Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-05 – PDF DOWNLOAD

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-05 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-05 – PDF DOWNLOAD

Language : English
Pages : 3136
Downloadable : Yes
File Type : PDF
Size: 185 MB

TABLE OF CONTENTS:

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-05 – PDF DOWNLOAD

00 INDEX AND FOREWORD 00 1
FOREWORD, SAFETY, BASIC INFORMATION 00 19
HOW TO READ THE SHOP MANUAL 00 19
SAFETY NOTICE FOR OPERATION 00 21
PRECAUTIONS TO PREVENT FIRE 00 29
ACTIONS IF FIRE OCCURS 00 30
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS 00 30
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS 00 31
PRECAUTIONS FOR DEF 00 32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 34
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00 36
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00 45
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 46
PRACTICAL USE OF KOMTRAX 00 47
DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER 00 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00 52
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00 56
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00 58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 61
STANDARD TIGHTENING TORQUE TABLE 00 62
CONVERSION TABLE 00 69
ABBREVIATIONS 00 74
01 SPECIFICATIONS 01 1
SPECIFICATIONS 01 3
SPECIFICATION DRAWING 01 3
SPECIFICATIONS 01 5
WEIGHT TABLE 01 11
FUEL, COOLANT, AND LUBRICATING OIL 01 13
10 STRUCTURE AND FUNCTION 10 1
UREA SCR SYSTEM 10 7
LAYOUT DRAWING OF UREA SCR STSTEM 10 7
UREA SCR SYSTEM DIAGRAM 10 10
FUNCTION OF UREA SCR SYSTEM 10 12
COMPONENT PARTS OF UREA SCR SYSTEM 10 18
BOOT UP SYSTEM 10 24
LAYOUT DRAWING OF BOOT UP SYSTEM 10 24
SYSTEM OPERATING LAMP SYSTEM 10 27
BATTERY DISCONNECT SWITCH 10 28
STARTING MOTOR DISCONNECT SWITCH 10 29
ENGINE SHUTDOWN SECONDARY SWITCH 10 30
EXTERNAL POWER SUPPLY ENGINE PREHEATER 10 32
ENGINE SYSTEM 10 35
LAYOUT DRAWING OF ENGINE SYSTEM 10 35
ENGINE CONTROL SYSTEM 10 37
COMPONENT PARTS OF ENGINE SYSTEM 10 41
HD1500 8E0 00 3
00 INDEX AND FOREWORD INDEX
COOLING SYSTEM 10 42
LAYOUT DRAWING OF COOLING SYSTEM 10 42
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 10 44
COMPONENT PARTS OF COOLING SYSTEM 10 45
CONTROL SYSTEM 10 73
LAYOUT DRAWING OF CONTROL SYSTEM 10 73
RETARDER AND HOIST CONTROL SYSTEM 10 75
MACHINE MONITOR SYSTEM 10 77
REARVIEW MONITOR SYSTEM 10 79
KOMTRAX Plus SYSTEM 10 80
PAYLOAD METER SYSTEM 10 85
COMPONENT PARTS OF CONTROL SYSTEM 10 97
HYDRAULIC SYSTEM 10 145
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10 145
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 146
POWER TRAIN SYSTEM 10 181
LAYOUT DRAWING OF POWER TRAIN SYSTEM 10 181
TRANSMISSION CONTROL SYSTEM 10 184
GEAR SHIFT CONTROL SYSTEM 10 190
DIRECTION CONTROL SYSTEM 10 193
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10 194
TRAVEL SPEED LIMITATION SYSTEM 10 196
REAR AXLE OIL FILTRATION SYSTEM 10 200
COMPONENT PARTS OF POWER TRAIN SYSTEM 10 202
WORK EQUIPMENT SYSTEM 10 258
WORK EQUIPMENT CONTROL 10 258
HOIST CONTROL 10 259
BUDDY SYSTEM 10 261
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 263
STEERING SYSTEM 10 270
LAYOUT DRAWING OF STEERING SYSTEM 10 270
FUNCTION OF STEERING SYSTEM 10 271
STEERING COLUMN 10 272
STEERING CONTROL LINKAGE 10 273
COMPONENT PARTS OF STEERING SYSTEM 10 274
BRAKE SYSTEM 10 286
LAYOUT DRAWING OF BRAKE SYSTEM 10 286
RETARDER CONTROL 10 289
ARSC SYSTEM 10 291
COMPONENT PARTS OF BRAKE SYSTEM 10 292
AUTO GREASING SYSTEM 10 321
LAYOUT DRAWING OF AUTO GREASING SYSTEM 10 321
AUTO GREASING SYSTEM DIAGRAM 10 324
FUNCTION OF AUTO GREASING SYSTEM 10 325
GREASE REFILL AUTOMATIC STOP SYSTEM 10 326
COMPONENT PARTS OF AUTO GREASING SYSTEM 10 327
SERVICE CENTER 10 331
LAYOUT DRAWING OF SERVICE CENTER 10 331
FUNCTION OF SERVICE CENTER 10 331
00 4 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
UNDERCARRIAGE AND FRAME 10 332
REAR AXLE SUPPORT 10 332
SUSPENSION 10 333
FRONT SUSPENSION 10 334
REAR SUSPENSION 10 335
FRONT SUSPENSION CYLINDER 10 336
REAR SUSPENSION CYLINDER 10 338
WORK EQUIPMENT 10 339
STRUCTURE OF WORK EQUIPMENT 10 339
CAB AND ITS ATTACHMENTS 10 340
ROPS CAB 10 340
CAB MOUNT 10 341
LIFTING SYSTEM 10 342
POWER LADDER SYSTEM 10 342
20 STANDARD VALUE TABLE 20 1
STANDARD VALUE TABLE FOR ENGINE 20 3
STANDARD VALUE TABLE FOR ENGINE: HD1500 8E0 20 3
STANDARD VALUE TABLE FOR MACHINE 20 5
STANDARD VALUE TABLE FOR MACHINE: HD1500 8E0 20 5
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20 25
30 TEST AND ADJUST 30 1
RELATED INFORMATION TO TEST AND ADJUST 30 6
TOOLS TO TEST AND ADJUST 30 6
ENGINE AND COOLING SYSTEM 30 14
TEST ENGINE SPEED 30 14
TEST EXHAUST GAS COLOR 30 17
TEST BLOWBY PRESSURE 30 20
TEST FUEL PRESSURE 30 22
BLEED AIR FROM FUEL CIRCUIT 30 24
CLEAN AdBlue/DEF TANK 30 25
POWER TRAIN 30 28
TEST POWER TRAIN OIL PRESSURE 30 28
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 30 44
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 30 45
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 30 46
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 30 47
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 30 48
CLEAN FINAL DRIVE CASE MAGNET 30 50
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 30 51
STEERING SYSTEM 30 56
TEST STEERING CIRCUIT OIL PRESSURE 30 56
TEST STEERING CYLINDER PRESSURE 30 58
BLEED AIR FROM STEERING CYLINDER CIRCUIT 30 59
BRAKE SYSTEM 30 61
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 30 61
TEST WHEEL BRAKE OIL PRESSURE 30 62
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 30 67
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 30 70
PROCEDURE TO RELEASE NITROGEN GAS WHEN DISPOSING ACCUMULATOR 30 81
TEST BRAKE PERFORMANCE 30 82
HD1500 8E0 00 5
00 INDEX AND FOREWORD INDEX
BLEED AIR FROM BRAKE CIRCUIT 30 85
TEST PARKING BRAKE OIL PRESSURE 30 89
RELEASE PARKING BRAKE MANUALLY 30 91
TEST THE AMOUNT OF WHEEL BRAKE DISC WEAR 30 93
HYDRAULIC SYSTEM 30 95
TEST HOIST CIRCUIT OIL PRESSURE 30 95
TEST HOIST CYLINDER SUPPLY PRESSURE 30 97
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 30 98
TEST AND ADJUST FRONT SUSPENSION CYLINDER 30 100
TEST AND ADJUST REAR SUSPENSION CYLINDER 30 106
BLEED AIR FROM HYDRAULIC CIRCUIT 30 112
CALIBRATION OF LADDER POSITION 30 120
WORK EQUIPMENT 30 121
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 30 121
LOWER THE DUMP BODY MANUALLY 30 123
LIFT THE DUMP BODY MANUALLY 30 124
LIFT THE DUMP BODY WITH BUDDY SYSTEM 30 126
CAB AND ITS ATTACHMENTS 30 130
ADJUST STEERING WHEEL TILT LOCK LEVER 30 130
ADJUST RATTLING OPERATOR’S SEAT 30 131
ADJUST CLEARANCE OF ESCAPE DOOR 30 132
LIFTING SYSTEM 30 134
BLEED AIR FROM POWER LADDER CYLINDER 30 134
ELECTRICAL SYSTEM 30 135
SET AND ADJUST EACH EQUIPMENT 30 135
SET AND OPERATE OF MACHINE MONITOR 30 139
START UP KOMTRAX TERMINAL 30 270
STOP USE OF KOMTRAX TERMINAL 30 275
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 30 277
DEFAULT SETTING OF WIRELESS LAN MODEM 30 280
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 30 282
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 30 286
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 30 289
SET REGION OF Bluetooth® COMPATIBLE RADIO 30 292
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 30 294
BATTERY DISCONNECT SWITCH WORK 30 295
TEST DIODES 30 296
Pm CLINIC 30 297
Pm CLINIC SERVICE 30 297
PERFORM QUICK Pm 30 309
40 TROUBLESHOOTING 40 1
CONTENTS 40 2
RELATED INFORMATION ON TROUBLESHOOTING 40 12
GENERAL TROUBLESHOOTING POINTS 40 12
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 13
CHECKS BEFORE TROUBLESHOOTING 40 15
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40 18
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 20
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARATION 40 44
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 50
00 6 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
SYMPTOM AND TROUBLESHOOTING NUMBERS 40 53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 56
CONNECTORS LIST AND LAYOUT 40 58
CONNECTOR CONTACT IDENTIFICATION 40 94
T BRANCH BOX AND T BRANCH ADAPTER TABLE 40 136
FUSE LOCATION TABLE 40 142
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 40 148
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 40 150
FAILURE CODES TABLE 40 156
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40 194
FAILURE CODE [1500L0] 40 194
FAILURE CODE [15B0NX] 40 195
FAILURE CODE [15F0KM] 40 197
FAILURE CODE [15F0MB] 40 198
FAILURE CODE [15F7KM] 40 199
FAILURE CODE [15G0MW] 40 200
FAILURE CODE [15G7KM] 40 202
FAILURE CODE [15H0MW] 40 203
FAILURE CODE [15J0MW] 40 205
FAILURE CODE [15K0MW] 40 207
FAILURE CODE [15L0MW] 40 209
FAILURE CODE [15M0MW] 40 211
FAILURE CODE [15N0MW] 40 213
FAILURE CODE [15SBL1] 40 215
FAILURE CODE [15SBMA] 40 218
FAILURE CODE [15SCL1] 40 219
FAILURE CODE [15SCMA] 40 222
FAILURE CODE [15SDL1] 40 223
FAILURE CODE [15SDMA] 40 226
FAILURE CODE [15SEL1] 40 227
FAILURE CODE [15SEMA] 40 230
FAILURE CODE [15SFL1] 40 232
FAILURE CODE [15SFMA] 40 235
FAILURE CODE [15SGL1] 40 237
FAILURE CODE [15SGMA] 40 240
FAILURE CODE [15SHL1] 40 242
FAILURE CODE [15SHMA] 40 245
FAILURE CODE [15SJMA] 40 246
FAILURE CODE [2B0QNX] 40 247
FAILURE CODE [2F00KM] 40 248
FAILURE CODE [2G42ZG] 40 250
FAILURE CODE [2G43ZG] 40 251
FAILURE CODE [2G44ZG] 40 252
FAILURE CODE [879AKA] 40 254
FAILURE CODE [879AKB] 40 255
FAILURE CODE [879BKA] 40 256
FAILURE CODE [879BKB] 40 257
FAILURE CODE [879CKA] 40 259
FAILURE CODE [879CKB] 40 260
FAILURE CODE [879EMC] 40 261
HD1500 8E0 00 7
00 INDEX AND FOREWORD INDEX
FAILURE CODE [879FMC] 40 262
FAILURE CODE [879GKX] 40 263
FAILURE CODE [989D00] 40 264
FAILURE CODE [989X00] 40 265
FAILURE CODE [989Y00] 40 266
FAILURE CODE [AA10NX] 40 267
FAILURE CODE [AB00KE] 40 269
FAILURE CODE [AB00KY] 40 271
FAILURE CODE [B@C6NS] 40 272
FAILURE CODE [B@C7NS] 40 273
FAILURE CODE [B@CENS] 40 274
FAILURE CODE [B@JANS] 40 275
FAILURE CODE [D150KB] 40 276
FAILURE CODE [D150KZ] 40 278
FAILURE CODE [D151KB] 40 280
FAILURE CODE [D151KZ] 40 282
FAILURE CODE [D164KY] 40 284
FAILURE CODE [D19HKZ] 40 285
FAILURE CODE [D19JKZ] 40 287
FAILURE CODE [D19QKZ] 40 288
FAILURE CODE [D1EHKA] 40 290
FAILURE CODE [D1EHKB] 40 291
FAILURE CODE [D1EHKY] 40 292
FAILURE CODE [D1ENKZ] 40 293
FAILURE CODE [D1EPKA] 40 295
FAILURE CODE [D1EPKB] 40 297
FAILURE CODE [D1EPKY] 40 299
FAILURE CODE [D1EQKA] 40 300
FAILURE CODE [D1EQKB] 40 302
FAILURE CODE [D1EQKY] 40 304
FAILURE CODE [D1ERKA] 40 306
FAILURE CODE [D1ERKB] 40 308
FAILURE CODE [D1ERKY] 40 310
FAILURE CODE [D1ESKA] 40 312
FAILURE CODE [D1ESKB] 40 314
FAILURE CODE [D1ESKY] 40 316
FAILURE CODE [D1EWKA] 40 318
FAILURE CODE [D1EWKB] 40 320
FAILURE CODE [D1EWKY] 40 322
FAILURE CODE [D1J0KB] 40 324
FAILURE CODE [D5ZHL6] 40 326
FAILURE CODE [D862KA] 40 328
FAILURE CODE [DAF0KT] 40 329
FAILURE CODE [DAF0MB] 40 330
FAILURE CODE [DAF0MC] 40 331
FAILURE CODE [DAF3KK] 40 332
FAILURE CODE [DAF8KB] 40 334
FAILURE CODE [DAFDKB] 40 335
FAILURE CODE [DAFGMC] 40 337
FAILURE CODE [DAFLKA] 40 338
00 8 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DAFLKB] 40 340
FAILURE CODE [DAFQKR] 40 342
FAILURE CODE [DAQ0KK] 40 343
FAILURE CODE [DAQ0KT] 40 346
FAILURE CODE [DAQ0MC] 40 347
FAILURE CODE [DAQ1KA] 40 348
FAILURE CODE [DAQ2KK] 40 350
FAILURE CODE [DAQ9KQ] 40 352
FAILURE CODE [DAQLKA] 40 353
FAILURE CODE [DAQLKB] 40 355
FAILURE CODE [DAQQKR] 40 357
FAILURE CODE [DAQRKR] 40 358
FAILURE CODE [DAQRMA] 40 359
FAILURE CODE [DAQV00] 40 360
FAILURE CODE [DAQW00] 40 361
FAILURE CODE [DAZ9KQ] 40 362
FAILURE CODE [DAZQKR] 40 363
FAILURE CODE [DB10KT] 40 364
FAILURE CODE [DB10MC] 40 365
FAILURE CODE [DB11KA] 40 366
FAILURE CODE [DB12KK] 40 369
FAILURE CODE [DB13KK] 40 372
FAILURE CODE [DB19KQ] 40 374
FAILURE CODE [DB1LKA] 40 375
FAILURE CODE [DB1LKB] 40 377
FAILURE CODE [DB1QKR] 40 379
FAILURE CODE [DB1QMA] 40 380
FAILURE CODE [DB1RKR] 40 381
FAILURE CODE [DB2QKR] 40 387
FAILURE CODE [DBBUKM] 40 393
FAILURE CODE [DBBUKR] 40 394
FAILURE CODE [DBP0KM] 40 396
FAILURE CODE [DBP0KT] 40 397
FAILURE CODE [DBP0NR] 40 398
FAILURE CODE [DBP5KP] 40 399
FAILURE CODE [DBPLKA] 40 401
FAILURE CODE [DBPLKB] 40 403
FAILURE CODE [DBPQKR] 40 405
FAILURE CODE [DBPRKR] 40 408
FAILURE CODE [DBPRMA] 40 411
FAILURE CODE [DBPUKR] 40 412
FAILURE CODE [DBPVKR] 40 417
FAILURE CODE [DBPWKR] 40 422
FAILURE CODE [DBPXKR] 40 423
FAILURE CODE [DBV0MC] 40 424
FAILURE CODE [DBV1KK] 40 425
FAILURE CODE [DBV6KB] 40 427
FAILURE CODE [DBV7KB] 40 429
FAILURE CODE [DBVLKA] 40 430
FAILURE CODE [DBVLKB] 40 432
HD1500 8E0 00 9
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DBVQKR] 40 434
FAILURE CODE [DBVRKR] 40 435
FAILURE CODE [DBVVKR] 40 436
FAILURE CODE [DBVWKR] 40 437
FAILURE CODE [DDAAL6] 40 438
FAILURE CODE [DDD7KX] 40 440
FAILURE CODE [DDDGL4] 40 442
FAILURE CODE [DDDHL4] 40 444
FAILURE CODE [DDTHKA] 40 446
FAILURE CODE [DDTJKA] 40 448
FAILURE CODE [DDTKKA] 40 450
FAILURE CODE [DDTLKA] 40 452
FAILURE CODE [DDTMKA] 40 454
FAILURE CODE [DDTNKA] 40 456
FAILURE CODE [DDTPKA] 40 458
FAILURE CODE [DDU1KA] 40 460
FAILURE CODE [DF10KA] 40 462
FAILURE CODE [DF10KB] 40 466
FAILURE CODE [DGE5KX] 40 469
FAILURE CODE [DGF1KX] 40 471
FAILURE CODE [DGR2KB] 40 473
FAILURE CODE [DGR2L8] 40 474
FAILURE CODE [DGR4KB] 40 476
FAILURE CODE [DGR4L8] 40 477
FAILURE CODE [DGR6KB] 40 479
FAILURE CODE [DGR6L8] 40 480
FAILURE CODE [DGREKB] 40 482
FAILURE CODE [DGREL8] 40 483
FAILURE CODE [DGT1KX] 40 485
FAILURE CODE [DHP4KY] 40 487
FAILURE CODE [DHP4KZ] 40 489
FAILURE CODE [DHP5KY] 40 491
FAILURE CODE [DHP5KZ] 40 493
FAILURE CODE [DHP6KA] 40 495
FAILURE CODE [DHP6KX] 40 497
FAILURE CODE [DHP6KY] 40 499
FAILURE CODE [DHP6KZ] 40 501
FAILURE CODE [DHP7KA] 40 503
FAILURE CODE [DHP7KX] 40 505
FAILURE CODE [DHP7KY] 40 507
FAILURE CODE [DHP7KZ] 40 509
FAILURE CODE [DHQ2KX] 40 511
FAILURE CODE [DHQ4KX] 40 513
FAILURE CODE [DHQ6KX] 40 515
FAILURE CODE [DHT5KX] 40 517
FAILURE CODE [DHT5L6] 40 519
FAILURE CODE [DHT7KX] 40 520
FAILURE CODE [DHT7L6] 40 522
FAILURE CODE [DHT8KX] 40 523
FAILURE CODE [DHT8ZG] 40 525
00 10 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DHU2KX] 40 526
FAILURE CODE [DHU3KX] 40 528
FAILURE CODE [DHUBKX] 40 530
FAILURE CODE [DHUCKX] 40 532
FAILURE CODE [DHUDKX] 40 534
FAILURE CODE [DHUEKX] 40 536
FAILURE CODE [DHUHKX] 40 538
FAILURE CODE [DHUJKX] 40 540
FAILURE CODE [DHUKKX] 40 542
FAILURE CODE [DHULKX] 40 544
FAILURE CODE [DHUMKX] 40 546
FAILURE CODE [DHUQKX] 40 548
FAILURE CODE [DHUSKX] 40 550
FAILURE CODE [DJF1KA] 40 552
FAILURE CODE [DK30KX] 40 554
FAILURE CODE [DK51L5] 40 556
FAILURE CODE [DK52KX] 40 559
FAILURE CODE [DK53L8] 40 561
FAILURE CODE [DK54KX] 40 563
FAILURE CODE [DK5VKX] 40 565
FAILURE CODE [DK5VMA] 40 567
FAILURE CODE [DK60KX] 40 568
FAILURE CODE [DKH0KX] 40 570
FAILURE CODE [DKH1KX] 40 572
FAILURE CODE [DLF1KA] 40 574
FAILURE CODE [DLF1LC] 40 575
FAILURE CODE [DLF2KA] 40 577
FAILURE CODE [DLF2LC] 40 578
FAILURE CODE [DLF8LC] 40 580
FAILURE CODE [DLF9LC] 40 582
FAILURE CODE [DLFKLC] 40 584
FAILURE CODE [DLFLLC] 40 586
FAILURE CODE [DLT3KA] 40 588
FAILURE CODE [DLT3LC] 40 589
FAILURE CODE [DPQ1KR] 40 591
FAILURE CODE [DPQ1LD] 40 594
FAILURE CODE [DPQ2KR] 40 597
FAILURE CODE [DPQ3KR] 40 600
FAILURE CODE [DPQ4KB] 40 602
FAILURE CODE [DQ11KM] 40 603
FAILURE CODE [DQ11KT] 40 604
FAILURE CODE [DQ12KM] 40 605
FAILURE CODE [DQ12KT] 40 606
FAILURE CODE [DQ13KM] 40 607
FAILURE CODE [DQ13KT] 40 608
FAILURE CODE [DQ14KM] 40 609
FAILURE CODE [DQ14KT] 40 610
FAILURE CODE [DQ15KM] 40 611
FAILURE CODE [DQ15KT] 40 612
FAILURE CODE [DQ16KM] 40 613
HD1500 8E0 00 11
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DQ16KT] 40 614
FAILURE CODE [DR10KA] 40 615
FAILURE CODE [DR20KA] 40 617
FAILURE CODE [DR30KA] 40 619
FAILURE CODE [DR40KA] 40 621
FAILURE CODE [DR50KA] 40 623
FAILURE CODE [DR60KA] 40 625
FAILURE CODE [DSJ0KR] 40 627
FAILURE CODE [DUMBKB] 40 628
FAILURE CODE [DV00KB] 40 629
FAILURE CODE [DV01KB] 40 631
FAILURE CODE [DW2AKA] 40 633
FAILURE CODE [DW2AKB] 40 634
FAILURE CODE [DW2AKY] 40 636
FAILURE CODE [DW2AL1] 40 637
FAILURE CODE [DW2ALH] 40 638
FAILURE CODE [DW2BKA] 40 639
FAILURE CODE [DW2BKB] 40 640
FAILURE CODE [DW2BKY] 40 641
FAILURE CODE [DW2BL1] 40 642
FAILURE CODE [DW2BLH] 40 643
FAILURE CODE [DW2CKA] 40 644
FAILURE CODE [DW2CKB] 40 645
FAILURE CODE [DW2CKY] 40 647
FAILURE CODE [DW2CL1] 40 648
FAILURE CODE [DW2CLH] 40 649
FAILURE CODE [DW4BK4] 40 650
FAILURE CODE [DW4BMA] 40 653
FAILURE CODE [DW72KZ] 40 656
FAILURE CODE [DW73KA] 40 658
FAILURE CODE [DW73KB] 40 660
FAILURE CODE [DW73KY] 40 662
FAILURE CODE [DW7NKZ] 40 663
FAILURE CODE [DW7SKZ] 40 665
FAILURE CODE [DWNJKZ] 40 667
FAILURE CODE [DWNMKZ] 40 669
FAILURE CODE [DX13KA] 40 671
FAILURE CODE [DX13KB] 40 673
FAILURE CODE [DX13KY] 40 675
FAILURE CODE [DX30K4] 40 676
FAILURE CODE [DX30KA] 40 678
FAILURE CODE [DX30KB] 40 680
FAILURE CODE [DX30KY] 40 682
FAILURE CODE [DX30MA] 40 684
FAILURE CODE [DX33K4] 40 686
FAILURE CODE [DX33KA] 40 688
FAILURE CODE [DX33KB] 40 690
FAILURE CODE [DX33KY] 40 692
FAILURE CODE [DX33MA] 40 694
FAILURE CODE [DX37K4] 40 696
00 12 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DX37KA] 40 698
FAILURE CODE [DX37KB] 40 700
FAILURE CODE [DX37KY] 40 702
FAILURE CODE [DX37MA] 40 703
FAILURE CODE [DX38K4] 40 705
FAILURE CODE [DX38KA] 40 707
FAILURE CODE [DX38KB] 40 709
FAILURE CODE [DX38KY] 40 711
FAILURE CODE [DX38MA] 40 712
FAILURE CODE [DX42KZ] 40 714
FAILURE CODE [DX43KZ] 40 716
FAILURE CODE [DXH1KA] 40 718
FAILURE CODE [DXH1KB] 40 720
FAILURE CODE [DXH1KY] 40 722
FAILURE CODE [DXH2KA] 40 723
FAILURE CODE [DXH2KB] 40 726
FAILURE CODE [DXH2KY] 40 729
FAILURE CODE [DXH3KA] 40 732
FAILURE CODE [DXH3KB] 40 735
FAILURE CODE [DXH3KY] 40 738
FAILURE CODE [DXH4KA] 40 741
FAILURE CODE [DXH4KB] 40 744
FAILURE CODE [DXH4KY] 40 747
FAILURE CODE [DXH5KA] 40 750
FAILURE CODE [DXH5KB] 40 753
FAILURE CODE [DXH5KY] 40 756
FAILURE CODE [DXH6KA] 40 759
FAILURE CODE [DXH6KB] 40 762
FAILURE CODE [DXH6KY] 40 765
FAILURE CODE [DXH7KA] 40 768
FAILURE CODE [DXH7KB] 40 771
FAILURE CODE [DXH7KY] 40 774
FAILURE CODE [DXHHKA] 40 777
FAILURE CODE [DXHHKB] 40 779
FAILURE CODE [DXHHKY] 40 781
FAILURE CODE [DY30MA] 40 784
FAILURE CODE [DY30MC] 40 787
FAILURE CODE [DY30ME] 40 790
FAILURE CODE [DY32MC] 40 792
FAILURE CODE [F9A0KT] 40 795
FAILURE CODE [F9A0MC] 40 796
FAILURE CODE [F9A1KK] 40 797
FAILURE CODE [F9A2KK] 40 800
FAILURE CODE [F9A9KQ] 40 803
FAILURE CODE [F9ALKA] 40 804
FAILURE CODE [F9ALKB] 40 806
FAILURE CODE [F9AQKR] 40 808
FAILURE CODE [F9AQMA] 40 809
FAILURE CODE [F9ARKR] 40 810
FAILURE CODE [F9AUKA] 40 811
HD1500 8E0 00 13
00 INDEX AND FOREWORD INDEX
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 40 814
E 1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 814
E 2 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 40 822
E 3 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 40 825
E 4 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)
40 827
E 5 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 40 829
E 6 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 40 831
E 7 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 40 834
E 8 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 40 837
E 9 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES
NOT OPERATE PROPERLY 40 839
E 10 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 40 841
E 11 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 40 843
E 12 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED
PROPERLY 40 845
E 13 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40 846
E 14 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40 848
E 15 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40 851
E 16 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 40 854
E 17 REARVIEW MONITOR IS NOT DISPLAYED IN CONJUNCTION WITH REVERSE WHEN THE CONSTANT
DISPLAY SETTING IS DISABLED 40 856
E 18 REARVIEW MONITOR REFERENCE LINE IS NOT DISPLAYED WHEN THE REFERENCE LINE DISPLAY
SETTING IS ENABLED 40 859
E 19 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40 861
E 20 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 40 863
E 21 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 40 865
E 22 ALARM BUZZER DOES NOT SOUND 40 866
E 23 ALARM BUZZER DOES NOT STOP SOUNDING 40 868
E 24 AISS FUNCTION DOES NOT OPERATE PROPERLY 40 870
E 25 HOIST LEVER DOES NOT OPERATE PROPERLY 40 872
E 26 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 40 874
E 27 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 40 878
E 28 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 40 881
E 29 TAIL LAMP DOES NOT LIGHT UP 40 884
E 30 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP 40 887
E 31 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP 40 890
E 32 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEADLAMPS LIGHTS UP 40 893
E 33 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 40 895
E 34 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40 897
E 35 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 40 899
E 36 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40 900
E 37 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40 903
E 38 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40 908
E 39 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL 40 911
E 40 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR 40 914
E 41 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION 40 916
E 42 EXTERNAL POWER SUPPLY ENGINE OIL PAN HEATER DOES NOT OPERATE 40 917
E 43 EXTERNAL POWER SUPPLY BRAKE TANK HEATER DOES NOT OPERATE 40 919
E 44 EXTERNAL POWER SUPPLY TRANSMISSION OIL PAN HEATER DOES NOT OPERATE 40 921
00 14 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
E 45 EXTERNAL POWER SUPPLY HYDRAULIC TANK HEATER DOES NOT OPERATE 40 923
E 46 BUZZER DOES NOT SOUND WHEN POWER LADDER IS OPERATED 40 925
E 47 POWER LADDER PUMP DOES NOT OPERATE 40 927
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40 929
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40 929
FAILURE MODE AND CAUSE TABLE 40 930
H 1 MACHINE DOES NOT START 40 943
H 2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 40 946
H 3 LOCKUP IS NOT RELEASED 40 947
H 4 ABNORMALLY STRONG SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 40 948
H 5 GEAR IS NOT UPSHIFTED 40 950
H 6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR
SPEEDS 40 953
H 7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE
40 954
H 8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT PARTICULAR GEAR SPEED 40 955
H 9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 40 957
H 10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 40 960
H 11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 40 961
H 12 STEERING WHEEL IS HEAVY TO OPERATE 40 962
H 13 STEERING WHEEL CANNOT BE OPERATED 40 963
H 14 STEERING WHEEL WAGGLES 40 964
H 15 FRONT BRAKE DOES NOT APPLY SUFFICIENTLY 40 965
H 16 REAR BRAKE DOES NOT APPLY SUFFICIENTLY 40 967
H 17 DUMP BODY RISING SPEED IS LOW 40 969
H 18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 40 971
H 19 DUMP BODY DOES NOT MOVE 40 972
H 20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 40 974
H 21 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40 975
H 22 POWER LADDER DOES NOT MOVE OR ITS SPEED IS LOW 40 976
50 DISASSEMBLY AND ASSEMBLY 50 1
ABBREVIATIONS 50 7
DISASSEMBLE AND ASSEMBLE RELATED INFORMATION 50 12
HOW TO READ THIS MANUAL 50 12
COATING MATERIALS LIST 50 14
SPECIAL TOOL LIST 50 17
DIAGRAMS OF SPECIAL TOOLS 50 39
ENGINE AND COOLING SYSTEM 50 48
REMOVE AND INSTALL RADIATOR ASSEMBLY 50 48
REMOVE AND INSTALL OIL COOLER ASSEMBLY 50 116
REMOVE AND INSTALL ENGINE ASSEMBLY 50 147
REMOVE AND INSTALL DAMPER ASSEMBLY 50 225
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 50 229
DISASSEMBLE AND ASSEMBLE OF RADIATOR ASSEMBLY 50 236
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 50 248
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 50 280
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 50 301
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 50 305
REMOVE AND INSTALL SCR ASSEMBLY 50 307
REMOVE AND INSTALL AdBlue/DEF INJECTOR 50 337
HD1500 8E0 00 15
00 INDEX AND FOREWORD INDEX
REMOVE AND INSTALL AdBlue/DEF PUMP 50 338
REMOVE AND INSTALL AdBlue/DEF HOSE 50 347
POWER TRAIN 50 377
REMOVE AND INSTALL FRONT DRIVE SHAFT 50 377
REMOVE AND INSTALL REAR DRIVE SHAFT ASSEMBLY 50 386
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50 392
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50 428
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER AND PTO ASSEMBLY 50 453
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 50 490
REMOVE AND INSTALL DIFFERENCIAL ASSEMBLY 50 551
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 50 557
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 50 586
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 50 591
BRAKE SYSTEM 50 605
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY 50 605
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB AND BRAKE ASSEMBLY 50 620
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 50 643
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE AND REAR BRAKE ASSEMBLY 50 645
STEERING SYSTEM 50 681
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 50 681
REMOVE AND INSTALL O RING OF STEERING VALVE ASSEMBLY 50 687
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 50 693
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 50 707
UNDERCARRIAGE AND FRAME 50 712
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 50 712
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 50 719
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 50 724
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) 50 738
REMOVE AND INSTALL KING PIN 50 742
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 50 745
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) 50 751
HYDRAULIC SYSTEM 50 756
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 50 756
REMOVE AND INSTALL O RING of FLOW AMPLIFIER VALVE ASSEMBLY 50 771
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 50 777
REMOVE AND INSTALL HOIST CYLINDER HEAD ASSEMBLY 50 792
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 50 795
WORK EQUIPMENT 50 807
REMOVE AND INSTALL DUMP BODY ASSEMBLY 50 807
CAB AND ITS ATTACHMENTS 50 817
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 50 817
REMOVE AND INSTALL OPERATOR CAB GLASS 50 887
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50 900
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 50 920
REMOVE AND INSTALL SEAT BELT 50 925
ELECTRICAL SYSTEM 50 927
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 50 927
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 50 929
00 16 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 50 931
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50 933
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 50 938
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50 940
REMOVE AND INSTALL REARVIEW CAMERA 50 942
REMOVE AND INSTALL KomVision CAMERA 50 943
REMOVE AND INSTALL KomVision RADAR 50 956
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 50 967
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 50 969
60 MAINTENANCE STANDARD 60 1
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 60 4
ENGINE AND COOLING SYSTEM 60 6
MAINTENANCE STANDARD OF ENGINE MOUNT 60 6
MAINTENANCE STANDARD OF DAMPER 60 7
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE MOTOR 60 9
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE MOTOR 60 11
POWER TRAIN 60 13
MAINTENANCE STANDARD OF DRIVE SHAFT 60 13
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 60 15
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 60 16
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE 60 20
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE 60 22
MAINTENANCE STANDARD OF TRANSMISSION 60 23
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 60 29
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV
60 30
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 60 31
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION SELECTOR VALVE 60 32
MAINTENANCE STANDARD OF FRONT AXLE 60 33
MAINTENANCE STANDARD OF REAR AXLE 60 34
MAINTENANCE STANDARD OF DIFFERENTIAL 60 35
MAINTENANCE STANDARD OF FINAL DRIVE 60 36
STEERING SYSTEM 60 37
MAINTENANCE STANDARD OF STEERING COLUMN 60 37
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE 60 38
MAINTENANCE STANDARD OF STEERING CYLINDER 60 41
BRAKE SYSTEM 60 42
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER 60 42
MAINTENANCE STANDARD OF REAR SLACK ADJUSTER 60 43
MAINTENANCE STANDARD OF FRONT BRAKE AND PARKING BRAKE 60 44
MAINTENANCE STANDARD OF REAR BRAKE AND PARKING BRAKE 60 45
UNDERCARRIAGE AND FRAME 60 46
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 60 46
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 60 48
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 60 49
HYDRAULIC SYSTEM 60 50
MAINTENANCE STANDARD OF STEERING PUMP 60 50
MAINTENANCE STANDARD OF DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR
60 54
MAINTENANCE STANDARD OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 60 56
HD1500 8E0 00 17
00 INDEX AND FOREWORD INDEX
MAINTENANCE STANDARD OF SERVO VALVE OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR
60 58
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP 60 59
MAINTENANCE STANDARD OF FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP 60 61
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE PUMP 60 63
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE AND AXLE OIL CIRCULATION 4 SPOOL
PUMP 60 65
WORK EQUIPMENT 60 67
MAINTENANCE STANDARD OF HOIST CYLINDER 60 67
CAB AND ITS ATTACHMENTS 60 68
MAINTENANCE STANDARD OF CAB MOUNT 60 68
80 THE OTHER INFORMATION 80 1
AIR CONDITIONER SYSTEM 80 4
PRECAUTIONS FOR REFRIGERANT 80 4
AIR CONDITIONER COMPONENT 80 5
SPECIFICATIONS OF AIR CONDITIONER 80 7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80 8
OUTLINE OF REFRIGERATION CYCLE 80 9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80 11
COMPONENT PARTS OF AIR CONDITIONER UNIT 80 14
AIR CONDITIONER CONTROLLER 80 18
COMPRESSOR 80 19
CONDENSER 80 20
SENSORS FOR AIR CONDITIONER SYSTEM 80 21
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 80 22
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80 24
AIR CONDITIONER SYSTEM DIAGRAM 80 26
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 80 29
TESTING AIR LEAKAGE (DUCT) 80 32
TESTING AIR CONDITIONER USING SELF DIAGNOSIS FUNCTION 80 35
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE
MACHINE MONITOR 80 36
TEST VENT (MODE) CHANGEOVER 80 38
TESTING FRESH/RECIRC AIR CHANGEOVER 80 39
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 80 40
TEST RELAYS 80 42
AIR CONDITIONER TROUBLESHOOTING CHART 1 80 43
AIR CONDITIONER TROUBLESHOOTING CHART 2 80 44
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80 47
TROUBLESHOOTING USING GAUGE PRESSURE 80 66
CONNECTION OF SERVICE TOOL 80 68
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
80 69
HANDLE COMPRESSOR OIL 80 71
METHOD FOR REPLACING DESICCANT 80 73
KomVision SYSTEM 80 75
STRUCTURE AND OPERATION OF KomVision SYSTEM 80 75
TESTING AND ADJUSTING KomVision SYSTEM 80 93
CAMERA CALIBRATION 80 116
TROUBLESHOOTING OF KomVision SYSTEM 80 157
00 18 HD1500 8E0
INDEX 00 INDEX AND FOREWORD
90 CIRCUIT DIAGRAMS 90 1
HOW TO READ ELECTRICAL WIRE CODE 90 3
HYDRAULIC CIRCUIT DIAGRAM 90 7
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 7
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST 90 11
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 90 13
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM 90 15
HYDRAULIC CIRCUIT DIAGRAM FOR POWER LADDER 90 17
HYDRAULIC CIRCUIT DIAGRAM OF MACHINE LOCKOUT SYSTEM 90 19
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (REVERSE 1ST + RIGHT TURN + BRAKE OPERATION)
90 21
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT REVERSE 1ST + RIGHT TURN + BRAKE OPERATION)
90 23
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE (REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 90 25
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (HOIST RAISE, FORWARD 2ND) 90 27
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT HOIST RAISE + FORWARD 2ND OPERATION) 90 29
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE (RETARDER BRAKE OPERATION) 90 31
ELECTRICAL CIRCUIT DIAGRAM 90 33
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90 33
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/10) 90 37
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/10) 90 39
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/10) 90 41
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/10) 90 43
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/10) 90 45
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/10) 90 47
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/10) 90 49
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/10) 90 51
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (9/10) 90 53
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (10/10) 90 55
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/11) 90 57
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/11) 90 59
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/11) 90 61
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/11) 90 63
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/11) 90 65
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/11) 90 67
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/11) 90 69
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/11) 90 71
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/11) 90 73
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/11) 90 75
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/11) 90 77
INDEX 1

DESCRIPTION:

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-05 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL: