Komatsu HD1500-7 Dump Truck Service Repair Shop Manual (A30049 and up) - CEBM021004

This complete service repair workshop manual PDF download for the Komatsu Dump Truck HD1500-7 (SN: A30049 and up) 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 : HD1500-7
Serial Numbers :
A30049-A30055, A30058-A30064,
A30067-A30070, A30073-A30075,
A30078-A30080, A30085-A30090,
A30095-A30108
Engine : SDA12V160


TABLE OF CONTENTS :

- GENERAL INFORMATION
- STRUCTURES
- ENGINE
- ELECTRICAL SYSTEM
- TRANSMISSION AND TORQUE CONVERTER
- DRIVE AXLE, SPINDLES AND WHEELS
- SUSPENSIONS
- BRAKE SYSTEM
- HYDRAULIC SYSTEM
- OPTIONS AND SPECIAL TOOLS
- OPERATOR CAB
- LUBRICATION AND SERVICE
- SYSTEM SCHEMATICS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM021004
Total Pages : 1391


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SECTION A - GENERAL INFORMATION -
INDEX
SECTION A2 -
MAJOR COMPONENTS AND SPECIFICATIONS
SECTION A3 - GENERAL SAFETY AND OPERATION - INDEX

GENERAL SAFETY AND OPERATION
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
HAUL ROADS
PRECAUTIONS DURING OPERATION
BEFORE STARTING THE ENGINE
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
Traveling
Traveling In Reverse
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
Loading The Body
Parking The Machine
TOWING
WORKING NEAR BATTERIES
Battery Hazard Prevention
Starting With Booster Cables
MAINTENANCE PRECAUTIONS
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
Walk Around Inspection
Cold Weather Heating System
ENGINE START-UP SAFETY PRACTICES
Cold Weather Starting
Jump Starting
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
TURNING OFF THE ENGINE
SUDDEN LOSS OF ENGINE POWER
Secondary Steering And Braking
DISABLED TRUCK DUMPING
Hookup
Raising the Body
Lowering the Body
DISABLED TRUCK STEERING AND BRAKING
TOWING
SECTION A4 -
WARNINGS AND CAUTIONS
SECTION A5 -
TORQUE TABLES AND CONVERSION CHARTS
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws
Hardware Tightening Method
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 THE ENGINE HAS STARTED
SHORT TERM ENGINE STORAGE
Preparing the Engine
Removing the Engine from Long Term Storage
TRANSMISSION PRESERVATION AND STORAGE
Storage, New Transmission
Storage, One Year- Without Oil
Storage, One Year - With Oil - Normally Installed On The Truck
Restoring The Transmission For Service

SECTION B - STRUCTURES - INDEX

SECTION B2 - STRUCTURAL COMPONENTS - INDEX

STRUCTURAL COMPONENTS
PREPARATION
GRILLE, HOOD AND LADDERS
DECKS
CENTER DECK
Removal
Installation
RIGHT DECK AND COMPONENTS
Removal
Installation
LEFT DECK AND CAB
Installation
SECTION B3 - DUMP BODY - INDEX

DUMP BODY
Removal
Installation
BODY PADS
Removal
Installation
Body Pad Adjustment
BODY GUIDE
BODY-UP RETENTION CABLE
ROCK EJECTORS
Inspection
SECTION B4 - FUEL TANK - INDEX

FUEL TANK
Removal
Cleaning
Repair
Installation
FUEL GAUGE AND SENDING UNIT
Removal
Installation
WIGGINS QUICK FILL FUEL SYSTEM
FUEL RECEIVER
FUEL TANK BREATHER
Removal
Installation
Disassembly
Assembly
LEFT SIDE FILL

SECTION C - ENGINE - INDEX

SECTION C3 - COOLING SYSTEM - INDEX

COOLING SYSTEM
DESCRIPTION
LEAKS AND CONTAMINATION
RADIATOR FILL PROCEDURE
RADIATOR REMOVAL
RADIATOR REPAIR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
Additional Service Information
RADIATOR INSTALLATION
TRANSMISSION AND BRAKE COOLERS
Removal
Disassembly
Cleaning And Inspection
Assembly
Inspection
Installation
SECTION C4 - ENGINE - INDEX

ENGINE
Removal
Inspection
Installation
DRIVE LINE ADAPTER
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
Bearing Tools
SECTION C5 - AIR FILTRATION SYSTEM - INDEX

AIR FILTRATION SYSTEM
AIR CLEANER
Operation
General Maintenance
FILTER SERVICE INDICATOR
MAIN FILTER ELEMENT
Removal
Installation
SAFETY FILTER ELEMENT
Removal
Installation
MAIN FILTER CLEANING
PRECLEANER CLEANING
AIR INTAKE GUIDELINES
Installation
AIR INTAKE TROUBLESHOOTING
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 - INDEX

SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX

BATTERIES AND STARTING SYSTEM
BATTERIES
MAINTENANCE AND SERVICE
Electrolyte Levels
Cleaning
Other Maintenance
ENGINE PRELUB™ SYSTEM
OPERATION
Oil Pressure Switch
Check Valve
Timer Solenoid
MAINTENANCE
Prelub™ System Operation
Prelub Pump
Check Valve
Timer Solenoid
PRELUB CIRCUIT TROUBLESHOOTING
STARTING SYSTEM
CRANKING MOTORS
Removal
Disassembly
Cleaning and Inspection
Armature Servicing
Field Coil Checks
Field Coil Removal
Solenoid Checks
Assembly
Installation
TROUBLESHOOTING
Preliminary Inspection
No-Load Test
Interpreting The Results of The Tests
MAGNETIC SWITCH
Removal
Installation
Coil Test
SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX

ELECTRICAL SYSTEM COMPONENTS
CAB MOUNTED COMPONENTS
CIRCUIT BREAKERS
RELAY CENTER
FUSE PANEL
EXTERIOR COMPONENTS
BATTERY BOX
BATTERY DISCONNECT SWITCH
GROUND LEVEL SHUT OFF SWITCH
CONTROL POWER RELAYS
CIRCUIT BREAKERS
BATTERY EQUALIZER
Test
BODY POSITION SWITCHES
Proximity Switch Operation
Body-Up Switch Adjustment
Hoist Limit Switch Adjustment
SPEED SENSORS
Sensor Adjustment
GENERAL TROUBLESHOOTING
SECTION D10 - CHARGING SYSTEM - IND
EX
CHARGING SYSTEM
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION
Excessive heat
Dirt and dust
Vibration
PREVENTIVE MAINTENANCE PROCEDURES
Alternator Cleanliness
Alternator Mounting
Belt Tension And Condition
TROUBLESHOOTING
ALTERNATOR PERFORMANCE TEST
ALTERNATOR CABLE TEST
VOLTAGE REGULATOR ADJUSTMENT
ALTERNATOR
Removal
Installation
SECTION D11 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX

AUTOMATIC TRANSMISSION CONTROLLER
GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES
TRANSMISSION OPERATING MODES
NETWORK DATA
SHIFT LOGIC
Shift Lever Position D, Up-Shifting
Shift Lever Position D, Down-Shifting
Shift Lever Positions 6, 5, 4, 3, 2, L
Shift Lever Positions R
Shift Lever Position N
Gear Shift Time Delay
SAFETY FUNCTIONALITY
Down-Shift Inhibitor Function
Neutral Safety Function
Directional Inhibit Function
Powertrain Overrun Prevention
Reverse Safety (Dump Body Raised)
Speed Range Limit Function (Dump Body Raised)
Self-diagnostic function
ATC REAL TIME MONITORING
LIMP HOME MODE
Limp Home Procedure 1
Limp Home Procedure 2
Limp Home Procedure 3
Limp Home Procedure 4
Limp Home Procedure 5
Limp Home Procedure 6
Limp Home Procedure 7
SECTION D15 - MACHINE MONITOR - INDEX

MACHINE MONITOR
CHARACTER DISPLAY
Mode Select Switches 1 & 2
Service Meter
Odometer
Operation Information
Reverse Travel Odometer
Filter And Oil Change Display
Display Items
Resetting The Filter/Oil Replacement Meter
Inputting Telephone Numbers
Selecting A Language
ACTION CODE DISPLAYS
E03 Codes
E02 Codes
E01 Codes
REAL TIME MONITOR
USING REAL TIME MONITOR
Viewing Two Streams of Data At Once
Real Time Monitoring Codes
MACHINE MONITOR FLOW CHART
SECTION D20 - FAILURE CODES - INDEX

FAILURE CODES
ACTION CODE DISPLAYS
CHECKING FAILURE CODES
LIMP HOME MODE
FAILURE CODE TABLE
SECTION D21 -
TROUBLESHOOTING
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION
FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR
FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR
FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING
FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR
FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING
FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING
FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING
FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING
FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF
FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION
FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING
FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION
FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION
FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE
FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR
FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE
FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE
FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE
FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION
FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT
FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW
FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING
FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING
FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING
FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION
FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION
FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR
FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR
FAILURE CODE [DASOMA] ENGINE MALFUNCTION: RED INDICATOR LIGHT
FAILURE CODE [DASOMC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT
FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW
FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR
FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR
FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR
FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR
FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT
FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE
FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT
FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT
FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT
FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT
FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT
FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT
FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT
FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT
FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT
FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE
FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE
FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT
FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT
FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE
FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE
FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION
FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION
FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION
FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT
FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION
FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL
FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT
FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT
FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON)
FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT
FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT
FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON)
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER
FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE)
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER
SECTION D30 - VHMS INITIALIZATION -
INDEX
INITIALIZATION OF VHMS CONTROLLER
Executing Quick PM
Downloading Existing VHMS Setting Data
Confirmation of Downloaded Data
Disconnecting the PC
Reporting to Komatsu
REPLACING THE VHMS CONTROLLER
Prior to Removing VHMS Controller
Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)
Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)
Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)
Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)
FINAL VHMS PROCEDURES-POST INSTALLATION
Correct the Load Weight Calculation
SECTION D31 - VEHICLE HEALTH MONITORING SYSTEM (VHMS) - INDEX

VEHICLE HEALTH MONITORING SYSTEM (VHMS)
VHMS DOWNLOADING
PAYLOAD METER
NORMAL OPERATION DISPLAY
EXTERNAL DISPLAY LAMPS
PREDICTED LOAD DISPLAY
CALIBRATING PLM
DATA STORED IN PAYLOAD METER
PLM DOWNLOADING
Downloading From Inside Of The Cab
Downloading From Ground Level Box
SETTING THE MACHINE ID AND OPEN ID
PAYLOAD - CYCLE DATA ITEM
ADDITIONAL FUNCTIONS
Other Settings

SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX

SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX

TORQUE CONVERTER AND TRANSMISSION
TORQUE CONVERTER
MAIN RELIEF VALVE
Function
Operation
TORQUE CONVERTER RELIEF VALVE
Function
Operation
TORQUE CONVERTER REGULATOR VALVE
Operation
LOCK-UP CLUTCH
Lock-up Clutch Accumulator
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
ECMV Operation
ECMV REPAIR
Preparation
Filter Replacement Procedure
ECMV Identification
ECMV Removal
Disassembly
Assembly
Installation
TRANSMISSION FILTERS
Service
Installation
TRANSMISSION SPEED SENSORS
Adjustment Procedure
TRANSMISSION OIL LEVEL CHECK
TRANSMISSION OIL PRESSURE CHECK
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING
Preliminary Checks
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
SECTION F2 - TORQUE CONVERTER AND TRANSMISSION (-40°C) - INDEX

TORQUE CONVERTER AND TRANSMISSION (-40°C)
TORQUE CONVERTER
MAIN RELIEF VALVE
Function
Operation
TORQUE CONVERTER RELIEF VALVE
Function
Operation
TORQUE CONVERTER REGULATOR VALVE
Operation
COLD RELIEF VALVE
Operation
LOCK-UP CLUTCH
Lock-up Clutch Accumulator
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
ECMV Operation
ECMV REPAIR
Preparation
Filter Replacement Procedure
ECMV Identification
ECMV Removal
Disassembly
Assembly
Installation
TRANSMISSION FILTERS
Service
Installation
COLD OIL FILTER RELIEF VALVE
TRANSMISSION SPEED SENSORS
Adjustment Procedure
TRANSMISSION OIL LEVEL CHECK
TRANSMISSION OIL PRESSURE CHECK
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING
Preliminary Checks
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX

TRANSMISSION OIL COOLER & STRAINERS
TRANSMISSION OIL COOLER
Removal and Installation
Repair
TRANSMISSION OIL STRAINER
Removal
Inspection
Installation
SECTION F5 - DRIVE SHAFTS - INDEX

DRIVE SHAFTS
FRONT DRIVE SHAFT
Removal
Disassembly
Assembly
Installation
FRONT DRIVE SHAFT ALIGNMENT
REAR DRIVE SHAFT
Removal
Disassembly
Assembly
Installation
SECTION F8 - TORQUE CONVERTER REBUILD - INDEX

TORQUE CONVERTER REBUILD
REMOVAL
INSTALLATION
DISASSEMBLY
PTO COVER DISASSEMBLY
CLEANING & INSPECTION
TABLE I. COMPONENT WEAR LIMITS
TABLE II. Gear Backlash
ASSEMBLY
ONE-WAY CLUTCH ASSEMBLY
STATOR BEARING PRE-LOAD ADJUSTMENT
PTO DRIVE ASSEMBLY
SPECIAL TOOLS
SECTION F8 - TORQUE CONVERTER REBUILD (-40°C) - INDEX

TORQUE CONVERTER REBUILD (-40°C)
REMOVAL
INSTALLATION
DISASSEMBLY
PTO COVER DISASSEMBLY
CLEANING & INSPECTION
TABLE I. COMPONENT WEAR LIMITS
TABLE II. Gear Backlash
ASSEMBLY
ONE-WAY CLUTCH ASSEMBLY
STATOR BEARING PRE-LOAD ADJUSTMENT
PTO DRIVE ASSEMBLY
SPECIAL TOOLS
SECTION F9 - TRANSMISSION REBUILD - INDEX

TRANSMISSION REBUILD
TRANSMISSION DISASSEMBLY
Number One Clutch Housing Disassembly
Bearing Cage & Cover Disassembly
Number Four Carrier Disassembly
Output Shaft Cover Disassembly
Rear Case Bearing Removal
Output Shaft Removal
Output Shaft Disassembly
Number Five/Six Carrier Disassembly
CLEANING AND INSPECTION
INSPECTION TABLE INDEX
TRANSMISSION ASSEMBLY
GENERAL INSTRUCTIONS
Number Five/Six Carrier Assembly
Output Shaft Assembly
Number Seven Clutch Assembly
Rear Case Assembly
Rear Case & Carrier Assembly
Number Six Clutch Assembly
Number Four Carrier Assembly
Number Four Carrier Bearing Cage Assembly
Number Five Clutch Assembly
Number Four Clutch Assembly
Number Three Clutch Assembly
Clutch Test
Number Two Clutch Ring Gear Installation
Number Three Carrier & Number Two Clutch Assembly
Number One Carrier Assembly
Number One Clutch Assembly
Checks Prior to Final Assembly
Final Assembly
Input Shaft Installation
External Components

SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX

SECTION G2 - TIRES AND RIMS - INDEX

TIRES AND RIMS
GENERAL INFORMATION
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRE AND RIM
Removal
Installation
TIRE MATCHING
RIM
Tire Removal From Rim
Tire Installation On Rim
FRONT WHEEL STUD INSTALLATION
REAR WHEEL STUD INSTALLATION
SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX

FRONT WHEEL HUB AND SPINDLE
OIL SAMPLE ANALYSIS
Oil Sampling Guidelines
Guidelines For Obtaining A Sample
FRONT WHEEL HUB
Removal
Disassembly
Inspection
Assembly
Installation
Front Wheel Hub Bearing Adjustment
FRONT SPINDLE
A-ARM
Removal
Inspection
Installation
CENTER TIE ROD PIVOT
Removal
Inspection
Installation
TOE IN ADJUSTMENT
Adjustment Procedure
SECTION G4 - REAR AXLE ATTACHMENTS - INDEX

REAR AXLE ATTACHMENTS
CENTER LINK AND LOWER LINKS
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
Straight-away-travel
Turning
REAR AXLE ASSEMBLY
Removal
Installation
DIFFERENTIAL OIL LEVEL CHECK
DIFFERENTIAL ASSEMBLY
Removal
Installation
Disassembly
Pinion Carrier Assembly
Differential Gear Unit
Differential Gear Unit
Cleaning and Inspection
Assembly
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
Oil Level Check
FINAL DRIVE CARRIER ASSEMBLY
Removal
Installation
Disassembly
Assembly
FINAL DRIVE ASSEMBLY
Disassembly
Assembly

SECTION H - SUSPENSIONS - INDEX

SECTION H2 - FRONT SUSPENSION - INDEX

FRONT SUSPENSION
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Pressure Tests
DAMPING VALVE REPAIR
Disassembly
Assembly
SECTION H3 - REAR SUSPENSION - INDEX

REAR SUSPENSION
Operation
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
LEAK TESTING
SPHERICAL BEARINGS
Removal
Inspection
Installation
SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX

SUSPENSION OILING AND CHARGING
GENERAL INFORMATION
Equipment List
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
GENERAL INFORMATION
Rear Suspension Oiling
Rear Suspension Nitrogen Charging
FRONT AND REAR CYLINDER LENGTH ADJUSTMENT

SECTION J - BRAKE SYSTEM - INDEX

SECTION J2 - BRAKE SYSTEM OPERATION - INDEX

BRAKE SYSTEM OPERATION
DESCRIPTION
SERVICE BRAKE OPERATION
SECONDARY BRAKING AND AUTOMATIC APPLY
BRAKE SYSTEM COMPONENTS
BRAKE MANIFOLD CARTRIDGE VALVES
SERVICE BRAKE CIRCUIT
RETARDING CIRCUIT
PARKING BRAKE CIRCUIT
AUTO APPLY
AUXILIARY BRAKE CIRCUIT
BRAKE LOCK CIRCUIT
AUTOMATIC SPIN REGULATOR
BRAKE COOLING CIRCUIT
BRAKE COOLING VALVE
COLD OIL DIVERTER VALVES
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
BENCH TEST AND ADJUSTMENT
Test Bench Only
Test Set Up Procedure
Brake Valve Output Pressure Adjustment
Final Test and Adjustment
Proximity Switch Installation and Adjustment
Installation Of Brake Pedal Actuator Assembly to Brake Valve
BRAKE ACCUMULATORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Leak Testing
ACCUMULATOR CHARGING
Temperature During Precharge
ACCUMULATOR STORAGE
Installation
BRAKE COOLING VALVE (BCV)
RETARDER CONTROL LEVER
Removal
Installation
Disassembly and Adjustment
Potentiometer Check
Assembly
Retard Lever Calibration
SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX

BRAKE CIRCUIT CHECK-OUT
REQUIRED EQUIPMENT
PREPARATION
BRAKE CIRCUIT TESTING
Initial System Setup
Parking Brake
Brake Lock
Low-Brake Pressure and Auto-Apply
Validation
Retarding
BRAKE SYSTEM DATA SHEET
BRAKE CIRCUIT TROUBLESHOOTING
SECTION J5 - FRONT WET DISC BRAKES - INDEX

FRONT WET DISC BRAKES
BRAKE MAINTENANCE
Checking Disc Wear
FRONT BRAKE ASSEMBLY
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Floating Seal Installation
BRAKE BLEEDING
SECTION J6 - REAR WET DISC BRAKES - INDEX

REAR WET DISC BRAKES
DESCRIPTION
OPERATION
MAINTENANCE
Checking Brake Disc Wear
REMOVAL
INSTALLATION
BRAKE REBUILD
Disassembly
Cleaning and Inspection
Assembly
Floating Seal Installation
WET DISC BRAKE BLEEDING
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 OVERVIEW - INDEX

HYDRAULIC SYSTEM OVERVIEW
SYSTEM COMPONENTS
HYDRAULIC TANK
BLEED-DOWN MANIFOLD
HOIST VALVE
HOIST PUMP
BRAKE COOLING PUMP
BRAKE CONTROL VALVE (BCV)
SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX

HYDRAULIC COMPONENT REPAIR
HYDRAULIC TANK
FILLING INSTRUCTIONS
MAINTENANCE
Removal
Installation
Gap Measurement - Hydraulic Tank Mounting
STRAINERS AND DIFFUSERS
Removal
Cleaning and Inspection
Installation
HYDRAULIC TANK BREATHER
Service
HYDRAULIC SYSTEM FLUSHING
HYDRAULIC PUMPS
Removal
Installation
PUMP REBUILD
Disassembly
Inspection Of Parts
Assembly
Bearing Replacement
Seal Replacement
TROUBLESHOOTING GUIDE
SECTION L4 - STEERING CIRCUIT - INDEX

