Komatsu Dump Trucks HD1500 Repair Service Manual + Operation & Maintenance Manual + Field Assembly Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD1500 Models, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Dump Truck HD1500-5, HD1500-7 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 14,061 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

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CEAM023003 - Dump Truck HD1500-7 Operation & Maintenance Manual.pdf
CEAW003001 - Dump Truck HD1500-5 Field Assembly Manual.pdf
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CEAW004903 - Dump Truck HD1500-7 Field Assembly Manual.pdf

MAIN SECTIONS
COVER...1
FOREWORD...4
TABLE OF CONTENTS...6
SECTION A GENERAL INFORMATION INDEX...8
  SECTION A2 - ...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 - ...52
  SECTION A5 - ...58
    EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...59
    STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts...59
    STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws...60
    STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws...61
      Hardware Tightening Method...69
  SECTION A7 - STORAGE PROCEDURES - INDEX...70
    STORAGE AND IDLE MACHINE PREPARATION...72
      SHORT TERM IDLE PERIODS...72
      PREPARATION FOR STORAGE...72
      REMOVAL FROM STORAGE...73
      RECONDITIONING AN IDLE VEHICLE...75
      ENGINE OPERATION...78
      AFTER THE ENGINE HAS STARTED...78
      SHORT TERM ENGINE STORAGE...79
        Preparing the Engine...79
        Removing the Engine from Long Term Storage...81
      TRANSMISSION PRESERVATION AND STORAGE...81
        Storage, New Transmission...81
        Storage, One Year- Without Oil...81
        Storage, One Year - With Oil - Normally Installed On The Truck...82
        Restoring The Transmission For Service...82
SECTION B - STRUCTURES - INDEX...84
  SECTION B2 - STRUCTURAL COMPONENTS - INDEX...86
    STRUCTURAL COMPONENTS...88
      PREPARATION...88
      GRILLE, HOOD AND LADDERS...89
        DECKS...90
      CENTER DECK...90
        Removal...90
        Installation...90
        RIGHT DECK AND COMPONENTS...90
          Removal...90
          Installation...90
        LEFT DECK AND CAB...91
          Installation...91
  SECTION B3 - DUMP BODY - INDEX...92
    DUMP BODY...94
      Removal...94
      Installation...96
      BODY PADS...96
        Removal...96
        Installation...97
        Body Pad Adjustment...97
      BODY GUIDE...99
      BODY-UP RETENTION CABLE...100
      ROCK EJECTORS...100
        Inspection...100
  SECTION B4 - FUEL TANK - INDEX...102
    FUEL TANK...104
      Removal...104
      Cleaning...105
      Repair...105
      Installation...105
      FUEL GAUGE AND SENDING UNIT...106
        Removal...106
        Installation...106
      WIGGINS QUICK FILL FUEL SYSTEM...106
        FUEL RECEIVER...106
        FUEL TANK BREATHER...107
          Removal...107
          Installation...107
          Disassembly...107
          Assembly...107
        LEFT SIDE FILL...108
SECTION C - ENGINE - INDEX...110
  SECTION C3 - COOLING SYSTEM - INDEX...112
    COOLING SYSTEM...114
      DESCRIPTION...114
      LEAKS AND CONTAMINATION...115
      RADIATOR FILL PROCEDURE...115
      RADIATOR REMOVAL...116
        RADIATOR REPAIR...118
          Internal Inspection...118
          External Cleaning...118
          Disassembly...119
          Cleaning and Inspection...120
          Assembly...120
          Pressure Testing...121
          Additional Service Information...121
      RADIATOR INSTALLATION...122
        TRANSMISSION AND BRAKE COOLERS...123
          Removal...124
          Disassembly...124
          Cleaning And Inspection...125
          Assembly...125
          Inspection...126
          Installation...127
  SECTION C4 - ENGINE - INDEX...128
    ENGINE...130
      Removal...130
      Inspection...133
      Installation...134
      DRIVE LINE ADAPTER...135
        Removal...136
        Disassembly...137
        Cleaning and Inspection...139
        Assembly...141
        Installation...145
        Bearing Tools...146
  SECTION C5 - AIR FILTRATION SYSTEM - INDEX...148
    AIR FILTRATION SYSTEM...150
      AIR CLEANER...150
        Operation...150
        AIR CLEANER MAINTENANCE...150
          Filter Service Indicator...152
          Replacing The Elements...152
        MAIN FILTER CLEANING...153
        PRECLEANER CLEANING...154
        AIR INTAKE GUIDELINES...155
          Installation...155
      AIR INTAKE TROUBLESHOOTING...156
  SECTION C7 - FAN CLUTCH - INDEX...158
    FAN CLUTCH...160
      REMOVAL & INSTALLATION TOOLING...160
      FAN CLUTCH - DISASSEMBLY...163
      CLEANING AND INSPECTION...173
      ASSEMBLY - FAN CLUTCH...177
      TEST PROCEDURE...191
SECTION D - ELECTRICAL SYSTEM - INDEX...192
  SECTION D2 - BATTERIES AND STARTING SYSTEM - INDEX...194
    BATTERIES AND STARTING SYSTEM...196
      BATTERIES...196
        MAINTENANCE AND SERVICE...196
          Electrolyte Levels...196
          Cleaning...196
          Other Maintenance...197
      ENGINE PRELUB? SYSTEM...199
        OPERATION...199
          Oil Pressure Switch...201
          Check Valve...201
          Timer Solenoid...201
        MAINTENANCE...201
          Prelub? System Operation...201
          Prelub Pump...201
          Check Valve...202
          Timer Solenoid...202
        PRELUB CIRCUIT TROUBLESHOOTING...203
      STARTING SYSTEM...205
        CRANKING MOTORS...205
          Removal...205
          Disassembly...206
          Cleaning and Inspection...206
          Armature Servicing...206
          Field Coil Checks...207
          Field Coil Removal...207
          Solenoid Checks...209
          Assembly...210
          Installation...212
        TROUBLESHOOTING...212
          Preliminary Inspection...212
          No-Load Test...212
          Interpreting The Results of The Tests...213
        MAGNETIC SWITCH...214
          Removal...214
          Installation...214
          Coil Test...214
  SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX...216
    ELECTRICAL SYSTEM COMPONENTS...218
      CAB MOUNTED COMPONENTS...218
        CIRCUIT BREAKERS...220
        RELAY CENTER...221
        FUSE PANEL...226
      EXTERIOR COMPONENTS...230
        BATTERY BOX...230
        BATTERY DISCONNECT SWITCH...230
        GROUND LEVEL SHUT OFF SWITCH...230
        CONTROL POWER RELAYS...230
        CIRCUIT BREAKERS...230
        BATTERY EQUALIZER...230
          Test...230
        BODY POSITION SWITCHES...232
          Proximity Switch Operation...232
          Body-Up Switch Adjustment...233
          Hoist Limit Switch Adjustment...233
        SPEED SENSORS...235
          Sensor Adjustment...236
      GENERAL TROUBLESHOOTING...236
  SECTION D10 - CHARGING SYSTEM - INDEX...238
    CHARGING SYSTEM...240
      PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION...240
        Excessive heat...240
        Dirt and dust...240
        Vibration...240
      PREVENTIVE MAINTENANCE PROCEDURES...241
        Alternator Cleanliness...241
        Alternator Mounting...241
        Belt Tension And Condition...241
      TROUBLESHOOTING...241
        ALTERNATOR PERFORMANCE TEST...241
        ALTERNATOR CABLE TEST...242
      VOLTAGE REGULATOR ADJUSTMENT...243
      ALTERNATOR...244
        Removal...244
        Installation...245
  SECTION D11 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX...248
    AUTOMATIC TRANSMISSION CONTROLLER...250
      GEAR SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES...251
      TRANSMISSION OPERATING MODES...252
      NETWORK DATA...252
      SHIFT LOGIC...254
        Shift Lever Position D, Up-Shifting...254
        Shift Lever Position D, Down-Shifting...254
        Shift Lever Positions 6, 5, 4, 3, 2, L...254
        Shift Lever Positions R...254
        Shift Lever Position N...254
        Gear Shift Time Delay...254
        SAFETY FUNCTIONALITY...255
          Down-Shift Inhibitor Function...255
          Neutral Safety Function...255
          Directional Inhibit Function...255
          Powertrain Overrun Prevention...255
          Reverse Safety (Dump Body Raised)...255
          Speed Range Limit Function (Dump Body Raised)...255
          Self-diagnostic function...255
      ATC REAL TIME MONITORING...256
      LIMP HOME MODE...256
        Limp Home Procedure 1...259
        Limp Home Procedure 2...259
        Limp Home Procedure 3...259
        Limp Home Procedure 4...259
        Limp Home Procedure 5...259
        Limp Home Procedure 6...259
        Limp Home Procedure 7...259
  SECTION D15 - MACHINE MONITOR - INDEX...260
    MACHINE MONITOR...262
      CHARACTER DISPLAY...262
        Mode Select Switches 1 & 2...263
        Service Meter...263
        Odometer...263
        Operation Information...263
        Reverse Travel Odometer...264
        Filter And Oil Change Display...264
        Display Items...265
        Resetting The Filter/Oil Replacement Meter...265
        Inputting Telephone Numbers...266
        Selecting A Language...266
      ACTION CODE DISPLAYS...267
        E03 Codes...267
        E02 Codes...268
        E01 Codes...268
      REAL TIME MONITOR...269
        USING REAL TIME MONITOR...269
          Viewing Two Streams of Data At Once...270
          Real Time Monitoring Codes...271
        MACHINE MONITOR FLOW CHART...275
  SECTION D20 - FAILURE CODES - INDEX...280
    FAILURE CODES...282
      ACTION CODE DISPLAYS...282
      CHECKING FAILURE CODES...283
      LIMP HOME MODE...284
      FAILURE CODE TABLE...285
  SECTION D21 - ...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 - ...564
    INITIALIZATION OF VHMS CONTROLLER...566
      Executing Quick PM...577
      Downloading Existing VHMS Setting Data...582
      Confirmation of Downloaded Data...583
      Disconnecting the PC...583
      Reporting to Komatsu...583
    REPLACING THE VHMS CONTROLLER...585
      Prior to Removing VHMS Controller...585
      Confirming and Saving VHMS Controller Settings (Versions older than 3.5.2.1)...585
      Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3.5.2.1)...589
      Confirming and Saving VHMS Controller Settings (Version 3.5.2.1 or newer)...591
      Loading Saved VHMS Settings To New VHMS Controller (Version 3.5.2.1 or newer)...592
    FINAL VHMS PROCEDURES-POST INSTALLATION...593
      Correct the Load Weight Calculation...595
  SECTION D31 - VEHICLE HEALTH MONITORING SYSTEM (VHMS) - INDEX...604
    VEHICLE HEALTH MONITORING SYSTEM (VHMS)...606
      VHMS DOWNLOADING...607
      PAYLOAD METER...608
        NORMAL OPERATION DISPLAY...609
        EXTERNAL DISPLAY LAMPS...610
        PREDICTED LOAD DISPLAY...610
        CALIBRATING PLM...611
        DATA STORED IN PAYLOAD METER...612
        PLM DOWNLOADING...613
          Downloading From Inside Of The Cab...613
          Downloading From Ground Level Box...613
        SETTING THE MACHINE ID AND OPEN ID...614
        PAYLOAD - CYCLE DATA ITEM...615
        ADDITIONAL FUNCTIONS...615
          Other Settings...615
SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX...616
  SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX...618
    TORQUE CONVERTER AND TRANSMISSION...620
      TORQUE CONVERTER...621
        MAIN RELIEF VALVE...623
          Function...623
          Operation...623
        TORQUE CONVERTER RELIEF VALVE...623
          Function...623
          Operation...623
        TORQUE CONVERTER REGULATOR VALVE...625
          Operation...625
        LOCK-UP CLUTCH...626
          Lock-up Clutch Accumulator...626
        HYDRAULIC PUMP...627
        TORQUE CONVERTER STALL CHECK...628
      TRANSMISSION...629
        LUBRICATION RELIEF VALVE...631
          Function...631
        TRANSMISSION CONTROL VALVE...632
        ELECTRONIC CONTROL MODULATION VALVE (ECMV)...634
          Pressure Control Valve...635
          Flow Sensor Valve...635
          ECMV and Proportional Solenoid...635
          ECMV and Fill Switch...635
          ECMV Operation...636
        ECMV REPAIR...639
          Preparation...639
          Filter Replacement Procedure...639
          ECMV Identification...640
          ECMV Removal...640
          Disassembly...640
          Assembly...642
          Installation...642
        TRANSMISSION FILTERS...644
          Service...644
          Installation...644
        TRANSMISSION SPEED SENSORS...645
          Adjustment Procedure...645
        TRANSMISSION OIL LEVEL CHECK...646
        TRANSMISSION OIL PRESSURE CHECK...647
      TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING...649
        Preliminary Checks...649
        TRANSMISSION REMOVAL...653
        TRANSMISSION INSTALLATION...654
  SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX...658
    TRANSMISSION OIL COOLER & STRAINERS...660
      TRANSMISSION OIL COOLER...660
        Removal and Installation...660
        Repair...660
      TRANSMISSION OIL STRAINER...660
        Removal...661
        Inspection...661
        Installation...661
  SECTION F5 - DRIVE SHAFTS - INDEX...662
    DRIVE SHAFTS...664
      FRONT DRIVE SHAFT...664
        Removal...664
        Disassembly...664
        Assembly...664
        Installation...665
        FRONT DRIVE SHAFT ALIGNMENT...666
      REAR DRIVE SHAFT...669
        Removal...669
        Disassembly...670
        Assembly...670
        Installation...670
  SECTION F8 - TORQUE CONVERTER REBUILD - INDEX...672
    TORQUE CONVERTER REBUILD...674
      REMOVAL...674
      INSTALLATION...676
      DISASSEMBLY...678
        PTO COVER DISASSEMBLY...686
      CLEANING & INSPECTION...687
        TABLE I. COMPONENT WEAR LIMITS...688
        TABLE II. Gear Backlash...688
      ASSEMBLY...689
        ONE-WAY CLUTCH ASSEMBLY...690
        STATOR BEARING PRE-LOAD ADJUSTMENT...692
        PTO DRIVE ASSEMBLY...696
      SPECIAL TOOLS...701
  SECTION F9 - TRANSMISSION REBUILD - INDEX...704
    TRANSMISSION REBUILD...706
      TRANSMISSION DISASSEMBLY...706
        Number One Clutch Housing Disassembly...710
        Bearing Cage & Cover Disassembly...713
        Number Four Carrier Disassembly...714
        Output Shaft Cover Disassembly...715
        Rear Case Bearing Removal...715
        Output Shaft Removal...716
        Output Shaft Disassembly...716
        Number Five/Six Carrier Disassembly...716
      CLEANING AND INSPECTION...718
        INSPECTION TABLE INDEX...718
      TRANSMISSION ASSEMBLY...724
        GENERAL INSTRUCTIONS...724
          Number Five/Six Carrier Assembly...724
          Output Shaft Assembly...725
          Number Seven Clutch Assembly...726
          Rear Case Assembly...727
          Rear Case & Carrier Assembly...727
          Number Six Clutch Assembly...729
          Number Four Carrier Assembly...730
          Number Four Carrier Bearing Cage Assembly...731
          Number Five Clutch Assembly...731
          Number Four Clutch Assembly...732
          Number Three Clutch Assembly...732
          Clutch Test...733
          Number Two Clutch Ring Gear Installation...733
          Number Three Carrier & Number Two Clutch Assembly...734
          Number One Carrier Assembly...734
          Number One Clutch Assembly...737
          Checks Prior to Final Assembly...739
          Final Assembly...739
          Input Shaft Installation...740
          External Components...742
SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX...744
  SECTION G2 - TIRES AND RIMS - INDEX...746
    TIRES AND RIMS...748
      GENERAL INFORMATION...748
      FRONT TIRES AND RIMS...749
        Removal...749
        Installation...750
      REAR TIRE AND RIM...750
        Removal...750
        Installation...752
      TIRE MATCHING...753
      RIM...753
        Tire Removal From Rim...753
        Tire Installation On Rim...754
      FRONT WHEEL STUD INSTALLATION...755
      REAR WHEEL STUD INSTALLATION...756
  SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...758
    FRONT WHEEL HUB AND SPINDLE...760
      OIL SAMPLE ANALYSIS...760
        Oil Sampling Guidelines...760
        Guidelines For Obtaining A Sample...760
      FRONT WHEEL HUB...761
        Removal...761
        Disassembly...761
        Inspection...761
        Assembly...762
        Installation...764
        Front Wheel Hub Bearing Adjustment...764
      FRONT SPINDLE...765
      A-ARM...765
        Removal...765
        Inspection...765
        Installation...765
      CENTER TIE ROD PIVOT...766
        Removal...766
        Inspection...766
        Installation...766
      TOE IN ADJUSTMENT...767
        Adjustment Procedure...767
  SECTION G4 - REAR AXLE ATTACHMENTS - INDEX...772
    REAR AXLE ATTACHMENTS...774
      CENTER LINK AND LOWER LINKS...774
        Removal...774
        Inspection...775
        Spherical Bearing Replacement...775
        Installation...775
      PANHARD ROD (DIAGONAL LINK)...776
        Removal...776
        Inspection...777
        Installation...777
  SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX...778
    REAR AXLE & FINAL DRIVE ASSEMBLY...780
      DIFFERENTIAL OPERATION...780
        Straight-away-travel...780
        Turning...780
        REAR AXLE ASSEMBLY...781
          Removal...781
          Installation...781
        DIFFERENTIAL OIL LEVEL CHECK...782
        DIFFERENTIAL ASSEMBLY...783
          Removal...783
          Installation...784
          Disassembly...784
          Pinion Carrier Assembly...787
          Differential Gear Unit...787
          Differential Gear Unit...788
          Cleaning and Inspection...791
          Assembly...791
          Differential Bearing...791
          Assembly Of Differential Gear Assembly...791
          Installation Of Differential Assembly...793
          Input Pinion and Carrier Assembly...794
          Adjusting Tooth Contact, Backlash...798
  SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX...802
    FINAL DRIVE PLANETARIES AND WHEEL HUBS...804
      FINAL DRIVE...804
        Oil Level Check...805
        FINAL DRIVE CARRIER ASSEMBLY...805
          Removal...805
          Installation...806
          Disassembly...806
          Assembly...807
        FINAL DRIVE ASSEMBLY...808
          Disassembly...808
          Assembly...810
SECTION H - SUSPENSIONS - INDEX...812
  SECTION H2 - FRONT SUSPENSION - INDEX...814
    FRONT SUSPENSION...816
      Removal...818
      Installation...819
      Disassembly...820
      Cleaning and Inspection...822
      Assembly...822
      Pressure Tests...823
      DAMPING VALVE REPAIR...824
        Disassembly...824
        Assembly...825
  SECTION H3 - REAR SUSPENSION - INDEX...826
    REAR SUSPENSION...828
      Operation...829
      Removal...830
      Installation...830
      Disassembly...830
      Cleaning and Inspection...834
      Assembly...834
      LEAK TESTING...835
      SPHERICAL BEARINGS...835
        Removal...835
        Inspection...835
        Installation...835
  SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX...836
    SUSPENSION OILING AND CHARGING...838
      GENERAL INFORMATION...838
        Equipment List...838
      FRONT SUSPENSION...840
        Front Suspension Oiling...840
        Front Suspension Nitrogen Charging...843
      REAR SUSPENSION...845
        GENERAL INFORMATION...845
          Rear Suspension Oiling...845
          Rear Suspension Nitrogen Charging...849
      FRONT AND REAR CYLINDER LENGTH ADJUSTMENT...849
SECTION J - BRAKE SYSTEM - INDEX...852
  SECTION J2 - BRAKE SYSTEM OPERATION - INDEX...854
    BRAKE SYSTEM OPERATION...856
      DESCRIPTION...856
      SERVICE BRAKE OPERATION...857
      SECONDARY BRAKING AND AUTOMATIC APPLY...857
      BRAKE SYSTEM COMPONENTS...859
      BRAKE MANIFOLD CARTRIDGE VALVES...861
      SERVICE BRAKE CIRCUIT...865
        RETARDING CIRCUIT...867
        PARKING BRAKE CIRCUIT...869
        AUTO APPLY...871
        AUXILIARY BRAKE CIRCUIT...873
        BRAKE LOCK CIRCUIT...875
        AUTOMATIC SPIN REGULATOR...877
      BRAKE COOLING CIRCUIT...879
        BRAKE COOLING VALVE...880
        COLD OIL DIVERTER VALVES...883
  SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX...884
    BRAKE CIRCUIT COMPONENT SERVICE...886
      BRAKE VALVE...887
        Rebuild Criteria...887
        Removal...887
        Installation...888
        Disassembly...889
        Cleaning and Inspection...890
        Assembly...892
        Actuator Base Threaded Inserts...892
        Boot and Cap...892
        Valve Body Seal Installation...892
        Regulator Sleeve O-Ring Installation...892
        Actuator Plunger O-ring Installation...893
        Assembly of Valve...894
      BENCH TEST AND ADJUSTMENT...895
        Test Bench Only...895
        Test Set Up Procedure...895
        Brake Valve Output Pressure Adjustment...897
        Final Test and Adjustment...898
        Proximity Switch Installation and Adjustment...900
        Installation Of Brake Pedal Actuator Assembly to Brake Valve...900
      BRAKE ACCUMULATORS...901
        Removal...902
        Installation...902
        Disassembly...902
        Cleaning and Inspection...904
        Assembly...904
        Leak Testing...906
      ACCUMULATOR CHARGING...907
        Temperature During Precharge...909
      ACCUMULATOR STORAGE...910
        Installation...910
      BRAKE COOLING VALVE (BCV)...911
      RETARDER CONTROL LEVER...912
        Removal...912
        Installation...912
        Disassembly and Adjustment...912
        Potentiometer Check...914
        Assembly...914
        Retard Lever Calibration...915
  SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX...916
    BRAKE CIRCUIT CHECK-OUT...918
      REQUIRED EQUIPMENT...918
      PREPARATION...918
      BRAKE CIRCUIT TESTING...919
        Initial System Setup...919
        Parking Brake...920
        Brake Lock...921
        Low-Brake Pressure and Auto-Apply...921
        Validation...922
        Retarding...922
      BRAKE SYSTEM DATA SHEET...923
      BRAKE CIRCUIT TROUBLESHOOTING...926
  SECTION J5 - FRONT WET DISC BRAKES - INDEX...930
    FRONT WET DISC BRAKES...932
      BRAKE MAINTENANCE...933
        Checking Disc Wear...933
      FRONT BRAKE ASSEMBLY...935
        Removal...935
        Installation...935
        Disassembly...935
        Cleaning and Inspection...936
        Assembly...937
        Floating Seal Installation...940
      BRAKE BLEEDING...943
  SECTION J6 - REAR WET DISC BRAKES - INDEX...944
    REAR WET DISC BRAKES...946
      DESCRIPTION...946
      OPERATION...946
      MAINTENANCE...947
        Checking Brake Disc Wear...947
        REMOVAL...948
        INSTALLATION...949
        BRAKE REBUILD...951
          Disassembly...951
          Cleaning and Inspection...952
          Assembly...952
          Floating Seal Installation...954
        WET DISC BRAKE BLEEDING...957
  SECTION J7 - PARKING BRAKE - INDEX...958
    PARKING BRAKE...960
      Description...960
      Parking Brake Service Criteria...960
      Removal...961
      Installation...961
      PARKING BRAKE SPRING CYLINDER REPLACEMENT...963
        Removal...963
        Installation...963
      AUTOMATIC SLACK ADJUSTER...963
        Adjustment Procedure...963
      PARKING BRAKE CHECK-OUT...964
SECTION L - HYDRAULIC SYSTEM - ...966
  SECTION L2 - ...968
    HYDRAULIC SYSTEM OVERVIEW...970
      SYSTEM COMPONENTS...970
        HYDRAULIC TANK...970
        BLEED-DOWN MANIFOLD...972
        HOIST VALVE...972
        HOIST PUMP...972
        BRAKE COOLING PUMP...973
        BRAKE CONTROL VALVE (BCV)...973
  SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX...974
    HYDRAULIC COMPONENT REPAIR...976
      HYDRAULIC TANK...976
        FILLING INSTRUCTIONS...976
        MAINTENANCE...976
          Removal...977
          Installation...979
          Gap Measurement - Hydraulic Tank Mounting...979
        STRAINERS AND DIFFUSERS...980
          Removal...980
          Cleaning and Inspection...980
          Installation...981
      HYDRAULIC TANK BREATHER...981
        Service...982
      HYDRAULIC SYSTEM FLUSHING...982
      HYDRAULIC PUMPS...983
        Removal...983
        Installation...984
        PUMP REBUILD...985
          Disassembly...985
          Inspection Of Parts...988
          Assembly...988
          Bearing Replacement...991
          Seal Replacement...991
        TROUBLESHOOTING GUIDE...994
  SECTION L4 - STEERING CIRCUIT - INDEX...996
    STEERING CIRCUIT...998
      OPERATION...998
      COMPONENT DESCRIPTION...998
        Steering Control Valve...998
        Bleed-down Manifold...998
        Bleed-down Solenoid...999
        Accumulators...1000
        Flow Amplifier...1000
        High Pressure Filter...1000
        Warning Devices...1000
      FLOW AMPLIFIER OPERATION...1002
      STEERING/BRAKE PUMP...1010
        COMPONENTS...1010
        OPERATION...1012
  SECTION L5 - STEERING CONTROL UNIT - INDEX...1014
    STEERING CONTROL UNIT...1016
      Removal...1016
      Installation...1016
      REBUILD PROCEDURE...1017
        Disassembly...1018
        Cleaning and Inspection...1019
        Assembly...1021
  SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX...1026
    STEERING CIRCUIT COMPONENT REPAIR...1028
      BLEED-DOWN MANIFOLD...1028
        Removal...1028
        Adjusting Relief Valve...1028
        Testing and Adjustment...1029
        FLOW AMPLIFIER...1030
          Removal...1030
          Installation...1030
          Disassembly...1030
          Assembly...1033
        ACCUMULATORS...1034
          Removal...1034
          Installation...1035
          Disassembly...1036
          Cleaning and Inspection...1036
          Assembly...1036
          Leak Testing...1037
        STEERING ACCUMULATOR CHARGING...1039
          Temperature During Precharge...1042
        ACCUMULATOR STORAGE...1042
          Installation...1043
        STEERING CYLINDER...1044
          Removal...1044
          Installation...1044
        STEERING CYLINDER REBUILD...1045
          Disassembly...1045
          Cleaning and Inspection...1045
          Assembly...1046
          Testing...1046
        STEERING/BRAKE PUMP...1046
          Removal...1046
          Installation...1047
        PUMP REBUILD...1048
          Disassembly...1048
          Control Group...1049
          Valve Plate Group...1050
          Rotating Group...1050
          Drive Shaft Group...1051
          Swashblock Group...1051
          Inspection...1051
          Control Group...1051
          Valve Plate Group...1052
          Rotating Group...1052
          Swashblock Group...1053
          Drive Shaft Group...1053
          Assembly...1053
          Swashblock Group...1053
          Drive Shaft Group...1054
          Rotating Group...1054
          Valve Plate Group...1055
          Control Group...1056
        STEERING CIRCUIT FILTER...1057
          Removal...1057
          Installation...1057
    TROUBLESHOOTING CHART...1058
  SECTION L7 - HOIST CIRCUIT - INDEX...1060
    HOIST CIRCUIT...1062
      HOIST CIRCUIT OPERATION...1062
        COMPONENT DESCRIPTION...1063
          Hydraulic Tank...1063
          Hoist Pump...1063
          Hoist Valve...1063
          Hoist Pilot Valve...1064
          Power Up Solenoid...1065
          Pilot Operated Check Valve...1065
          Power Down Spool Limit Solenoid...1065
        HOIST CIRCUIT HYDRAULIC FLOW...1066
          POWER UP...1068
          HOLD...1070
          POWER DOWN...1072
          FLOAT...1074
  SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...1076
    HOIST CIRCUIT COMPONENT REPAIR...1078
      HOIST VALVE...1078
        Removal...1078
        Installation...1078
        O-Ring Replacement...1079
        INLET SECTION...1080
          Disassembly...1080
          Cleaning and Inspection...1081
          Assembly...1081
        SPOOL SECTION...1081
          Disassembly...1081
          Cleaning and Inspection...1082
          Assembly...1084
      HOIST PILOT VALVE...1085
        Removal...1085
        Installation...1085
        Disassembly...1086
        Cleaning and Inspection...1087
        Assembly...1087
      HOIST CYLINDERS...1088
        Removal...1088
        Installation...1090
        Disassembly...1090
        Cleaning and Inspection...1092
        Assembly - Quill And Cylinder...1093
        Quill Installation...1093
        Installation Of Check Balls And Plugs In Quill...1094
        Assembly of Cylinder...1095
        Pressure Testing...1096
  SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX...1098
    HYDRAULIC SYSTEM FILTERS...1100
      HIGH PRESSURE FILTER...1100
        Removal...1100
        Installation...1101
      LOW PRESSURE FILTERS...1101
        BRAKE COOLING & HOIST FILTERS...1101
        TRANSMISSION FILTER...1101
          Removal...1102
          Installation...1102
  SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...1104
    HYDRAULIC CHECK-OUT PROCEDURE...1106
      GENERAL INFORMATION...1106
      STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE...1106
        Equipment Requirements...1107
        Installation Of Gauges...1107
        Initial Startup And Flushing...1107
        Component Checkout And Adjustment...1108
      CHECKING HOIST SYSTEM PRESSURES...1110
        Equipment Requirements...1110
        Steering Components Leakage Test...1112
      HYDRAULIC SYSTEM CHECKOUT DATA SHEET...1113
SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX...1114
  SECTION M7 - HOT START SYSTEM - ...1116
    HOT START SYSTEM...1118
      SYSTEM OPERATION...1118
      HEATER INFORMATION...1119
      TROUBLESHOOTING GUIDELINES...1121
  SECTION M8 - ...1122
SECTION N - OPERATOR CAB - INDEX...1126
  SECTION N2 - OPERATOR CAB - INDEX...1128
    OPERATOR CAB...1130
      Removal...1131
      Installation...1133
      CAB DOORS...1133
        Removal...1133
        Installation...1134
        Door Striker Adjustment...1134
        Door Handle Plunger Adjustment...1135
        DOOR PANEL...1136
          Removal...1136
          Installation...1136
        DOOR WINDOW...1137
          Removal...1137
          Installation...1139
        WINDOW REGULATOR...1141
          Removal...1141
          Installation...1141
        DOOR HANDLE AND DOOR LATCH...1141
          Removal...1141
          Installation...1141
      DOOR SEALS...1142
        Removal...1142
        Installation...1142
      DOOR OPENING SEAL...1142
        Removal...1142
        Installation...1142
      GLASS REPLACEMENT...1143
        Replacement...1143
        WINDSHIELD AND REAR GLASS...1144
          Removal...1144
          Installation...1145
  SECTION N3 - CAB COMPONENTS -...1146
    CAB COMPONENTS...1148
      WINDSHIELD WIPERS...1148
        WIPER MOTOR...1148
          Removal...1148
          Installation...1148
        WIPER ARM...1148
          Removal...1148
          Installation...1149
        WIPER LINKAGE...1149
          Removal...1149
          Installation...1149
      WINDSHIELD WASHER...1150
        Operation...1150
        Service...1150
      OPERATOR SEAT...1151
        Adjustment...1151
        Inspection...1152
        Removal...1152
        Installation...1152
      SEAT BELT...1152
        Removal...1152
        Installation...1154
  SECTION N4 - HEATING AND AIR CONDITIONING - INDEX...1156
    HEATING AND AIR CONDITIONING...1158
      HEATER/AIR CONDITIONER UNIT...1158
        Fan Speed Control Knob...1158
        Temperature Control Knob...1158
        Air Flow Directional Knob...1158
        Heater/Air Conditioner Vents...1159
      COMPONENTS...1159
        Fuse...1159
        Relays...1159
        Heater Core...1159
        Fan Motor And Speed Control...1160
        Actuators...1160
        Cab Air Filter...1160
      ENVIRONMENTAL IMPACT OF AIR CONDITIONING...1163
      AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES...1163
      PRINCIPLES OF REFRIGERATION...1163
        Air Conditioning...1163
        Refrigeration - The Act Of Cooling...1164
        The Refrigeration Cycle...1164
      AIR CONDITIONER SYSTEM COMPONENTS...1165
        Compressor (Refrigerant Pump)...1165
        Service Valves...1165
        Condenser...1165
        Receiver-Drier...1165
        Expansion Block Valve...1166
        Accumulator...1166
        Evaporator...1166
      ELECTRICAL CIRCUIT...1167
        Thermostat...1167
        Compressor Clutch...1167
        Trinary? Switch...1168
      SYSTEM SERVICING...1169
      SERVICE TOOLS AND EQUIPMENT...1170
        Recovery/Recycle Station...1170
        Leak Detector...1170
        Service Valves...1171
        Vacuum Pump...1171
        Manifold Gauge Set...1172
        Installing Manifold Gauge Set...1173
        Purging Air From Service Hoses...1173
      SYSTEM PERFORMANCE TEST...1174
      SYSTEM OIL...1175
        Handling and Reusing PAG Oil...1175
        Oil Quantity...1175
        Checking System Oil...1175
      REFRIGERANT...1176
        Recycled Refrigerant...1176
        Reclaimed Refrigerant...1176
        Refrigerant Quantity...1176
        R-134a Refrigerant Containers...1177
      SYSTEM LEAK TESTING...1177
        Electronic Leak Detector...1178
        Tracer Dyes...1178
        Soap and Water...1178
      RECOVERING AND RECYCLING THE REFRIGERANT...1178
        Draining Oil from the Previous Recovery Cycle...1178
        Performing the Recovery Cycle...1178
        Performing the Recycling Procedure...1179
        Evacuating and Charging the A/C System...1179
      SYSTEM REPAIR...1179
        System Flushing...1179
      A/C DRIVE BELT CHECKOUT PROCEDURE...1180
        Pulley Alignment...1180
        Belt Tension Check...1180
      COMPONENT REPLACEMENT...1182
        Hoses and Fittings...1182
        Lines...1182
        Expansion Valve...1182
        Receiver-Drier...1182
        Thermostat...1182
        Compressor...1183
        Accumulator...1183
        Clutch...1183
        Servicing the Compressor Clutch...1184
        Pulley Removal...1186
        Clutch Coil Check...1187
        Pulley Installation...1187
        Clutch Assembly Installation...1187
      EVACUATING THE SYSTEM...1189
      CHARGING THE A/C SYSTEM...1191
    TROUBLESHOOTING...1192
      Preliminary Checks...1192
      Diagnosis Of Gauge Readings And System Performance...1192
    TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS...1193
    PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM...1199
  SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX...1200
    OPERATOR CAB AND CONTROLS...1202
      STEERING WHEEL AND CONTROLS...1203
        Horn Button...1203
        ARSC Set Lever...1203
        Telescoping/Tilt Wheel Lever...1203
        Multi-Function Turn Signal Lever...1203
      RETARDER CONTROL LEVER...1204
      STEERING WHEEL...1205
        Removal...1205
        Installation...1205
      SERVICE BRAKE PEDAL...1205
      ACCELERATOR PEDAL...1205
      INSTRUMENT PANEL...1205
      HEATER / AIR CONDITIONER CONTROLS...1206
      RETARDING CAPACITY CHART...1206
      RADIO SPEAKERS...1206
      AIR CLEANER VACUUM GAUGES...1206
      WARNING ALARM BUZZER...1206
      AM/FM RADIO / CD PLAYER...1206
      CENTER CONSOLE...1207
        Hoist Control Lever...1208
        Transmission Shift Lever...1208
        Parking Brake Switch...1209
        LH Window Control Switch...1209
        RH Window Control Switch...1209
        Auxiliary Power Outlets...1209
      INSTRUMENT PANEL AND INDICATORS...1210
        UPPER RH SWITCH PANEL...1211
          Brake Lock Switch...1211
          F1 Start Switch...1211
          Hazard Warning Lights Switch...1211
        LOWER RH SWITCH PANEL...1212
          Key Switch...1212
          Ether Starting Aid Switch...1213
          ASR Cut Switch...1213
          ARSC Switch...1213
          Automatic Idle Selector Switch (AISS)...1213
          Auxiliary Brake Switch...1214
        UPPER LH SWITCH PANEL...1215
          Automatic Lubrication System Indicator...1215
        LOWER LH SWITCH PANEL...1216
          Head Light Switch...1216
          Ladder Light Switch...1216
          BackUp/Deck Light Switch...1217
          Fog Light Switch...1217
          Mode Select Switches 1 & 2...1217
          Panel Light Dimmer Switch...1217
      ELECTRONIC DISPLAY PANEL...1218
        PILOT DISPLAY ITEMS...1219
        METER DISPLAYS...1221
        CAUTION ITEMS...1223
        EMERGENCY STOP ITEMS...1225
        CHARACTER DISPLAY...1228
      REAR ELECTRICAL COMPARTMENT...1229
      AUTOMATIC RETARD SPEED CONTROL (ARSC)...1232
      AUTOMATIC SPIN REGULATOR (ASR)...1235
SECTION P - LUBRICATION AND SERVICE - INDEX...1238
  SECTION P2 - LUBRICATION AND SERVICE - INDEX...1240
    LUBRICATION AND SERVICE...1242
      COOLANT SPECIFICATIONS...1242
        Unacceptable Practices...1242
      RADIATOR FILL PROCEDURE...1242
      HYDRAULIC TANK SERVICE...1243
        Filling Instructions...1243
      TRANSMISSION OIL LEVEL CHECK...1243
      QUICK FILL SERVICE CENTER...1244
      PERIODIC REPLACEMENT OF CRITICAL PARTS...1244
      10 HOUR (DAILY) INSPECTION...1246
      10 HOUR (DAILY) INSPECTION (continued)...1247
      250 HOUR INSPECTION...1248
      250 HOUR INSPECTION (continued)...1249
      250 HOUR INSPECTION (continued)...1250
      500 HOUR INSPECTION...1251
      1000 HOUR INSPECTION...1252
      2000 HOUR INSPECTION...1253
      5000 HOUR INSPECTION...1254
  SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX...1256
    AUTOMATIC LUBRICATION SYSTEM...1258
      GENERAL DESCRIPTION...1258
      SYSTEM COMPONENTS...1262
      SYSTEM OPERATION...1264
      INJECTOR OPERATION...1265
      LUBRICANT PUMP...1266
        Pump Housing Oil Level...1266
        Pump Pressure Control...1266
      INJECTORS (SL-1 Series ?H?))...1267
        Injector Specifications...1267
        Injector Adjustment...1267
      SYSTEM PRIMING...1268
        Filter Assembly...1268
      SYSTEM CHECK...1269
        Lubrication Controller Check...1269
        Lubrication Controller Operation...1269
        Lubrication Controller Components...1269
        Lubrication Controller Adjustment...1269
      SYSTEM TROUBLESHOOTING CHART...1271
      PREVENTATIVE MAINTENANCE...1273
        Daily Lubrication System Inspection...1273
        250 Hour Inspection...1273
        1000 Hour Inspection...1274
      PUMP REBUILD...1275
        Disassembly...1275
        Cleaning and Inspection...1278
        Assembly...1278
SECTION R - SYSTEM SCHEMATICS - INDEX...1280
  HYDRAULIC SYSTEM SCHEMATIC...1282
  HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40? C)...1283
  BRAKE...1284
  HOOKUP...1285
  ELECTRICAL WIRING...1293
  HVAC WIRING...1316
  CONNECTOR LOCATOR...1317