 1 FAILURE
d022:SOLENOID OUTPUT 2 FAILURE
d023:SOLENOID OUTPUT 3 FAILURE
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING
SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed.
SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed.
SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed
SP-4: Fault Code d016: Fault in Steering Sensor System Displayed
SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed
SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed
SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed
SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS
SECTION D30 - MESSAGE FOR OPERATION AND MAINTENANCE (MOM) - INDEX
MOM - MESSAGE FOR OPERATION AND MAINTENANCE
INTRODUCTION
SYSTEM CONFIGURATION
SOFTWARE
Service Meters (SMR)
FUNCTION
Operator Information
Maintenance Information (Screen Hierarchy)
Display Able/Disable By Machine Status
Vehicle State
Display Able/Disable by Truck Model and Optional Equipment Status
SCREEN DATA
Realtime Data
Machine Trend Data
Fault Condition Data
Machine Information
Parameter Set
WARNING MESSAGE
HARDWARE TROUBLESHOOTING AND MAINTENANCE
TROUBLESHOOTING THE MOM UNIT
PROBLEMS AND CORRECTIVE ACTIONS
Program Errors
Warning & Communication Errors
SELF-DIAGNOSIS
System Check
System Information
Communication Port Check
Key Input Check
MAINTENANCE
Battery Replacement
Replacement of Protective Sheet
Back Light Replacement
Setting Display OFF Time
SECTION D31 - MOM SCREEN DISPLAYS - INDEX
MOM SCREEN DISPLAYS
i1 INITIAL MESSAGE
i2 INITIAL CHECK1
i3 INITIAL CHECK2
i4 NORMAL RUNNING
i7 BACKLIGHT OFF
To Access a Maintenance Information Screen:
i9 MENU SELECT
s1 SERVICE MENU
s2 COMPONENT CHECK MENU
s21 ENGINE
s212 MACHINE TREND MENU (ENG.)
s213 FAULT CONDITION MENU (ENG.)
s2131 FAULT CONDITION (ENG.)
s22 TRANSMISSION
s222 MACHINE TREND MENU (T/M)
s2221 L/C ON/OFF COUNT
s222E AB-USE COUNT
s223 FAULT CONDITION MENU (T/M)
S2231 FAULT CONDITION (T/M)
s23 BRAKE MENU
s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE)
s233 FAULT CONDITION MENU (BRAKE)
s2331 FAULT CONDITION (BRAKE)
s24 SUSPENSION MENU
s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION)
s242 FAULT CONDITION MENU (SUS)
s2421 FAULT CONDITION (SUS)
s25 PMC MENU
s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC)
s252 FAULT CONDITION MENU (PMC)
s2521 FAULT CONDITION (PMC)
s26 ELECTRONIC DISPLAY PANEL MENU
s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel)
s262 FAULT CONDITION MENU (ELE. DISPLAY PANEL)
s2621 FAULT CONDITION (ELE. DISPLAY PANEL)
s27 PLM MENU
s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM)
s272 CALIBRATION DATA
s28 TMS MENU
s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS)
s283 FAULT CONDITION MENU (TMS)
s2831 FAULT CONDITION (TMS)
s3 MACHINE INFORMATION MENU
s32-1/3 CONTROLLER INFORMATION
SELECTOR SWITCH STATUS of the PMC
s32-2/3 CONTROLLER INFORMATION
s32-3/3 CONTROLLER INFORMATION
s33 OPTIONAL FUNCTION INFORMATION
s34 HISTORY OF USE
t1 PARAMETER SET MENU
t2 TIME/DATE SET
t3 TRAVEL MODE MENU
t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)
t32 SPEED LIMITER
t33 T/M MAX GEAR SELECT
t34 T/M MAX GEAR SELECT (BODY UP)
t35 SUSPENSION MODE SET
t4 PARAMETER UNIT SET
t5 TMS SET MENU
t51 TIRE PRESSURE LIMIT SET
t52 TIRE TEMPERATURE LIMIT SET
t53 CORRELATION CONSTANTS SET
t54 TMS CLOCK SET
t55 ID CODE SET
SECTION D32 - DATA ACQUISITION DEVICE (DAD) - INDEX
DAD - DATA ACQUISITION DEVICE
INTRODUCTION
HARDWARE HOOKUP
SOFTWARE
Installation Requirements
Installing the Software
Starting the Software Program
Service Meters (SMR)
Display Able/disable By Machine Status
Vehicle State
MAINTENANCE INFORMATION (SCREEN HIERARCHY)
Display Enable/Disable by Truck Model and Optional Equipment Status
SCREEN DATA
Real Time Data
Fault condition data
Snap-Shot Data
Transmission Snapshot Example
Sample Snapshot Screens
Machine Trend Data
Machine Check
Machine Information
Event Recorder
Parameter Set
SECTION D33 - DAD SCREEN DISPLAYS - INDEX
DAD SCREEN DISPLAYS
PASSWORD INPUT
Changing the Password
i3 MENU SELECT
s1 SERVICE MENU
s2 COMPONENT CHECK MENU
s21 Engine
s21 CUMMINS ENG. MENU (for the CUMMINS engine)
s21 KOMATSU ENG. MENU (for the KOMATSU engine)
s22 TRANSMISSION
s23 BRAKE MENU
s24 SUSPENSION MENU
s25 PMC MENU
s26 ELECTRONIC DISPLAY PANEL MENU
s27 PLM MENU
s28 TMS MENU
s3 MACHINE INFORMATION MENU
s31 MACHINE INFORMATION MENU
s32-1/3 CONTROLLER INFORMATION
s32-2/3 CONTROLLER INFORMATION
s32-3/3 CONTROLLER INFORMATION
s33 OPTIONAL FUNCTION INFORMATION
s34 HISTORY OF USE
t1 PARAMETER SET MENU
t2 TIME/DATE SET
t3 TRAVEL MODE MENU
t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)
t32 SPEED LIMITER
t33 T/M MAX GEAR SELECT
t34 T/M MAX GEAR SELECT (BODY UP)
t35 SUSPENSION MODE SET
t4 PARAMETER UNIT SET
t5 TMS SET MENU
t51 TIRE PRESSURE LIMIT SET
t52 TIRE TEMPERATURE LIMIT SET
t53 CORRELATION CONSTANTS SET
t54 TMS CLOCK SET
t55 ID CODE SET
SECTION D34 - REAL TIME DATA TABLES - INDEX
REAL TIME DATA TABLES
ACCESSING REAL TIME DATA SCREENS
Real Time Data Screen Switches
SECTION D35 - PAYLOAD METER II - INDEX
GENERAL INFORMATION
Haul Cycles
LIGHTS, SWITCHES AND COMPONENTS
TIPS FOR OPERATION
EXTERNAL DISPLAY LIGHTS
THEORY OF OPERATION
Basic Description
Inclinometer
Linkage Factor
Gain Factor
Brake Lock
Sources of Error
Typical Data From Service Check Mode
Example Calculation of Payload
Viewing Payload Calculation Inputs
Checking the Gain
Adjusting the Gain
TYPES OF DATA STORED
Cycle Data
Engine ON/OFF Data
Fault Codes and Warning Data
Engine Operation
Total Payload and Total Number of Cycles
Other Data
OPERATOR FUNCTIONS
Using the Operator Load Counter
Viewing the Operator Load Counter
Clearing the Operator Load Counter
Dimming the Lights on the Display
INITIAL SETUP OF PAYLOAD METER
Switch Settings
Checking the Operator Check Mode
Checking the Service Check Mode
Checking the Gt setting:
Checking the Inclinometer Settings
Calibrating a Truck
DISPLAYS AT START-UP
Normal Operation
SETUP AND MAINTENANCE
Setting The Speed Limit
Setting the Option Code
Setting The Machine I.D. Code
Setting The Operator I.D. Code
Setting The Time and Date
DOWNLOAD OF INFORMATION
DISPLAY OF FAULT CODES
Monitoring Input Signals
Service Check Mode
UP FACTOR - PAYLOAD CALCULATION GAIN
PL MODE -LOAD CALCULATION TIMING