STEERING CIRCUIT
OPERATION
COMPONENT DESCRIPTION
Steering Control Valve
Bleed-down Manifold
Bleed-down Solenoid
Accumulators
Flow Amplifier
High Pressure Filter
Warning Devices
FLOW AMPLIFIER OPERATION
STEERING/BRAKE PUMP
COMPONENTS
OPERATION
SECTION L5 - STEERING CONTROL UNIT - INDEX

STEERING CONTROL UNIT
Removal
Installation
REBUILD PROCEDURE
Disassembly
Cleaning and Inspection
Assembly
SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX

STEERING CIRCUIT COMPONENT REPAIR
BLEED-DOWN MANIFOLD
Removal
Adjusting Relief Valve
Testing and Adjustment
FLOW AMPLIFIER
Removal
Installation
Disassembly
Assembly
ACCUMULATORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Leak Testing
STEERING ACCUMULATOR CHARGING
Temperature During Precharge
ACCUMULATOR STORAGE
Installation
STEERING CYLINDER
Removal
Installation
STEERING CYLINDER REBUILD
Disassembly
Cleaning and Inspection
Assembly
Testing
STEERING/BRAKE PUMP
Removal
Installation
PUMP REBUILD
Disassembly
Control Group
Valve Plate Group
Rotating Group
Drive Shaft Group
Swashblock Group
Inspection
Control Group
Valve Plate Group
Rotating Group
Swashblock Group
Drive Shaft Group
Assembly
Swashblock Group
Drive Shaft Group
Rotating Group
Valve Plate Group
Control Group
STEERING CIRCUIT FILTER
Removal
Installation
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 Solenoid
Pilot Operated Check Valve
Power Down Spool Limit Solenoid
HOIST CIRCUIT HYDRAULIC FLOW
POWER UP
HOLD
POWER DOWN
FLOAT
SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX

HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Installation
O-Ring Replacement
INLET SECTION
Disassembly
Cleaning and Inspection
Assembly
SPOOL SECTION
Disassembly
Cleaning and Inspection
Assembly
HOIST PILOT VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
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
Pressure Testing
SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX

HYDRAULIC SYSTEM FILTERS
HIGH PRESSURE FILTER
Removal
Installation
LOW PRESSURE FILTERS
BRAKE COOLING & HOIST FILTERS
TRANSMISSION FILTER
Removal
Installation
SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX

HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE
Equipment Requirements
Installation Of Gauges
Initial Startup And Flushing
Component Checkout And Adjustment
CHECKING HOIST SYSTEM PRESSURES
Equipment Requirements
Steering Components Leakage Test
HYDRAULIC SYSTEM CHECKOUT DATA SHEET

SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX

SECTION M7 - HOT START SYSTEM -
INDEX
HOT START SYSTEM
SYSTEM OPERATION
HEATER INFORMATION
TROUBLESHOOTING GUIDELINES
SECTION M8 -
SPECIAL TOOLS

SECTION N - OPERATOR CAB - INDEX

SECTION N2 - OPERATOR CAB - INDEX

OPERATOR CAB
Removal
Installation
CAB DOORS
Removal
Installation
Door Striker Adjustment
Door Handle Plunger Adjustment
DOOR PANEL
Removal
Installation
DOOR WINDOW
Removal
Installation
WINDOW REGULATOR
Removal
Installation
DOOR HANDLE AND DOOR LATCH
Removal
Installation
DOOR SEALS
Removal
Installation
DOOR OPENING SEAL
Removal
Installation
GLASS REPLACEMENT
Replacement
WINDSHIELD AND REAR GLASS
Removal
Installation
SECTION N3 - CAB COMPONENTS - INDEX

CAB COMPONENTS
WIPER MOTOR
Removal
Installation
WIPER ARM
Removal
Installation
WIPER LINKAGE
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR SEAT
Adjustment
Seat Removal
Seat Installation
Seat Belt Replacement
SECTION N4 - HEATING AND AIR CONDITIONING - INDEX

HEATING AND AIR CONDITIONING
HEATER/AIR CONDITIONER UNIT
Fan Speed Control Knob
Temperature Control Knob
Air Flow Directional Knob
Heater/Air Conditioner Vents
COMPONENTS
Fuse
Relays
Heater Core
Fan Motor And Speed Control
Actuators
Cab Air Filter
ENVIRONMENTAL IMPACT OF AIR CONDITIONING
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES
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
Accumulator
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
SYSTEM SERVICING
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
SYSTEM PERFORMANCE TEST
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Checking System Oil
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SYSTEM LEAK TESTING
Electronic Leak Detector
Tracer Dyes
Soap and Water
RECOVERING AND RECYCLING THE REFRIGERANT
Draining Oil from the Previous Recovery Cycle
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the A/C System
SYSTEM REPAIR
System Flushing
A/C DRIVE BELT CHECKOUT PROCEDURE
Pulley Alignment
Belt Tension Check
COMPONENT REPLACEMENT
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Accumulator
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
EVACUATING THE SYSTEM
CHARGING THE A/C SYSTEM
TROUBLESHOOTING
Preliminary Checks
Diagnosis Of Gauge Readings And System Performance
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX

OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
Horn Button
ARSC Set Lever
Telescoping/Tilt Wheel Lever
Multi-Function Turn Signal Lever
RETARDER CONTROL LEVER
STEERING WHEEL
Removal
Installation
SERVICE BRAKE PEDAL
ACCELERATOR PEDAL
INSTRUMENT PANEL
HEATER / AIR CONDITIONER CONTROLS
RETARDING CAPACITY CHART
RADIO SPEAKERS
AIR CLEANER VACUUM GAUGES
WARNING ALARM BUZZER
AM/FM RADIO / CD PLAYER
CENTER CONSOLE
Hoist Control Lever
Transmission Shift Lever
Parking Brake Switch
LH Window Control Switch
RH Window Control Switch
Auxiliary Power Outlets
INSTRUMENT PANEL AND INDICATORS
UPPER RH SWITCH PANEL
Brake Lock Switch
F1 Start Switch
Hazard Warning Lights Switch
LOWER RH SWITCH PANEL
Key Switch
Ether Starting Aid Switch
ASR Cut Switch
ARSC Switch
Automatic Idle Selector Switch (AISS)
Auxiliary Brake Switch
UPPER LH SWITCH PANEL
Automatic Lubrication System Indicator
LOWER LH SWITCH PANEL
Head Light Switch
Ladder Light Switch
BackUp/Deck Light Switch
Fog Light Switch
Mode Select Switches 1 & 2
Panel Light Dimmer Switch
ELECTRONIC DISPLAY PANEL
PILOT DISPLAY ITEMS
METER DISPLAYS
CAUTION ITEMS
EMERGENCY STOP ITEMS
CHARACTER DISPLAY
REAR ELECTRICAL COMPARTMENT
AUTOMATIC RETARD SPEED CONTROL (ARSC)
AUTOMATIC SPIN REGULATOR (ASR)

SECTION P - LUBRICATION AND SERVICE - INDEX

SECTION P2 - LUBRICATION AND SERVICE - INDEX

LUBRICATION AND SERVICE
COOLANT SPECIFICATIONS
Unacceptable Practices
RADIATOR FILL PROCEDURE
HYDRAULIC TANK SERVICE
Filling Instructions
TRANSMISSION OIL LEVEL CHECK
QUICK FILL SERVICE CENTER
PERIODIC REPLACEMENT OF CRITICAL PARTS
10 HOUR (DAILY) INSPECTION
10 HOUR (DAILY) INSPECTION (continued)
250 HOUR INSPECTION
250 HOUR INSPECTION (continued)
250 HOUR INSPECTION (continued)
500 HOUR INSPECTION
1000 HOUR INSPECTION
2000 HOUR INSPECTION
5000 HOUR INSPECTION
SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX

AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
SYSTEM COMPONENTS
SYSTEM OPERATION
INJECTOR OPERATION
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
INJECTORS (SL-1 Series “H”))
Injector Specifications
Injector Adjustment
SYSTEM PRIMING
Filter Assembly
SYSTEM CHECK
Lubrication Controller Check
Lubrication Controller Operation
Lubrication Controller Components
Lubrication Controller Adjustment
SYSTEM TROUBLESHOOTING CHART
PREVENTATIVE MAINTENANCE
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection
PUMP REBUILD
Disassembly
Cleaning and Inspection
Assembly

SECTION R - SYSTEM SCHEMATICS - INDEX

HYDRAULIC SYSTEM SCHEMATIC
HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40°C)

BRAKE
SYSTEM SCHEMATIC
HOOKUP
SCHEMATIC
ELECTICAL WIRING
SCHEMATIC
HVAC WIRING
SCHEMATIC
CONNECTOR LOCATOR

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