Komatsu ARTICULATED DUMP TRUCK HM250-2 Shop Manual SEN04733-07 – PDF DOWNLOAD

Description

Komatsu ARTICULATED DUMP TRUCK HM250-2 Shop Manual SEN04733-07 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ARTICULATED DUMP TRUCK HM250-2 Shop Manual SEN04733-07 – PDF DOWNLOAD

Language : English
Pages :1456
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ARTICULATED DUMP TRUCK HM250-2 Shop Manual SEN04733-07 – PDF DOWNLOAD

SERIAL NUMBERS 2001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu ARTICULATED DUMP TRUCK HM250-2 Shop Manual SEN04733-07 – PDF DOWNLOAD

SERIAL NUMBERS 2001 and up

COVER 1
00 Index and foreword 0
100 Index 3
Composition of shop manual 4
Table of contents 6
200 Foreword and general information 19
Safety notice 20
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling of electric equipment and hydraulic component 29
Handling of connectors newly used for engines 38
How to read electric wire code 41
Precautions when carrying out operation 44
Method of disassembling and connecting push-pull type coupler 47
Standard tightening torque table 50
Conversion table 54
01 Specification 0
100 Specification and technical data 61
Specification drawings 62
Specifications 63
Weight table 66
Fuel, coolant and lubricants 67
10 Structure, function and maintenance standard 0
100 Engine and cooling system 71
Radiator, oil cooler, aftercooler 72
Output shaft 73
201 Power train, Part 1 77
Power train skeleton 78
Torque converter and transmission hydraulic piping 80
Brake cooling oil control valve (BCV) 82
Power train pump 83
Torque converter 86
Transmission 92
Transmission control valve 120
ECMV 122
Main relief, torque converter relief valve 129
202 Power train, Part 2 133
Drive shaft 134
Axle 135
Differential 138
Limited slip differential 144
Final drive 148
300 Steering system 155
Steering column 156
400 Brake system 159
Brake piping 160
Brake valve 162
Accumulator charge valve 165
Accumulator 169
Slack adjuster 170
Brake 172
Proportional reducing valve 177
Brake system tank 178
Parking brake 180
Parking brake solenoid 184
500 Undercarriage and frame 187
Suspension 188
Suspension cylinder 194
Oscillation hitch 196
600 Hydraulic system 201
Steering, hoist oil pressure piping diagram 202
Dump body control 203
Hydraulic tank and filter 204
Flow amp valve 205
Steering valve 208
Steering cylinder 212
Hoist valve 214
EPC valve 220
Hoist cylinder 222
Hydraulic pump 223
700 Cab and its attachments 227
ROPS cab 228
Cab tilt 229
Rear view monitor 230
Controller related 233
801 Electrical system, Part 1 235
Machine monitor system 236
802 Electrical system, Part 2 257
Automatic shift control system 258
Retarder control system 290
Auto emergency steering system 302
Battery disconnector switch 304
Dump control lever 306
803 Electrical system, Part 3 311
Sensors, switches 312
KOMTRAX terminal system (If equipped) 320
20 Standard value table 0
100 Standard service value table 323
Standard value table for engine 324
Standard value table for chassis 325
30 Testing and adjusting 0
101 Testing and adjusting, Part 1 331
Tools for testing, adjusting, and troubleshooting 333
Testing engine speed 336
Testing intake air pressure (boost pressure) 337
Testing exhaust temperature 338
Testing exhaust gas color 340
Adjusting valve clearance 341
Testing compression pressure 343
Testing blow-by pressure 345
Testing engine oil pressure 346
Testing EGR valve and bypass valve drive oil pressure 347
Handling of fuel system devices 348
Releasing residual pressure from fuel system 348
Testing fuel pressure 349
Handling of reduced cylinder mode operation 350
Handling of no injection cranking operation 350
Testing fuel return and leak amount 351
Bleeding air from fuel circuit 354
Testing the fuel circuit for leakage 355
Testing and adjusting alternator belt tension 356
Testing and adjusting air conditioner compressor belt tension 356
Adjusting the body mount 357
102 Testing and adjusting, Part 2 359
Testing torque converter stall speed 361
Testing power train oil pressure 362
Adjusting transmission speed sensor 370
Testing and adjusting brake oil pressure 372
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 375
Testing brake performance 378
Bleeding air from brake circuit 379
Testing wear of wheel brake disc 380
Testing wear of parking brake pad 381
Method for emergency release of parking brake 383
Testing and adjusting steering circuit oil pressure 384
Testing and adjusting suspension cylinder 386
Method of tilting cab up 390
Testing and adjusting dump circuit oil pressure 392
Adjusting body positioner sensor 395
Procedure for adjusting length of spring in body heating spherical joint 396
Handling engine controller high voltage circuit 396
Adjusting transmission controller 397
Method for emergency escape at electrical system failure 398
103 Testing and adjusting, Part 3 403
Setting and adjusting various equipments 404
Special function of machine monitor (EMMS) 416
How to start operation of KOMTRAX terminal 453
Lamp display of KOMTRAX terminal 458
Pm Clinic check sheet 461
40 Troubleshooting 0
100 Failure code table and fuse locations 465
Failure codes table 466
Fuse locations 473
200 General information on troubleshooting 479
Points to remember when troubleshooting 480
Sequence of events in troubleshooting 481
Check before troubleshooting 482
Classification and procedures for troubleshooting 483
Information in troubleshooting table 484
Connection table for connector pin numbers 486
T-branch box and T-branch adapter table 522
301 Troubleshooting by failure code, Part 1 527
Failure code [1500L0] Double engagement 529
Failure code [15B0NX] Transmission oil filter: Clogged 530
Failure code [15F0KM] R → F shifting abuse 1 532
Failure code [15F0MB] R → F shifting abuse 2 532
Failure code [15F7KM] Transmission forward clutch abuse 533
Failure code [15G0MW] Trouble in reverse clutch system (Slip) 534
Failure code [15G7KM] Transmission reverse clutch abuse 536
Failure code [15H0MW] Trouble in Hi clutch system (Slip) 538
Failure code [15J0MW] Trouble in Lo clutch system (Slip) 540
Failure code [15K0MW] Trouble in 1st clutch system (Slip) 542
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) 544
Failure code [15M0MW] Trouble in 3rd clutch system (Slip) 546
Failure code [15SBL1] Trouble in reverse clutch pressure control valve I 548
Failure code [15SBMA] Trouble in reverse clutch pressure control valve II 551
Failure code [15SCL1] Trouble in Hi clutch pressure control valve I 552
Failure code [15SCMA] Trouble in Hi clutch pressure control valve II 555
Failure code [15SDL1] Trouble in Lo clutch pressure control valve I 556
Failure code [15SDMA] Trouble in Lo clutch pressure control valve II 559
302 Troubleshooting by failure code, Part 2 561
Failure code [15SEL1] Trouble in 1st clutch pressure control valve I 563
Failure code [15SEMA] Trouble in 1st clutch pressure control valve II 566
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I 567
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II 570
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I 571
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II 574
Failure code [15SJMA] Trouble in lockup clutch pressure control valve II 576
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II 578
Failure code [2C4MNX] Clogging of retarder cooling oil filter 580
Failure code [2F00KM] Dragging of parking brake 582
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 584
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 584
Failure code [989A00] Operation of engine overrun prevention system 585
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 585
Failure code [A570NX] Clogging of engine oil filter 586
Failure code [AA10NX] Clogging of air cleaner 588
Failure code [AB00MA] Trouble in battery charge circuit 590
Failure code [B@BAZG] Lowering of engine oil pressure 591
Failure code [B@BAZK] Lowering of engine oil level 592
Failure code [B@BCNS] Overheating of engine 593
Failure code [B@BCZK] Lowering of coolant level 594
Failure code [B@BFZK] Lowering of fuel level 596
Failure code [B@C6NS] Overheating of brake cooling oil (front) 597
Failure code [B@C8NS] Overheating of brake cooling oil (center) 597
Failure code [B@CENS] Overheating of torque converter oil 598
Failure code [B@HAZK] Hydraulic oil level low 599
Failure code [B@JANS] Overheating of steering oil 600
303 Troubleshooting by failure code, Part 3 603
Failure code [CA111] Trouble in engine controller 606
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors 608
Failure code [CA122] Abnormally high charge pressure 610
Failure code [CA123] Abnormally low charge pressure 612
Failure code [CA131] Abnormally high throttle sensor signal 614
Failure code [CA132] Abnormally low throttle sensor signal 616
Failure code [CA135] Abnormally high engine oil pressure 618
Failure code [CA141] Abnormally low engine oil pressure 620
Failure code [CA144] Abnormally high coolant temperature 622
Failure code [CA145] Abnormally low coolant temperature 624
Failure code [CA153] Abnormally high charge temperature 626
Failure code [CA154] Abnormally low charge temperature 628
Failure code [CA187] Abnormally low voltage in sensor power supply 2 629
Failure code [CA221] Abnormally high ambient pressure 630
Failure code [CA222] Abnormally low ambient pressure 632
Failure code [CA227] Abnormally high voltage in sensor power supply 2 634
Failure code [CA234] Engine overspeed 636
Failure code [CA238] Trouble in Ne speed sensor power supply 638
Failure code [CA263] Abnormally high fuel temperature 640
Failure code [CA265] Abnormally low fuel temperature 642
Failure code [CA271] PCV1 short circuit 644
Failure code [CA272] PCV1 disconnection 646
Failure code [CA273] PCV2 short circuit 648
Failure code [CA274] PCV2 disconnection 650
Failure code [CA322] Disconnection or short circuit in injector #1 (L#1) 652
Failure code [CA323] Disconnection or short circuit in injector #5 (L#5) 654
Failure code [CA324] Disconnection or short circuit in injector #3 (L#3) 656
Failure code [CA325] Disconnection or short circuit in injector #6 (L#6) 658
Failure code [CA331] Disconnection or short circuit in injector #2 (L#2) 660
Failure code [CA332] Disconnection or short circuit in injector #4 (L#4) 662
Failure code [CA342] Matching error in engine controller data 664
Failure code [CA351] Trouble in injector drive circuit 666
Failure code [CA352] Abnormally low voltage in sensor power supply 1 668
Failure code [CA386] Abnormally high voltage in sensor power supply 1 670
304 Troubleshooting by failure code, Part 4 673
Failure code [CA431] Trouble in idle validation switch 676
Failure code [CA432] Trouble in idle validation process 679
Failure code [CA441] Abnormally low voltage in power supply 679
Failure code [CA442] Abnormally high voltage in power supply 680
Failure code [CA449] Abnormally high common rail pressure 2 681
Failure code [CA451] Abnormally high common rail pressure 682
Failure code [CA452] Abnormally low common rail pressure 684
Failure code [CA553] Abnormally high common rail pressure 1 684
Failure code [CA554] In-range error in common rail pressure sensor 685
Failure code [CA559] Supply pump low pressure 1 686
Failure code [CA689] Trouble in engine Ne speed sensor 690
Failure code [CA731] Phase error in engine Bkup speed sensor 692
Failure code [CA757] Loss of all data in engine controller 693
Failure code [CA778] Trouble in engine Bkup speed sensor 694
Failure code [CA1117] Loss of partial data in engine controller 696
Failure code [CA1228] Trouble in EGR valve servo 1 696
Failure code [CA1625] Trouble in EGR valve servo 2 697
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit 698
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit 700
Failure code [CA1628] Trouble in bypass valve servo 1 701
Failure code [CA1629] Trouble in bypass valve servo 2 702
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor 704
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor 706
Failure code [CA1633] Trouble in KOMNET 708
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor 710
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor 712
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply 714
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply 716
Failure code [CA2249] Low pressure in supply pump 2 717
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor 718
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor 720
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit 722
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit 724
Failure code [CA2555] Disconnection in intake air heater relay 724
Failure code [CA2556] Short circuit in intake air heater relay 726
305 Troubleshooting by failure code, Part 5 729
Failure code [DAF9KM] Wrong connection of connector 731
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) 732
Failure code [DAQ0KK] Lowering of source voltage 734
Failure code [DAQ0KT] Trouble in non-volatile memory 736
Failure code [DAQ2KK] Trouble in solenoid power supply system 738
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 740
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) 742
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 746
Failure code [DB10KT] Trouble in non-volatile memory 746
Failure code [DB12KK] Trouble in solenoid power supply system 748
Failure code [DB13KK] Lowering of battery direct voltage 750
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 752
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) 752
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) 754
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) 758
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 762
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 764
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 766
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 768
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 770
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 772
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 774
Failure code [DF10KA] Input of no lever signals 776
Failure code [DF10KB] Input of multiple lever signals 780
Failure code [DGF1KX] Transmission oil temperature out of range 784
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) 786
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 788
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) 790
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 792
Failure code [DGR6KX] Steering oil temperature out of range 794
306 Troubleshooting by failure code, Part 6 797
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 800
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 802
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 804
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system 806
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system 808
Failure code [DJF1KA] Disconnection in fuel level sensor system 810
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS 812
Failure code [DK52KX] Trouble in dump lever potentiometer 1 814
Failure code [DK53L8] Trouble in dump lever potentiometer 2 816
Failure code [DK54KX] Trouble in dump positioner sensor 818
Failure code [DKH0KX] Pitch angle sensor signal out of range 820
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 822
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor 823
Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor 824
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system 825
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 826
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 827
Failure code [DV00KB] Short circuit in buzzer output circuit 828
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system 830
Failure code [DW73KZ] Trouble in dump selector valve output system 832
Failure code [DW78KZ] Trouble in rear wheel BCV command output system 834
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 836
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve 838
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve 840
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve 842
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 844
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 846
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 848
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve 850
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve 852
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 854
307 Troubleshooting by failure code, Part 7 857
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve 860
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve 862
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 864
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid 866
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid 868
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid 870
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 872
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid 874
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid 876
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid 878
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch solenoid 880
Failure code [DXH2KY] Hot short in output circuit of Hi clutch solenoid 882
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid 886
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch solenoid 888
Failure code [DXH3KY] Hot short in output circuit of Lo clutch solenoid 890
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid 894
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch solenoid 896
Failure code [DXH4KY] Hot short in output circuit of 1st clutch solenoid 898
308 Troubleshooting by failure code, Part 8 903
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid 904
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve 906
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve 908
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid 912
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve 914
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve 916
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid 920
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve 922
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve 924
400 Troubleshooting of electrical system (E-mode) 929
Information in troubleshooting table 931
E-1 Engine does not start (Starting motor does not turn) 932
E-2 Auto preheater does not operate 936
E-3 When starting switch is turned ON, machine monitor displays nothing 940
E-4 When starting switch is turned OFF, machine monitor cannot be operated 942
E-5 Alarm buzzer does not sound 944
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section 946
E-7 Display of character display section cannot be changed 947
E-8 Power mode selection function does not operate normally 950
E-9 AISS function does not operate normally 952
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) 954
E-11 Interaxle differential lock-up function does not operate normally 958
E-12 Display of seat belt caution lamp is abnormal 960
E-13 Turn signal lamps and pilot lamps do not operate normally 962
E-14 Night lighting is abnormal 967
E-15 Backup lamp and backup buzzer operate abnormally 973
E-16 Emergency steering system does not operate 977
E-17 Dump lever does not operate normally 982
500 Troubleshooting of hydraulic and mechanical system (H-mode) 985
Contents of troubleshooting table 987
H-1 Machine does not start 988
H-2 Machine does not travel smoothly (machine jerks) 990
H-3 Lockup cannot be cancelled 990
H-4 Excessive shock when starting or shifting 991
H-5 Transmission does not shift up 992
H-6 Machine lacks power or speed when traveling 994
H-7 Time lag is excessive when starting or shifting gear 996
H-8 Torque converter oil temperature is high 997
H-9 Torque converter oil pressure is low 998
H-10 Front brake is ineffective 999
H-11 Center brake is ineffective1000
H-12 Steering wheel is heavy1001
H-13 Steering wheel does not work1002
H-14 Steering wheel vibrates1003
H-15 Dump body lifting speed is slow1004
H-16 Dump body does not work1005
H-17 Hydraulic drift of dump body is large1006
600 Troubleshooting of engine (S-mode)1009
How to use a troubleshooting chart1011
S-1 Engine is hard to start1014
S-2 Engine does not start1016
S-3 Engine does not pick up smoothly1020
S-4 Engine stops during operations1021
S-5 Engine does not rotate smoothly1022
S-6 Engine lacks output (or lacks power)1023
S-7 Exhaust gas color is black (incomplete combustion)1024
S-8 Oil consumption is excessive (or exhaust gas color is blue)1026
S-9 Oil gets contaminated prematurely1027
S-10 Fuel consumption is excessive1028
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1029
S-12 Oil pressure drops1030
S-13 Oil level rises (coolant or fuel mixes)1032
S-14 Coolant temperature rises too high (overheat)1034
S-15 Abnormal noise comes out1035
S-16 Vibration is excessive1036
50 Disassembly and assembly 0
100 General information on disassembly and assembly1039
How to read this manual1040
Coating materials list1042
Special tool list1045
Sketches of special tools1049
200 Engine and cooling system1065
Removal and installation of fuel supply pump assembly1066
Removal and installation of fuel injector assembly1072
Removal and installation of engine front oil seal1078
Removal and installation of engine rear oil seal1080
Removal and installation of cylinder head assembly1084
Removal and installation of engine assembly1096
Removal and installation of radiator assembly1105
Removal and installation of cooling assembly1108
Removal and installation of aftercooler assembly1111
Removal and installation of output shaft assembly1113
Disassembly and assembly of output shaft assembly1118
301 Power train, Part 11123
Removal and installation of transmission and front differential assembly1124
Disconnection and connection of front differential assembly and transmission assembly1130
Disassembly and assembly of front differential assembly1132
Disassembly and assembly of torque converter assembly1147
302 Power train, Part 21155
Disassembly and assembly of transmission assembly1156
303 Power train, Part 31199
Removal and installation of center differential assembly1200
Disassembly and assembly of center differential assembly1204
Removal and installation of rear differential assembly1221
Disassembly and assembly of rear differential assembly1224
304 Power train, Part 41239
Removal and installation of front final drive and brake assembly1240
Disassembly and assembly of front final drive and brake assembly1243
Removal and installation of center final drive and brake assembly1253
Disassembly and assembly of center final drive and brake assembly1255
305 Power train, Part 51265
Disassembly and assembly of rear final drive assembly1266
Removal and installation of center axle assembly1273
Removal and installation of rear axle assembly1276
400 Undercarriage and frame1279
Removal and installation of front suspension cylinder assembly1280
Removal and installation of rear suspension cylinder assembly1282
Removal and installation of equalizer bar1283
Removal and installation of hitch frame assembly1285
Removal and installation of hitch frame assembly1287
Disassembly and assembly of hitch frame assembly1297
500 Hydraulic system1305
Removal and installation of flow amp valve1306
Removal and installation of hoist valve assembly1309
Disassembly and assembly of hydraulic cylinder assembly1313
600 Body1321
Removal and installation of body assembly1322
700 Cab and its attachments1325
Method of tilting cab up1326
Removal and installation of cab assembly1328
Removal and installation of operator’s cab glass (Stuck glass)1335
Disassembly and assembly of operator’s seat assembly1342
Removal and installation of air conditioner unit assembly1352
800 Electrical system1361
Removal and installation of engine controller1362
Removal and installation of retarder controller1363
Removal and installation of transmission1364
Removal and installation of KOMTRAX terminal assembly1365
60 Air conditioner 0
100 Structure, function, testing, adjusting, and troubleshooting1367
Structure and function1369
Air conditioner component1369
Configuration and function of refrigerating cycle1370
Outline of refrigerating cycle1371
Air conditioner unit1373
Function of major components in the air conditioner unit1374
Blower and intake unit1376
Compressor1378
Condenser1379
Receiver drier1380
Air conditioner control panel1382
Testing, adjusting and troubleshooting1384
Caution about refrigerant1384
Troubleshooting procedure1385
Block diagram and circuit diagram of control system1386
Detail of air conditioner unit1388
Arrangement of connector pins1390
Part and connector locations1391
Cab tilting1395
Testing air leakage (ducts)1396
Testing with self-diagnosis function (indication on control panel)1399
Testing temperature control1400
Testing vent (mode) changeover1402
Testing Recirc/Fresh changeover1403
Testing evaporator temperature sensor1405
Testing relays1408
Troubleshooting chart 11409
Troubleshooting chart 21410
Troubleshooting for electrical system (E mode)1413
E-1 Power supply system (Air conditioner does not operate)1414
E-2 Compressor system (Air is not cooled)1418
E-3 Blower motor system (No air comes out or air flow is abnormal)1421
E-4 Temperature cannot be controlled1424
E-5 Vent (mode) cannot be changed over1426
E-6 Recirc/Fresh air cannot be changed over1428
Troubleshooting with gauge pressure1430
Connection of service tool1432
Precautions for connecting air conditioner piping1433
Handling of compressor oil1434
1 Control of compressor oil1434
2 Adding of compressor oil1434
3 Compressor replacement1435
4 Applying compressor oil for O-ring1435
90 Diagrams and drawings 0
100 Hydraulic diagrams and drawings1437
Power train hydraulic circuit diagram1439
Steering and hoist hydraulic circuit diagram1440
Brake hydraulic circuit diagram1442
Brake cooling hydraulic circuit diagram1443
200 Electrical diagrams and drawings1445
Electrical circuit diagram for inside cab (1/4)1447
Electrical circuit diagram for inside cab (2/4)1448
Electrical circuit diagram for inside cab (3/4)1449
Electrical circuit diagram for inside cab (4/4)1450
Electrical circuit diagram for outside cab (1/3)1451
Electrical circuit diagram for outside cab (2/3)1452
Electrical circuit diagram for outside cab (3/3)1453
Connectors table and arrangement drawing1454

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24