Komatsu Dump Truck HM350-1 Shop Manual SEBM030305 – PDF DOWNLOAD

Komatsu Dump Truck HM350-1 Shop Manual SEBM030305 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Dump Truck HM350-1 Shop Manual SEBM030305 – PDF DOWNLOAD

Language : English
Pages : 1048
Downloadable : Yes
File Type : PDF
Size: 81 MB

TABLE OF CONTENTS:

Komatsu Dump Truck HM350-1 Shop Manual SEBM030305 – PDF DOWNLOAD

Machine model   Serial number
HM350-1               1001 and up

COVER 1
CONTENTS 2
LIST OF REVISED PAGES 3
01 GENERAL 7
SPECIFICATION DRAWINGS 8
SPECIFICATIONS 9
WEIGHT TABLE 12
FUEL,COOLANT AND LUBRICANTS 13
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 15
RADIATOR,OIL COOLER, AFTERCOOLER 16
POWER TRAIN SKELETON 18
OUTPUT SHAFT 22
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 24
TORQUE CONVERTER 26
TRANSMISSION 32
TRANSMISSION VALVE 54
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 55
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE 62
DRIVE SHAFT 64
AXLE 65
DIFFERENTIAL 68
LIMITED SLIP DIFFERENTIAL 82
FINAL DRIVE 86
STEERING COLUMN 91
BRAKE PIPING 92
BRAKE VALVE 94
ACCUMULATOR CHARGE VALVE 97
ACCUMULATOR 101
SLACK ADJUSTER 102
BRAKE 104
PROPORTIONAL REDUCING VALVE 109
BRAKE SYSTEM TANK 110
PRAKING BRAKE 112
PARKING BRAKE CALIPER 114
SPRING CYLINDER 115
PARKING BRAKE SOLENOID 116
SUSPENSION 118
SUSPENSION CYLINDER 124
OSCILLATION HITCH 127
STEERING,HOIST OIL PRESSURE PIPING DIAGRAM 130
DUMP BODY CONTROL 131
HYDRAULIC TANK AND FILTER 132
FLOW AMP VALVE 133
STEERING VALVE 136
STEERING CYLINDER 140
HOIST VALVE 142
EPC VALVE 148
PILOT CHECK VALVE 149
HOIST CYLINDER 151
HYDRAULIC PUMP 152
CAB TILT 159
AIR CONDITIONER 160
MACHINE MONITOR SYSTEM 165
AUTOMATIC SHIFT CONTROL SYSTEM 179
TRANSMISSION CONTROLLER 181
AUTO EMERGENCY STEERING SYSTEM 187
SENSORS,SWITCHES 188
RETARDER CONTROL SYSTEM 196
BRAKE CONTROL SYSTEM (E-SPEC) 206
DUMP CONTROL LEVER 216
20 TESTING AND ADJUSTING 221
STANDARD VALUE TABLE FOR ENGINE 222
STANDARD VALUE TABLE FOR CHASSIS 223
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 227
TESTING AND ADJUSTING 241
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING 242
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 244
MEASURING EXHAUST TEMPERATURE 245
MEASURING EXHAUST COLOR 247
MEASURING COMPRESSION PRESSURE 248
ADJUSTING VALVE CLEARANCE 249
MEASURING BLOW-BY PRESSURE 250
MEASURING ENGINE OIL PRESSURE 251
HANDLING EQUIPMENT IN FUEL CIRCUIT 252
RELEASING REMAINING PRESSURE IN FUEL SYSTEM 252
MEASURING FUEL PRESSURE 253
BLEEDING AIR FROM FUEL CIRCUIT 254
REDUCED CYLINDER MODE OPERATION 255
CHECKING FOR LEAKAGE IN FUEL CIRCUIT 256
ADJUSTING ENGINE SPEED SENSOR 257
TESTING AND ADJUSTING FAN BELT TENSION 258
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 261
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 261
ADJUSTING THE BODY MOUNT 262
TESTING TORQUE CONVERTER STALL SPEED 264
MEASURING POWER TRAIN OIL PRESSURE 265
TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL) 273
ADJUSTING TRANSMISSION SPEED SENSOR 278
TESTING AND ADJUSTING BRAKE OIL PRESSURE 279
TESTING OF ACCUMULATORNITROGEN GAS PRESSUREAND PROCEDURE FORCHARGING ACCUMULATORWITH NITROGEN GAS 284
TESTING BRAKE PERFORMANCE 292
RELEASING REMAINING PRESSURE IN BRAKE CIRCUIT 294
BLEEDING AIR FORM BRAKE CIRCUIT 296
TESTING WEAR OF WHEEL BRAKE DISC 298
TESTING WEAR OF PARKING BRAKE PAD 299
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE 301
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE 302
TESTING AND ADJUSTING SUSPENSION CYLINDER 304
METHOD OF TILTING CAB UP 308
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE 310
ADJUSTING BODY POSITIONER SENSOR 313
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT 314
ADJUSTING TRANSMISSION CONTROLLER 315
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM 316
ADJUSTING MACHINE MONITOR 320
SPECIAL FUNCTIONS OF MACHINE MONITOR 324
TROUBLESHOOTING 365
POINTS TO REMEMBER WHEN TROUBLESHOOTING 366
SEQUENCE OF EVENTS IN TROUBLESHOOTING 367
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 368
CHECKS BEFORE TROUBLESHOOTING 376
CONNECTOR TYPES AND MOUNTING LOCATIONS 377
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 393
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS 415
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE) 419
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 421
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 424
ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1)) 436
ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX) 437
ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2)) 438
ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA)) 438
ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3)) 439
ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA)) 441
ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB)) 441
ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA)) 442
ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB)) 443
ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA)) 444
ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB)) 445
ENG-12 FAILURE CODE [ADA1KA] (NO 1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 446
ENG-13 FAILURE CODE [ADZKKB] (NO 1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)) 447
ENG-14 FAILURE CODE [ADB1KA] (NO 2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 451
ENG-15 FAILURE CODE [ADC1KA] (NO 3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 452
ENG-16 FAILURE CODE [ADD1KA] (NO 4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 453
ENG-17 FAILURE CODE [ADDZKB] (NO 4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)) 454
ENG-18 FAILURE CODE [ADE1KA] (NO 5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA) 458
ENG-19 FAILURE CODE [ADF1KA] (NO 6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)) 459
ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG)) 460
ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK)) 461
ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS)) 462
ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ)) 463
ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 465
ENG-25 FAILURE CODE [D1DDKB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB)) 466
ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 468
ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT)) 469
ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE,INPUT (KK)) 470
ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ)) 472
ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA)) 473
ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)) 474
ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5)) 475
ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6)) 477
ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMERATURE): INPUT SIGNAL OUTSIDE RANGE (KX)) 479
ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6)) 480
ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 481
ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 482
ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 484
ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 486
ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC)) 488
ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC)) 489
ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN) 490
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE) 493
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 496
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 502
TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW)) 528
TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO)) 529
TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX)) 530
TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW)) 531
TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW)) 532
TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW)) 533
TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW)) 534
TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW)) 535
TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW)) 536
TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) 537
TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA)) 538
TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1)) 539
TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA)) 540
TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1)) 541
TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA)) 542
TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1)) 543
TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA)) 544
TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1)) 545
TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA)) 546
TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1)) 547
TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA)) 548
TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1)) 549
TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA)) 550
TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1)) 551
TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA)) 552
TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW)) 553
TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 554
TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX)) 556
TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00)) 557
TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 558
TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00)) 559
TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX)) 561
TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA)) 562
TM-34 FAILURE CODE [B@BCZK] (RADIATOR WATER: DROP IN LEVEL (ZK)) 563
TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK)) 564
TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK)) 565
TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)) 566
TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 568
TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)) 569
TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4)) 570
TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)) 572
TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 573
TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 574
TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 575
TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)) 576
TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP)) 577
TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP)) 578
TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP)) 579
TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP)) 580
TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA)) 580
TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA)) 581
TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA)) 582
TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA)) 583
TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA)) 584
TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA)) 585
TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA)) 586
TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA)) 587
TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA)) 588
TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA)) 589
TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB)) 591
TM-61 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 593
TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8)) 595
TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8)) 596
TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 597
TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 598
TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6)) 600
TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6)) 601
TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 602
TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA)) 604
TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC)) 605
TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)) 606
TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 607
TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA)) 608
TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 609
TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)) 610
TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)) 611
TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA)) 612
TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB)) 613
TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA)) 614
TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB)) 615
TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA)) 616
TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB)) 617
TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA)) 618
TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB)) 619
TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA)) 620
TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB)) 621
TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA)) 622
TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB)) 623
TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA)) 624
TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB)) 625
TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA)) 626
TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB)) 627
TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY 628
TROUBLESHOOTING OF RETARDER CONTROLLER(※1) SYSTEM (BK MODE) 631
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 634
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 640
BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) 654
BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) 655
BK-3 FAILURE CODE [2B62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) 656
BK-4 FAILURE CODE [2B62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) 657
BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX)) 658
BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA)) 659
BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA)) 660
BK-8 FAILURE CODE [2D03CA] (CENTER BRAKE (RIGHT): WEAR (CA)) 661
BK-9 FAILURE CODE [2D04CA] (CENTER BRAKE (LEFT): WEAR (CA)) 662
BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)) 663
BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)) 663
BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)) 664
BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 665
BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ)) 666
BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK) 667
BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)) 668
BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)) 669
BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)) 670
BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 671
BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ)) 672
BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX)) 673
BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX)) 675
BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK)) 677
BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX)) 680
BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8)) 682
BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)) 683
BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA)) 685
BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA)) 686
BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 687
BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 688
BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 689
BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA)) 690
BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB)) 691
BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 692
BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA)) 693
BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB)) 694
BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 695
BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA)) 696
BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB)) 697
BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)) 698
BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 699
BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) 700
BK-45 PARKING BRAKE DOES NOT WORK PROPERLY 702
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE) 705
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 706
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE 710
MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS)) 712
MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS)) 712
MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS)) 712
MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 713
MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) 714
MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ)) 715
MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 716
MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 718
MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)) 720
MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB)) 722
MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY 723
MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED 724
MON-14 ALARM BUZZER DOES NOT SOUND 725
MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY 726
MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY 728
MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY 729
MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY 732
MON-19 AISS FUNCTION DOES NOT WORK PROPERLY 733
MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY 734
MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY 737
MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE) 738
MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY 740
MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY 741
MON-25 NIGHT LIGHTING IS NOT NORMAL 746
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 753
H-1 MACHINE DOES NOT START 754
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 755
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS) 755
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 756
H-5 TRANSMISSION DOES NOT SHIFT UP 756
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 757
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 760
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 761
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 762
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 763
H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE 764
H-12 STEERING WHEEL IS HEAVY 765
H-13 STEERING WHEEL DOES NOT WORK 766
H-14 STEEIRNG WHEEL VIBRATES 767
H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER 768
H-16 DUMP DOES NOT WORK 769
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 770
30 DISASSEMBLY AND ASSEMBLY 771
METHOD OF USING MANUAL 773
PRECAUTIONS WHEN CARRYING OUT OPERATION 774
SPECIAL TOOL LIST 776
SKETCHES OF SPECIAL TOOLS 782
REMOVAL OF ENGINE ASSEMBLY 794
INSTALLATION OF ENGINE ASSEMBLY 797
REMOVAL OF CYLINDER HEAD ASSEMBLY 797
INSTALLATION OF CYLINDER HEAD 801
REMOVAL OF RADIATOR ASSEMBLY 807
INSTALLATION OF RADIATOR ASSEMBLY 809
REMOVAL OF OUTPUT SHAFT ASSEMBLY 810
INSTALLATION OF OUTPUT SHAFT ASSEMBLY 813
DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY 814
ASSEMBLY OF OUTPUT SHAFT ASSEMBLY 815
REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 817
INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 823
DISCONNECTION OF FRONT FINAL DRIVE AND TRANSMISSION 825
COUPLING OF FRONT FINAL DRIVE AND TRANSMISSION 825
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY 826
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 830
DISASSEMBLY OF TRANSMISSION ASSEMBLY 834
ASSEMBLY OF TRANSMISSION ASSEMBLY 853
DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY 879
ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY 886
REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY 898
INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY 900
DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY 902
ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY 908
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY 918
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY 919
DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY 919
ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY 923
REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 931
INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 932
DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 933
ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY 940
REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 950
INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 951
DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 952
ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY 957
REMOVAL OF REAR FINAL DRIVE ASSEMBLY 966
INSTALLATION OF REAR FINAL DRIVE ASSEMBLY 967
DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY 967
ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY 969
REMOVAL OF CENTER AXLE ASSEMBLY 974
INSTALLATION OF CENTER AXLE ASSEMBLY 976
REMOVAL OF REAR AXLE ASSEMBLY 977
INSTALLATION OF REAR AXLE ASSEMBLY 979
REMOVAL OF FRONT SUSPENSION CYLINDER ASSEMBLY 980
INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY 981
REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY 981
INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY 982
REMOVAL OF EQUALIZER BAR ASSEMBLY 982
INSTALLATION OF EQUALIZER BAR ASSEMBLY 984
REMOVAL OF FRONT WHEEL ASSEMBLY 985
INSTALLATION OF FRONT WHEEL ASSEMBLY 985
REMOVAL OF CENTER WHEEL ASSEMBLY 986
INSTALLATION OF CENTER WHEEL ASSEMBLY 986
REMOVAL OF REAR WHEEL ASSEMBLY 986
INSTALLATION OF REAR WHEEL ASSEMBLY 986
REMOVAL OF HITCH FRAME ASSEMBLY 987
INSTALLATION OF HITCH FRAME ASSEMBLY 993
DISASSEMBLY OF HITCH FRAME 997
ASSEMBLY OF HITCH FRAME ASSEMBLY 1000
STANDARD INTEGRAL ORBITROL 1004
DISASSEMBLY OF STEERING VALVE 1006
ASSEMBLY OF STEERING VALVE 1008
REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY 1013
INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY 1013
REMOVAL OF HOIST VALVE ASSEMBLY 1014
INSTALLATION OF HOIST VALVE ASSEMBLY 1014
DISASSEMBLY OF HOIST VALVE ASSEMBLY 1015
ASSEMBLY OF HOIST VALVE ASSEMBLY 1016
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY 1017
ASSEMBLY OF STEERING CYLINDER ASSEMBLY 1018
DISASSEMBLY OF HOIST CYLINDER ASSEMBLY 1020
ASSEMBLY OF HOIST CYLINDER ASSEMBLY 1021
REMOVAL OF BODY ASSEMBLY 1023
INSTALLATION OF BODY ASSEMBLY 1024
90 OTHERS 1025
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1026
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 1027
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM 1028
BRAKE HYDRAULIC CIRCUIT DIAGRAM 1029
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM 1031
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER 1033
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4) 1035
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4) 1037
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4) 1039
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4) 1041
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2) 1043
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2) 1045
EXTERNAL POWER SUPPLY HEATER 1047

IMAGES PREVIEW OF THE MANUAL: