Komatsu GALEO HM350-1L Dump Truck Shop Manual CEBM015400 PDF

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Komatsu GALEO HM350-1L Dump Truck Shop Manual CEBM015400 – PDF DOWNLOAD 

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Komatsu GALEO HM350-1L Dump Truck Shop Manual CEBM015400 – PDF DOWNLOAD 

Language : English
Pages : 1220
Downloadable : Yes
File Type : PDF

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Komatsu GALEO HM350-1L Dump Truck Shop Manual CEBM015400 – PDF DOWNLOAD 

SERIAL NUMBERS HM350-1L A10001 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu GALEO HM350-1L Dump Truck Shop Manual CEBM015400 – PDF DOWNLOAD 

SERIAL NUMBERS HM350-1L A10001 and UP

COVER 1
FOREWORD 2
CONTENTS 2
SAFETY 3
SAFETY NOTICE 3
IMPORTANT SAFETY NOTICE 3
GENERAL PRECAUTIONS 3
PREPARATIONS FOR WORK 3
PRECAUTIONS DURING WORK 3
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
VOLUMES 6
DISTRIBUTION AND UPDATING 6
FILING METHOD 6
REVISED EDITION MARK 6
REVISIONS 6
SYMBOLS 6
HOISTING INSTRUCTIONS 7
HOISTING 7
WIRE ROPES 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
Disconnection 8
Connection 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 12
TIGHTENING TORQUE OF HOSE NUTS 13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 13
TIGHTENING TORQUE FOR FLARED NUTS 13
TIGHTENING TORQUE FOR 102 ENGINE SERIES 14
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) 14
ELECTRIC WIRE CODE 16
CLASSIFICATION BY THICKNESS 16
CLASSIFICATION BY COLOR AND CODE 16
CONVERSION TABLES 17
METHOD OF USING THE CONVERSION TABLE 17
TEMPERATURE 22
01 GENERAL 23
SPECIFICATION DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 29
ENGINE OIL SPECIFICATIONS 30
NORMAL OPERATION 30
ARCTIC OPERATION 30
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS 31
FINAL DRIVE OIL SPECIFICATIONS 31
DRIVE AXLE OIL SPECIFICATIONS 31
DIESEL FUEL SPECIFICATIONS 31
COOLANT SPECIFICATIONS 32
GENERAL 32
WATER 32
ANTIFREEZE 32
SUPPLEMENTAL COOLANT ADDITIVES 34
COOLING SYSTEM TEST KIT 38
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 39
COOLING SYSTEMS 43
SPECIFICATIONS 43
POWER TRAIN 44
LOCKING DIFFERENTIAL 44
TORQUE DAMPER 46
FUNCTION 46
TORQUE CONVERTER AND TRANSMISSION 48
HYDRAULIC PIPING 48
TORQUE CONVERTER 49
SPECIFICATIONS 49
TRANSMISSION POWER FLOW 53
OIL FLOW 54
TRANSMISSION 55
OUTLINE 59
FL – R CLUTCH 60
FH – 1ST CLUTCH 61
2ND – 3RD CLUTCH 62
DIFFERENTIAL LOCK 63
CLUTCH AND TRANSMISSION OPERATIONS 65
FORWARD 1ST 66
OPERATION 66
FORWARD 2ND 67
OPERATION 67
FORWARD 3RD 68
OPERATION 68
FORWARD 4TH 69
OPERATION 69
FORWARD 5TH 70
OPERATION 70
FORWARD 6TH 71
OPERATION 71
REVERSE 1ST 72
OPERATION 72
TRANSMISSION VALVE OPERATIONS 73
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 74
ECMV LOCK-UP CLUTCH 75
OUTLINE 75
OPERATION 75
DURING DIRECT TRAVEL 76
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL 76
ECMV SPEED CLUTCH 77
ECMV OUTLINE 77
ECMV AND PROPORTIONAL SOLENOID 77
ECMV AND FILL SWITCH 77
ECMV OPERATION 78
ECMV FOR DIFFERENTIAL LOCK 80
OPERATION 80
MAIN AND TORQUE CONVERTER RELIEF VALVE 81
VALVE OUTLINE AND OPERATIONS 82
TORQUE CONVERTER RELIEF VALVE 82
MAIN RELIEF VALVE 82
OPERATION 82
DRIVE SHAFT 83
OUTLINE 83
DRIVE AXLES 84
FRONT 84
CENTER 85
REAR 86
LOCKING DIFFERENTIAL 87
FRONT 87
CENTER 89
REAR 91
OPERATION 93
TRAVELING IN A STRAIGHT LINE 93
TURNING 93
WHEN DIFFERENTIAL LOCK IS ACTUATED 93
FINAL DRIVE SYSTEM 94
FRONT 94
CENTER 96
REAR 98
FUNCTION 99
OPERATION 99
STEERING COLUMN 100
WHEEL BRAKING SYSTEM 101
PIPING LAY-OUT 101
BRAKE VALVE 102
VALVE OPERATION 103
ACCUMULATOR CHARGE VALVE 105
FUNCTION 105
VALVE OPERATION 107
ACCUMULATOR 109
FUNCTION 109
SPECIFICATIONS 109
SLACK ADJUSTER 110
FUNCTION 111
OPERATION 111
FRONT BRAKE 112
CENTER, REAR BRAKE 114
FUNCTION 116
OPERATIONS 116
PROPORTIONAL REDUCING VALVE 117
FUNCTION 117
BRAKE SYSTEM TANK 118
PARKING BRAKE 119
FUNCTION 119
PARKING BRAKE CALIPER 121
OUTLINE 121
SPRING CYLINDER 122
OUTLINE 122
PARKING BRAKE SOLENOID 123
FUNCTION 123
SUSPENSION SYSTEM 124
FRONT 124
REAR 126
OUTLINE 128
FUNCTION 128
SUSPENSION CYLINDER 129
STRUCTURE AND OPERATION 130
OSCILLATION HITCH JOINT 131
OUTLINE 133
STEERING, HOIST OIL PIPING DIAGRAM 134
DUMP BODY CONTROL 135
FUNCTION 135
HYDRAULIC TANK AND FILTER 136
FLOW AMPLIFIER VALVE 137
OUTLINE 137
OPERATION 138
STEERING VALVE 140
OUTLINE 141
STRUCTURE 141
HAND PUMP AND SLEEVE CONNECTION 142
FUNCTION OF CENTER SPRING 143
STEERING CYLINDER 144
HOIST VALVE 145
HOIST VALVE AT HOLD POSITION 147
HOIST VALVE AT RAISE POSITION 148
HOIST VALVE AT FLOAT POSITION 149
HOIST VALVE AT LOWER POSITION 150
EPC VALVE 151
FUNCTION 151
PILOT CHECK VALVE 152
HOIST CYLINDER 153
HYDRAULIC PUMP 154
STEERING, HOIST + PILOT PUMP 154
TRANSMISSION + DIFFERENTIAL LOCK PUMP 155
BRAKE COOLING + BRAKE PUMP 156
AUXILIARY STEERING PUMP 157
DIFFERENTIAL LOCK PUMP 158
TRANSMISSION PUMP 159
CAB TILT SYSTEM VIEW 160
AIR CONDITIONING SYSTEM VIEW 161
FUNCTION 161
AIR CONDITIONER UNIT 162
RECEIVER DRYER 163
CONDENSER 164
REFRIGERANT COMPRESSOR 165
MACHINE MONITOR SYSTEM 166
NETWORK DATA 166
OUTLINE 167
MACHINE MONITOR PANEL 169
OPTION SETTING CONNECTOR DIAGRAM 171
ADJUSTING MACHINE MONITOR 171
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS 172
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH 175
CHECK FUNCTION OF MONITOR LAMPS AND METERS 176
SERVICE METER DISPLAY 176
ODOMETER 176
SERVICE MODE 176
OUTLINE 176
OPERATION METHOD 178
AUTOMATIC SHIFT CONTROL SYSTEM 179
OUTLINE 180
TRANSMISSION CONTROLLER 181
OUTLINE 181
SHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE 184
GEARSHIFTING CHARACTERISTICS 184
AUTOMATIC GEARSHIFTING GRAPH 185
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD 186
SHIFT HOLD FUNCTION 187
GEARSHIFTING TIME DELAY 187
SAFETY FUNCTIONS 187
SELF-DIAGNOSTIC FUNCTION 188
AUTO AUXILIARY STEERING SYSTEM 189
OUTLINE 189
SENSORS AND SWITCHES 190
ENGINE SPEED SENSOR 190
FUNCTION 190
ACCELERATOR PEDAL SENSOR 190
OUTLINE 191
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS 192
FUNCTION 192
STEERING OIL TEMPERATURE SENSOR 192
FUNCTION 192
FUEL LEVEL SENSOR 193
FUNCTION 193
TILT SENSOR 194
FUNCTION 194
AIR CLEANER CLOGGING SENSOR 195