FINAL GEAR RATIO SELECTION
BATTERY REPLACEMENT PROCEDURE
Replacing the Battery
After Replacing the Battery
SUSPENSION PRESSURE SENSOR
Removal
Installation
INCLINOMETER
Removal
Installation
Adjustment
PAYLOAD METER BACK PANEL
CONNECTIONS
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE
PAYLOAD CIRCUIT NUMBERS
TROUBLESHOOTING
COMMON PROBLEMS
Suspension Charging
Symptom Table
Missing Body-Up Signal
Missing Speed Signal
F-18: Alternator R-Terminal, Oil Pressure Signals
Shorted 18v Sensor Power Supply (930E)
FAULT TREE DIAGNOSIS
Payload Lights Won't Illuminate
Red, Amber or Green Payload Light Does Not Illuminate
Cannot Download - PC Communications
PC Communications Configuration
F.CAL: Payload Meter Won't Calibrate
F-20: Sensor Power Fault
F-21, F-25: Left Front Pressure Sensor
F-22, F-26: Right Front Pressure Sensor
F-23, F-27: Left Rear Pressure Sensor
F-24, F-28: Right Rear Pressure Sensor
F-31, F-32: Inclinometer
Body Up Input
Brake Lock Input
Speed Signal
Adjusting the Speed Sensor
CONNECTORS AND PRESSURE SENSORS
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM
Menu Functions
Using Scope
Log File Information
Connections to Payload Meter II™
USING SCOPE
Monitoring Inputs Using Scope
Monitoring Suspension Charging Using Scope
Pressure Sensor Dummy Loads
GAIN ADJUSTMENT WORKSHEET

SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX
SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX
TRANSMISSION
TORQUE CONVERTER
MAIN RELIEF VALVE
Function
Operation
TORQUE CONVERTER RELIEF VALVE
Function
Operation
TORQUE CONVERTER REGULATOR VALVE
Operation
LOCK-UP CLUTCH
HYDRAULIC PUMP
TORQUE CONVERTER STALL CHECK
TRANSMISSION
LUBRICATION RELIEF VALVE
Function
TRANSMISSION CONTROL VALVE
ELECTRONIC CONTROL MODULATION VALVE (ECMV)
Pressure Control Valve
Flow Sensor Valve
ECMV and Proportional Solenoid
ECMV and Fill Switch
Action of ECMV
ECMV REPAIR PROCEDURE
Filter Replacement Procedure
ECMV Removal
Disassembly
Reassembly
TRANSMISSION FILTERS
Service
Installation
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
Centering the Engine and Transmission
SECTION F3 - TRANSMISSION COOLER - INDEX
TRANSMISSION OIL COOLER
TRANSMISSION OIL COOLER
Removal and Installation
Repair
TRANSMISSION OIL STRAINER
Removal
Inspection
Installation
SECTION F5 - DRIVELINES - INDEX
DRIVESHAFTS
Removal - Front Drive Shaft
Installation - Front Drive Shaft
Disassembly - Driveshaft Assembly
Assembly - Drive Shaft Assembly
Removal - Rear Driveshaft
Installation - Rear Driveshaft
SECTION F6 - MISCELLANEOUS COMPONENETS - INDEX
MISCELLANEOUS COMPONENTS
General Information
TRANSMISSION SHIFT CONTROLLER
Event Memory
Fault History Data
Snap-Shot Data
Trend Data
TRANSMISSION RANGE SELECTOR
SENSORS and SWITCHES
Transmission Speed Sensors
Adjustment Procedure
Fill Switch
Shift Limit Switch
TRANSMISSION/TORQUE CONVERTER TROUBLESHOOTING
TRANSMISSION TROUBLESHOOTING PROCEDURES
Preliminary Checks

SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX
SECTION G2 - TIRES AND RIMS - INDEX
TIRES AND RIMS
General Information and Recommendations
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRE AND RIM
Removal
Installation Of Rear Wheel Assembly
TIRE MATCHING
RIM
Tire Removal From Rim
Tire Installation On Rim
SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX
FRONT WHEEL HUB AND SPINDLE
FRONT WHEEL HUB
Removal
(Wheel Hub Only; Brake Assy. Remains In Place)
Disassembly - Front Wheel Hub
Inspection
Assembly and Installation - Front Wheel Hub
Front Wheel Hub Bearing Adjustment
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION
SUSPENSION A-FRAME
Removal
Inspection of Parts
Installation
CENTER TIE ROD PIVOT
Removal
Inspection
Installation
TOE IN ADJUSTMENT
Adjustment Procedure
SECTION G4 - FINAL DRIVE ATTACHMENTS - INDEX
FINAL DRIVE ATTACHMENTS
REAR AXLE ATTACHMENT
Lower Side Links and Center Link
Removal
Inspection
Spherical Bearing Replacement
Installation
PANHARD ROD (DIAGONAL LINK)
Removal
Inspection
Installation
SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX
REAR AXLE & FINAL DRIVE ASSEMBLY
DIFFERENTIAL OPERATION
REAR AXLE ASSEMBLY
Removal
Installation
DIFFERENTIAL ASSEMBLY
Removal
Installation
DIFFERENTIAL ASSEMBLY
Disassembly
Disassembly of Pinion Carrier Assembly
Differential Gear Unit
Disassembly Of Differential Gear Unit
ASSEMBLY of DIFFERENTIAL
Differential Bearing
Assembly Of Differential Gear Assembly
Installation Of Differential Assembly
Input Pinion and Carrier Assembly
Adjusting Tooth Contact, Backlash
SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX
FINAL DRIVE PLANETARIES AND WHEEL HUBS
FINAL DRIVE
CARRIER ASSEMBLY
Removal
Installation
FINAL DRIVE CARRIER
Disassembly
Assembly
FINAL DRIVE ASSEMBLY
Disassembly
Assembly

SECTION H - HYDRAIR II SUSPENSIONS - INDEX
SECTION H2 - FRONT SUSPENSION - INDEX
FRONT SUSPENSION
FRONT SUSPENSION ASSEMBLY
Suspension Operation
3-MODE SUSPENSION (Optional)
Variable Damping Operation
3-Mode Suspension System Components
Automatic Suspension Controller
Manifold Valve
Actuator
Steering Sensor
Suspension Removal
Suspension Installation
Disassembly
Inspection
Assembly
DAMPING VALVE REPAIR
Damping Valve (Fixed Rate)
Disassembly
Assembly
Damping Valve/Actuator
(3-Mode Damping Rate)
Cleaning and Inspection
Assembly
SECTION H3 - REAR SUSPENSION - INDEX
REAR SUSPENSION
REAR SUSPENSION ASSEMBLY
SUSPENSION OPERATION
Removal
Installation
Disassembly
Assembly
REAR SUSPENSION SPHERICAL BEARING REPAIR
Disassembly
Inspection
Assembly
SECTION H4 - OILING AND CHARGING PROCEDURES - INDEX
OILING AND CHARGING PROCEDURES
GENERAL
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
General Information
Rear Suspension Oiling
Rear Suspension Nitrogen Charging
Length Adjustment - Front And Rear Cylinders

SECTION J - BRAKE CIRCUIT - INDEX
SECTION J2 - BRAKE CIRCUIT - INDEX
BRAKE CIRCUIT
SERVICE BRAKE CIRCUIT
SECONDARY BRAKING AND AUTOMATIC APPLY
PARKING BRAKE CIRCUIT
Normal Operation
BRAKE LOCK CIRCUIT
AUXILIARY CIRCUIT
RETARDING CIRCUIT
WARNING CIRCUIT
BRAKE SYSTEM ELECTRICAL COMPONENTS
SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE VALVE
Rebuild Criteria
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Actuator Base Threaded Inserts
Boot and Cap
Valve Body Seal Installation
Regulator Sleeve O-Ring Installation
Actuator Plunger O-ring Installation
Assembly of Valve
DIFFERENTIAL PRESSURE SWITCH
Disassembly
Cleaning and Inspection
Assembly
VALVE BENCH TEST AND ADJUSTMENT
Test Bench Only
Test Set Up Procedure
Brake Valve Output Pressure Adjustment
Differential Pressure Switch Adjustment
Final Test and Adjustment
Proximity Switch Installation and Adjustment
Installation Of Brake Pedal Actuator Assembly to Brake Valve
RELAY VALVES
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
VALVE TEST AND ADJUSTMENT
Test Set Up Procedure
Relay Valve
Output Pressure Adjustment
HYDRAULIC BRAKE ACCUMULATORS
Brake Accumulator Bleed Down Procedure
BRAKE ACCUMULATOR CHARGING PROCEDURE
BRAKE ACCUMULATOR REBUILD
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Testing
Storage
BRAKE COOLING VALVE (BCV)
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)
Lever Assembly Removal
Lever Assembly Installation
Disassembly and Adjustment
Potentiometer Check
Assembly
SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX
BRAKE CIRCUIT CHECK-OUT PROCEDURE
EQUIPMENT REQUIRED
Preparation
BRAKE SYSTEM CHECKOUT
Failure Modes Check-Out
RCM Calibration Check
RCM Calibration Procedure
Preparation
How to Perform Calibration
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING
KOMATSU CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
KOMATSU CHECK-OUT PROCEDURE
HYDRAULIC BRAKE SYSTEM DATA SHEET
SECTION J5 - FRONT WET DISC BRAKES - INDEX
FRONT WET DISC BRAKES
DESCRIPTION
FRONT DISC BRAKE ASSEMBLY
Removal
Installation
BRAKE ASSEMBLY REBUILD
DISC BRAKE MAINTENANCE
Brake Disc Wear Indicator
Checking Disc Wear
WEAR INDICATOR SENSOR
SPEED SENSOR
WET DISC BRAKE BLEEDING PROCEDURE
SECTION J6 - REAR WET DISC BRAKES - INDEX
REAR WET DISC BRAKES
DESCRIPTION
Operation
MAINTENANCE
Brake Disc Wear Indicator
Checking Disc Wear
Wear Indicator Sensor
Brake Assembly Removal
Brake Assembly Installation
BRAKE ASSEMBLY REBUILD
Disassembly
Cleaning and Inspection
Assembly
Floating Ring Seal Assembly/Installation
Alternate Procedure:
SECTION J7 - PARKING BRAKE - INDEX
PARKING BRAKE
Description
Parking Brake Service Criteria
Removal
Installation
PARKING BRAKE SPRING CYLINDER REPLACEMENT
Removal
Installation
AUTOMATIC SLACK ADJUSTER
Adjustment Procedure
PARKING BRAKE CHECK-OUT

SECTION L - HYDRAULIC SYSTEM - INDEX
SECTION L2 - HYDRAULIC SYSTEM - INDEX
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DESCRIPTION
Hydraulic Tank
Bleeddown Manifold
Hoist Valve
Hoist Pump
Brake Cooling Pump
Brake Control Valve (BCV)
Filters
High Pressure Filter
Low pressure
SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX
HYDRAULIC COMPONENT REPAIR
HYDRAULIC TANK
Filling Instructions
Service
Removal
Installation
Gap Measurement - Hydraulic Tank Mounting
HYDRAULIC TANK STRAINERS AND DIFFUSERS
Removal
Cleaning and Inspection
Installation
HYDRAULIC TANK BREATHER
Service
HYDRAULIC SYSTEM FLUSHING PROCEDURE
HYDRAULIC PUMPS
Removal
Installation
PUMP REBUILD
Disassembly
Inspection Of Parts
Assembly
Bearing Replacement
Seal Replacement
TROUBLESHOOTING GUIDE
SECTION L4 - STEERING CIRCUIT - INDEX
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
COMPONENT DESCRIPTION
Steering Control Valve
Bleeddown Manifold
Bleeddown Solenoid
Accumulators
High Pressure Filter
Warning Devices
Flow Amplifier
Steering Left
STEERING/BRAKE PUMP
Construction
Principle of Operation
SECTION L5 - STEERING CONTROL VALVE - INDEX
STEERING CONTROL UNIT
Removal
Installation
REBUILD PROCEDURE
Disassembly
Cleaning and Inspection
Assembly
SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX
STEERING CIRCUIT COMPONENT REPAIR
BLEEDDOWN MANIFOLD
Removal
Adjusting Relief Valve
Testing and Adjustment
FLOW AMPLIFIER
Removal
Installation
Disassembly
Assembly
ACCUMULATORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Testing
STEERING ACCUMULATOR CHARGING PROCEDURE
STEERING CYLINDER
Removal
Installation
STEERING CYLINDER REBUILD
Disassembly
Cleaning and Inspection
Assembly
STEERING/BRAKE PUMP
Removal
Installation
PUMP REBUILD
Disassembly
Control Group
Valve Plate Group
Rotating Group
Driveshaft Group
Swashblock Group
Inspection
Control Group
Valve Plate Group
Rotating Group
Swashblock Group
Driveshaft Group
Assembly
Swashblock Group
Driveshaft Group
Rotating Group
Valve Plate Group
Control Group
TROUBLESHOOTING CHART
SECTION L7 - HOIST CIRCUIT - INDEX
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
COMPONENT DESCRIPTION
Hydraulic Tank
Hoist Pump
Hoist Valve
Hoist Pilot Valve
Power Up Limit Solenoid
Pilot Operated Check Valve
Power Down Spool Limit Solenoid
HOIST CIRCUIT OPERATION
POWER UP Operation (Figure 7-5)
HOLD Operation (Figure 7-6)
POWER DOWN Operation (Figure 7-7)
FLOAT Operation (Figure 7-8)
SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Installation
O-Ring Replacement
INLET SECTION
Disassembly
Cleaning and Inspection
Reassembly
SPOOL SECTION
Disassembly
Cleaning and Inspection
Reassembly
HOIST PILOT VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Reassembly
HOIST CYLINDERS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly - Quill And Cylinder
Quill Installation
Installation Of Check Balls And Plugs In Quill
Assembly of Cylinder
Power Up Spool Limit Solenoid
Pilot Operated Check Valve
Power Down Hoist Limit Solenoid
SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX
HYDRAULIC SYSTEM FILTERS
HIGH PRESSURE FILTER
Filter Element Replacement
Removal
Installation
LOW PRESSURE FILTERS
Brake Cooling/Hoist Circuit Filters
Transmission Lubrication Circuit Filter
Filter Element Replacement
Removal
Installation
SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX
HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE
Equipment Requirements
Pump Pressure Control Adjustment
Steering Components Leakage Test
CHECKING HOIST SYSTEM PRESSURES
Equipment Requirements
Power Down Relief Valve Adjustment

SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX
SECTION M2 - FIRE CONTROL SYSTEMS - INDEX
FIRE CONTROL SYSTEM (MANUAL)
Operation
Inspection and Maintenance
Recharging Procedures
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1
Control Module
Actuator
Linear Detection Wire
Power Wire
Test Kit
Squib
Securing the Detection Wire
Preliminary Test Before Final Hook-Up
Installation Procedure for Squib
Placing the Electric Detection & Actuation System Into Service
INSPECTION AND MAINTENANCE SCHEDULES
Daily
Normal Maintenance Based On Actual Operating Hours
IN CASE OF FIRE
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM
SECTION M8 - SPECIAL TOOLS

SECTION N - CAB COMPONENTS - INDEX
SECTION N2 - TRUCK CAB - INDEX
TRUCK CAB
Description
Preparation
Removal
Installation
CAB DOOR
Removal
Installation
Door Adjustment
Door Jam Bolt Adjustment
Door Handle Plunger Adjustment
Replace Door Glass
Replace Door Window Regulator
Replace Door Handle or Latch Assembly
Door and Door Hinge Seal Replacement
Door Opening Seal Removal
Installation
GLASS REPLACEMENT
Replacement Procedure
REAR GLASS
Removal
Installation
SECTION N3 - CAB COMPONENTS - INDEX
CAB COMPONENTS
WINDSHIELD WIPERS
Wiper Motor Replacement
Removal
Installation
Wiper Arm Replacement
Removal
Installation
Wiper Linkage Replacement
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR SEAT
Adjustment
Removal
Installation
SECTION N4 - OPERATOR COMFORT - INDEX
OPERATOR COMFORT
HEATER/AIR CONDITIONER
Operation
HEATER/AIR CONDITIONER
Operation
HEATER COMPONENTS
Circuit Breaker
D/C - D/C Converter
Flapper Door Motors
Temperature Control Potentiometer
Motorized Coolant Control Valve
Heater Coil
Fan Motor and Speed Control
Test
FILTER
Service
AIR CONDITIONING SYSTEM
Environmental Impact
OPERATOR CAB AIR CONDITIONING
PRINCIPLES OF REFRIGERATION
Air Conditioning
Refrigeration - The Act Of Cooling
The Refrigeration Cycle
AIR CONDITIONER SYSTEM COMPONENTS
Compressor (Refrigerant Pump)
Service Valves
Condenser
Receiver-Drier
Expansion Block Valve
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
SYSTEM SERVICING
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Replacing Oil After Servicing the System
Setting Up a New Compressor
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Leak Detector
Service Valves
Vacuum Pump
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air From Service Hoses
Stabilizing the AC System
SYSTEM PERFORMANCE TEST
SYSTEM LEAK TESTING
Electronic leak detector
Tracer dyes
Soap and water
SYSTEM REPAIR
System Cleaning
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
RECOVERING AND RECYCLING THE REFRIGERANT
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the AC System
EVACUATING THE SYSTEM
CHARGING THE AC SYSTEM
TROUBLESHOOTING
Pre-Diagnosis Checks
Preparing For Diagnosis
Preliminary Steps
System Performance Test
Diagnosis Of Gauge Readings And System Performance
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM
SECTION N5 - OPERATOR CAB & CONTROLS - INDEX
OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
Horn Button
Telescope Lock Ring
Tilt Wheel Lever
Turn Signal / Headlight Dimmer
Windshield Wiper / Washer Control
RETARDER CONTROL LEVER
SERVICE BRAKE PEDAL
ACCELERATOR (THROTTLE) PEDAL
INSTRUMENT PANEL
RETARDING CAPACITY CHART
Radio Speakers
MOM Display Screen
MOM Dimmer Switch
Warning Alarm Buzzer
Cab Radio
PMC Interface Connector
Air Cleaner Vacuum Gauges
Payload Meter
Windshield Wipers
CENTER CONSOLE
Transmission Range Selector
Control Switches
Shift Limiter Switch
F1 Start Switch
Hoist Control Lever