FUNCTION 195
HYDRAULIC OIL LEVEL SENSOR 196
FUNCTION 196
BODY POSITIONER SENSOR 197
FUNCTION 197
RETARDER CONTROL SYSTEM 198
RETARDER CONTROLLER UNIT 199
OUTLINE 199
RETARDER CONTROL FUNCTION 203
SYSTEM DIAGRAM 203
HOIST CONTROL FUNCTION 205
SYSTEM DIAGRAM 205
DIFFERENTIAL LOCK CONTROL FUNCTION 207
SYSTEM DIAGRAM 207
BRAKE CONTROL SYSTEM (E-SPEC) 209
BRAKE CONTROLLER (E-SPEC) UNIT 210
OUTLINE 210
BRAKE CONTROL FUNCTION 214
SYSTEM DIAGRAM 214
HOIST CONTROL SYSTEM 215
SYSTEM DIAGRAM 215
DIFFERENTIAL LOCK CONTROL SYSTEM 217
SYSTEM DIAGRAM 217
DUMP CONTROL LEVER 220
FUNCTION 221
OPERATION 222
DUMP CONTROL LEVER OPERATED TO FLOAT 222
DUMP CONTROL LEVER FLOAT CANCELED 222
DUMP CONTROL LEVER OPERATED TO LOWER 222
DUMP CONTROL LEVER OPERATED TO RAISE 223
DUMP CONTROL LEVER RAISE CANCELED 223
20 TESTING, ADJUSTING AND TROUBLESHOOTING 225
STANDARD VALUE TABLE 227
FOR ENGINE 227
STANDARD VALUE TABLE 228
FOR CHASSIS 228
STANDARD VALUE TABLE 232
FOR ELECTRICAL COMPONENTS 232
TOOLS 246
FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 246
ENGINE COMPONENTS 248
MEASURING EXHAUST SMOKE 248
MEASURING EXHAUST TEMPERATURE 248
ADJUSTING VALVE CLEARANCE 248
MEASURING COMPRESSION PRESSURE 248
MEASURING CRANKCASE PRESSURE 248
MEASURING ENGINE OIL PRESSURE 248
MEASURING BOOST PRESSURE 248
MEASURING FUEL PRESSURE 248
BLEEDING AIR FROM FUEL SYSTEM 248
ADJUSTING ENGINE SPEED SENSOR 249
ADJUSTING ALTERNATOR BELT 251
ADJUSTING REFRIGERANT COMPRESSOR BELT 252
TESTING TORQUE CONVERTER STALL SPEED 253
MEASURING POWER TRAIN OIL PRESSURES 254
MEASURING POWER TRAIN MAIN RELIEF PRESSURE 255
MEASURING TORQUE CONVERTER “INLET” OIL PRESSURE 255
MEASURING TORQUE CONVERTER “OUTLET” OIL PRESSURE 255
MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE 256
MEASURING TRANSMISSION “LO” CLUTCH PRESSURE 257
MEASURING TRANSMISSION “HI” CLUTCH PRESSURE 257
MEASURING TRANSMISSION “1ST” CLUTCH PRESSURE 257
MEASURING TRANSMISSION “2ND” CLUTCH PRESSURE 258
MEASURING TRANSMISSION “3RD” CLUTCH PRESSURE 258
MEASURING TRANSMISSION “R” CLUTCH PRESSURE 259
MEASURING INTER-AXLE “DIFFERENTIAL LOCK” CLUTCH PRESSURE 259
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE 260
TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE 260
TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE 261
TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE 261
ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE 262
ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE 263
ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE 263
ADJUSTING TRANSMISSION SPEED SENSOR 264
TESTING AND ADJUSTING BRAKE OIL PRESSURE 266
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE 266
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP 266
MEASURING ACTUATION PRESSURE ON PARKING BRAKE 267
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID 268
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE 269
TESTING BRAKE PERFORMANCE 270
TESTING BRAKING PERFORMANCE OF FOOT BRAKE 270
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE 270
TESTING PARKING BRAKE BRAKING PERFORMANCE 271
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE 271
BLEEDING AIR FROM BRAKE CIRCUIT 272
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE 272
BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT 273
BLEEDING AIR FROM PARKING BRAKE CIRCUIT 273
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD 274
CHECKING BRAKE DISC 274
CHECKING BRAKE PAD 275
ADJUSTING PAD CLEARANCE 276
RELEASING EMERGENCY PARKING BRAKE 277
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE 278
MEASURING STEERING RELIEF OIL PRESSURE 278
ADJUSTING STEERING RELIEF OIL PRESSURE 279
TESTING AND ADJUSTING SUSPENSION CYLINDER 280
CHECKING CYLINDER LENGTH 280
RELEASING NITROGEN GAS 280
ADJUSTING OIL LEVEL 281
CHARGING WITH NITROGEN GAS 282
ADJUSTING CYLINDER LENGTH 283
TILTING THE CAB UP 284
PREPARATORY WORK 284
TILTING CAB UP 284
USING EXTERNAL CRANE 285
HOLDING CAB IN POSITION 285
LOWERING CAB DOWN 285
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE 286
TESTING DUMP MAIN RELIEF OIL PRESSURE 286
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE 286
MEASURING DUMP PILOT RELIEF OIL PRESSURE 287
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE 287
ADJUSTING BODY POSITIONER SENSOR 288
CHECKING SENSOR OUTPUT/INPUT VOLTAGE 288
ADJUSTING LINK LENGTH 288
CALIBRATING SYSTEM 289
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT 290
ADJUSTING TRANSMISSION CONTROLLER 291
SETTING ROTARY SWITCH 291
ADJUSTING TRANSMISSION 291
ESCAPE METHOD FOR ELECTRICAL SYSTEM 292
ADJUSTING MACHINE MONITOR 296
FUNCTIONS OF MACHINE MONITOR 300
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR 300
FLOW OF MODES AND FUNCTIONS 301
OPERATION AND DISPLAYS FOR OPERATOR MODE 303
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY 311
POINTS TO REMEMBER WHEN TROUBLESHOOTING 332
SEQUENCE OF EVENTS IN TROUBLESHOOTING 334
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 335
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT 335
HANDLING ELECTRONIC CONTROL UNIT 340
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 341
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 342
CHECKS BEFORE TROUBLESHOOTING 344
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS 345
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS 346
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS 348
CONNECTOR TYPES AND MOUNTING LOCATIONS 350
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 358
T-ADAPTER TABLE 382
CONNECTOR LAYOUT DRAWING 385
CONNECTOR ARRANGEMENT AND LOCATIONS 393
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM 399
CONTENT OF CODE DISPLAY (1) 402
CONTENT OF CODE DISPLAY (2) 404
CONTENT OF CODE DISPLAY (3) 406
CONTENT OF CODE DISPLAY (4) 408
CONTENT OF CODE DISPLAY (5) 410
CONTENT OF CODE DISPLAY (6) 412
INFORMATION CONTAINED IN TESTING PROCEDURES 414
(ENG-1) FAILURE CODE [A000N1] 416
ENGINE OVERSPEEDS (N1) 416
(ENG-2) FAILURE CODE [A570NX] 417
ENGINE OIL FILTER CLOG SENSOR SYSTEM 417
(ENG-3) FAILURE CODE [AD00L2] 418
COMMON RAIL HIGHER THAN SET VALUE 418
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3] 419
COMMON RAIL PRESSURE HIGH OR LOW 419
(ENG-6) FAILURE CODE [AD10MA] 421
(ENG-7) FAILURE CODE [AD10MB] 421
(ENG-8 OR 9) FAILURE CODE [AD11KA] OR [AD11KB] 422
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM 422
(ENG-10 OR 11) FAILURE CODE [AD51KA] OR [AD51KB] 424
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM 424
(ENG-12) FAILURE CODE [ADA1KA] 425
OPEN IN NO 1 INJECTOR SOLENOID VALVE 425
(ENG-13) FAILURE CODE [ADZKKB] 427
SHORT CIRCUIT IN NO 1, 2, 3 INJECTOR SOLENOID VALVE 427
(ENG-14) FAILURE CODE [ADB1KA] 430
OPEN IN NO 2 INJECTOR SOLENOID VALVE 430
(ENG-15) FAILURE CODE [ADC1KA] 432
OPEN IN NO 3 INJECTOR SOLENOID VALVE 432
(ENG-16) FAILURE CODE [ADD1KA] 434
OPEN IN NO 4 INJECTOR SOLENOID VALVE 434
(ENG-17) FAILURE CODE [ADDZKB] 436
SHORT CIRCUIT IN NO 4, 5, 6 INJECTOR SOLENOID VALVE 436
(ENG-18) FAILURE CODE [ADE1KA] 439
OPEN IN NO 5 INJECTOR SOLENOID VALVE 439
(ENG-19) FAILURE CODE [ADF1KA] 441
OPEN IN NO 6 INJECTOR SOLENOID VALVE 441
(ENG-20) FAILURE CODE [B@BAZG] 443
ENGINE OIL PRESSURE DROP (ZG) 443
(ENG-21) FAILURE CODE [B@BAZK] 445
ENGINE OIL LEVEL DROP (ZK) 445
(ENG-22) FAILURE CODE [B@BCNS] 446
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS) 446
(ENG-23) FAILURE CODE [D181KZ] 448
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) 448
(ENG-24) FAILURE CODE [D182KZ] 450
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) 450
(ENG-25) FAILURE CODE [D1D0KB] 452
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB) 452
(ENG-26) FAILURE CODE [D5ZAKX] 454
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX) 454
(ENG-27) FAILURE CODE [DB20KT] 456
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW 456
(ENG-28) FAILURE CODE [DB22KK] 457
DROP IN VOLTAGE LOAD POWER SUPPLY (KK) 457
(ENG-29) FAILURE CODE [DB29KQ] 459
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ) 459
(ENG-30) FAILURE CODE [DB2AMA] 461
“Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA) 461
(ENG-31) FAILURE CODE [KK11KB] 462
TROUBLE IN INPUT OF IGNITION SWITCH C (KB) 462
(ENG-32) FAILURE CODE [DDA1L5] 463
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5) 463
(ENG-33) FAILURE CODE [DDE2L6] 465
ENGINE OIL PRESSURE DROP (L6) 465
(ENG-34) FAILURE CODE [DGE2KX] 467
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX) 467
(ENG-35) FAILURE CODE [DGE3LC] 468
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6) 468
(ENG-36) FAILURE CODE [DGE4KX] 469
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX) 469
(ENG-37) FAILURE CODE [DH30KX] 470
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX) 470
(ENG-38) FAILURE CODE [DH40KX] 472
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX) 472
(ENG-39) FAILURE CODE [DK10KX] 474
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX) 474
(ENG-40) FAILURE CODE [DLE3LC] 476
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM 476
(ENG-41) FAILURE CODE [DLE1LC] 477
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC) 477
(ENG-42) NO FAILURE CODE DISPLAYED 478
ENGINE DOES NOT CRANK 478
CONNECTOR ARRANGEMENT AND LOCATIONS 485
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM 491