Parking Brake Switch
Brake Lock Switch
LH Window Control Switch
RH Window Control Switch
Ash Tray
Lighter
Passenger Seat w/Safety Belt
INSTRUMENT PANEL AND INDICATORS
Keyswitch
Auxiliary Brake Switch
RH Control/Indicator Panel (Pod)
Center Display Panel
LH Control/Indicator Panel (Pod)
Ladder Light Switch
Head Light Switch
BackUp/Deck Lights Switch
RH Control/Indicator Panel (Pod)
Cold Weather Starting Aid (Ether Injection) Switch
Hazard Warning Lights Switch
Automatic Idle Selector Switch (AISS)
Air Conditioner & Heater Vent
ASR Cut (Traction Control) Switch (Option)
Center Display Panel
Air Pressure Monitor (Not Used)
Air Pressure Gauge (Not Used)
Coolant Temperature Monitor
Engine Cooling Water Temperature Gauge
Torque Converter Oil Temperature Monitor
Torque Converter Oil Temperature Gauge
Retarder Oil Temperature Monitor
Retarder Oil Temperature Gauge
Left Turn Signal Pilot Lamp
High Beam Pilot Lamp
Right Turn Signal Pilot Lamp
Speedometer
Tachometer
Lock-up Pilot Lamp
Shift Limiter Pilot Lamp
Shift Indicator
Transmission Shift Position Pilot Lamp
Engine Controller Monitor
Automatic Transmission Mechatronics Monitor
Other Mechatronics Monitor (Optional)
Fuel Level Monitor
Fuel Gauge
Engine Power Derate Monitor
F1 Start Monitor
Auto Cruise Control (Not Used)
ASR Monitor (Optional)
ABS Monitor (Not Used)
Service Meter
Odometer
LH Control/Indicator Panel (Pod)
LH Panel/Pod Assembly
Engine Oil Temperature
Engine Coolant Level
Low Steering Pressure
Accumulator Pre-Charge
Battery Charge Amps
Check Engine
Parking Brake
Body Float
Transmission Oil Temperature
Service Brakes Applied
Maintenance Monitor
Transmission Oil Filters
Lamp Test
Low Brake Pressure
Lateral Slope Warning
Crankcase Pressure
Panel Dimmer Switch
Engine Oil Pressure
Central Warning Lamp
AC/Heater Vent
REAR OF OPERATOR CAB
QUANTUM™ FUEL SYSTEM DIAGNOSTICS
Determining Fault Codes
Exiting The Diagnostics Mode

SECTION P - LUBRICATION AND SERVICE - INDEX
SECTION P2 - LUBRICATION AND SERVICE - INDEX
LUBRICATION AND SERVICE
TRANSMISSION OIL LEVEL CHECK
10 HOUR (DAILY) INSPECTION
250 HOUR INSPECTION
500 HOUR INSPECTION
1000 HOUR INSPECTION
2000 HOUR INSPECTION
5000 HOUR INSPECTION
HYDRAULIC TANK SERVICE
Filling Instructions
Hydraulic Tank Service
STEERING CIRCUIT FILTER
Removal
Installation
HYDRAULIC TANK BREATHER
Cleaning
SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX
LINCOLN AUTOMATIC LUBRICATION SYSTEM
SYSTEM COMPONENTS
System Operation
System Priming
System Checkout
Pressure Reducer Adjustment
24 VDC Solid State Timer Check
24 VDC Solid State Timer Adjustment
INJECTORS (SL-1 Series "H")
Injector Specifications
Injector Adjustment
INJECTOR OPERATION
PUMP CYCLE TIMER (FLASHER TIMER)
Pump Cycle Timer (Flasher Timer) Installation
Pump Cycle Timer (Flasher Timer) Adjustment:
TROUBLESHOOTING CHART
RESERVOIR FILL PROCEDURE
Lubricant Required for System
Fill Procedure
Preventive Maintenance Procedures
Daily Lubrication System Inspection
250 Hour Inspection

SECTION Q ALPHABETICAL INDEX

SECTION R
HYDRAULIC SYSTEM SCHEMATIC
HYDRAULIC BRAKE SCHEMATIC
ELECTRICAL WIRING SCHEMATIC
ELECTRICAL HOOK-UP

-