CONTENT OF CODE DISPLAY (1) 498
CONTENT OF CODE DISPLAY (2) 500
CONTENT OF CODE DISPLAY (3) 502
CONTENT OF CODE DISPLAY (4) 504
CONTENT OF CODE DISPLAY (5) 506
CONTENT OF CODE DISPLAY (6) 508
CONTENT OF CODE DISPLAY (7) 510
CONTENT OF CODE DISPLAY (8) 512
CONTENT OF CODE DISPLAY (9) 514
CONTENT OF CODE DISPLAY (10) 516
CONTENT OF CODE DISPLAY (11) 518
CONTENT OF CODE DISPLAY (12) 520
CONTENT OF CODE DISPLAY (13) 522
INFORMATION CONTAINED IN TESTING PROCEDURES 524
(TM-1) FAILURE CODE [1380MW] 526
LOCK-UP CLUTCH SLIPPING (MW) 526
(TM-2) FAILURE CODE [1500LO] 528
TRANSMISSION CLUTCH (LO) 528
(TM-3) FAILURE CODE [15BONX] 529
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX) 529
(TM-4) FAILURE CODE [15GOMW] 531
“R” CLUTCH SLIPPING (MW) 531
(TM-5) FAILURE CODE [15HOMW] 533
“HI” CLUTCH SLIPPING (MW) 533
(TM-6) FAILURE CODE [15JOMW] 535
“LO” CLUTCH SLIPPING (MW) 535
(TM-7) FAILURE CODE [15KOMW] 537
1ST CLUTCH SLIPPING (MW) 537
(TM-8) FAILURE CODE [15LOMW] 539
2ND CLUTCH SLIPPING (MW) 539
(TM-9) FAILURE CODE [15MOMW] 541
3RD CLUTCH SLIPPING (MW) 541
(TM-10) FAILURE CODE [15SBL1] 543
ECMV FOR “R” CLUTCH NOT DISENGAGING (L1) 543
(TM-11) FAILURE CODE [15SBMA] 545
ECMV FOR “R” CLUTCH NOT ENGAGING (MA) 545
(TM-12) FAILURE CODE [15SCL1] 547
ECMV “HI” CLUTCH NOT DISENGAGING (L1) 547
(TM-13) FAILURE CODE [15SCMA] 549
ECMV “HI” CLUTCH NOT DISENGAGING (MA) 549
(TM-14) FAILURE CODE [15SDL1] 551
ECMV “LO” CLUTCH NOT DISENGAGING (L1) 551
(TM-15) FAILURE CODE [15SDMA] 553
ECMV “LO” CLUTCH NOT ENGAGING (MA) 553
(TM-16) FAILURE CODE [15SEL1] 555
ECMV “1ST ” CLUTCH NOT DISENGAGING (L1) 555
(TM-17) FAILURE CODE [15SEMA] 557
ECMV “1ST ” CLUTCH NOT ENGAGING (MA) 557
(TM-18) FAILURE CODE [15SFL1] 559
ECMV “2ND ” CLUTCH NOT DISENGAGING (L1) 559
(TM-19) FAILURE CODE [15SFMA] 561
ECMV “2ND ” CLUTCH NOT ENGAGING (MA) 561
(TM-20) FAILURE CODE [15SGL1] 563
ECMV “3RD ” CLUTCH NOT DISENGAGING (L1) 563
(TM-21) FAILURE CODE [15SGMA] 565
ECMV “3RD ” CLUTCH NOT ENGAGING (MA) 565
(TM-22) FAILURE CODE [15SJL1] 567
ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1) 567
(TM-23) FAILURE CODE [15SJMA] 569
ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA) 569
(TM-24) FAILURE CODE [15SKL1] 571
ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1) 571
(TM-25) FAILURE CODE [15SKMA] 573
ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA) 573
(TM-26) FAILURE CODE [2B61MW] 575
ECMV “INTER-AXLE” CLUTCH SLIPPING (MW) 575
(TM-27) FAILURE CODE [2F00KM] 577
PARKING BRAKE SYSTEM INDICATING FAILURE (KM) 577
(TM-28) FAILURE CODE [6014NX] 579
HYDRAULIC TANK FILTER CLOGGED (NX) 579
(TM-29) FAILURE CODE [989A00] 581
POSSIBLE ENGINE OVER SPEED CONDITION (00) 581
(TM-30) FAILURE CODE [989AKZ] 582
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ) 582
(TM-31)FAILURE CODE [989D00] 584
REAR OVERTURN SIGNAL OUT OF RANGE (00) 584
(TM-32)FAILURE CODE [AA10NX] 586
AIR CLEANER CLOG INDICATION (NX) 586
(TM-33) FAILURE CODE [AB00MA] 588
ALTERNATOR NOT CHARGING PROPERLY (MA) 588
(TM-34) FAILURE CODE [B@BCZK] 589
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK) 589
(TM-35) FAILURE CODE [B@HAZK] 591
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK) 591
(TM-36) FAILURE CODE [B@JANS] 592
STEERING OIL OVERHEAT CONDITION INDICATED (ZK) 592
(TM-37) FAILURE CODE [D1B0KZ] 593
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ) 593
(TM-38) FAILURE CODE [D5ZBKX] 595
DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX) 595
(TM-39) FAILURE CODE [D5ZCKZ] 597
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ) 597
(TM-40) FAILURE CODE [DF10KA] 599
FORCED NEUTRAL DEMAND SIGNAL (L4) 599
(TM-41) FAILURE CODE [D5ZEKX] 601
ENGINE LOAD SIGNAL OUT OF RANGE (KX) 601
(TM-42) FAILURE CODE [DAQ0KK] 603
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 603
(TM-43) FAILURE CODE [DAQ1KK] 605
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 605
(TM-44) FAILURE CODE [DAQ2KK] 607
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK) 607
(TM-45) FAILURE CODE [DAQ3KK] 609
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 609
(TM-46) FAILURE CODE [DAQ5KP] 611
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP) 611
(TM-47) FAILURE CODE [DAQ9KM] 613
MISTAKEN OPERATION SETTING (KP) 613
(TM-48) FAILURE CODE [DAQ9KM] 614
NO MATCH IN MODEL SELECTION SIGNAL (KP) 614
(TM-49) FAILURE CODE [DAQAKQ] 615
TRANSMISSION CONTROLLER ROTARY SWITCH 615
(TM-50) FAILURE CODE [DAQSMA] 615
TRANSMISSION FUNCTION INOPERABLE 615
(TM-51) FAILURE CODE [DDTFKA] 616
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) 616
(TM-52) FAILURE CODE [DDTFKA] 618
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) 618
(TM-53) FAILURE CODE [DDTHKA] 620
“HI” CLUTCH SYSTEM OPEN OR SHORTED (KA) 620
(TM-54) FAILURE CODE [DDTJKA] 622
“LO” CLUTCH SYSTEM OPEN OR SHORTED (KA) 622
(TM-55) FAILURE CODE [DDTKKA] 624
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA) 624
(TM-56) FAILURE CODE [DDTLKA] 626
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) 626
(TM-57) FAILURE CODE [DDTMKA] 628
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA) 628
(TM-58) FAILURE CODE [DDTNKA] 630
“R” CLUTCH SYSTEM OPEN OR SHORTED (KA) 630
(TM-59) FAILURE CODE [DF10KA] 632
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) 632
(TM-60) FAILURE CODE [DF10KB] 634
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) 634
(TM-61) FAILURE CODE [DGF1KX] 636
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX) 636
(TM-63) FAILURE CODE [DGR3L8] 637
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) 637
(TM-64) FAILURE CODE [DGR4L8] 639
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) 639
(TM-65) FAILURE CODE [DGT1LX] 641
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX) 641
(TM-66) FAILURE CODE [DHT5KX] 642
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX) 642
(TM-67) FAILURE CODE [DHT5L6] 644
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6) 644
(TM-68) FAILURE CODE [DJF1KA] 646
FUEL LEVEL SENSOR OUT OF RANGE (L6) 646
(TM-69) FAILURE CODE [DK11KX] 648
THROTTLE ANGLE SENSOR OUT OF RANGE (KX) 648
(TM-70) FAILURE CODE [DLE2KA] 650
ENGINE SPEED SENSOR OPEN OR SHORTED (KA) 650
(TM-71) FAILURE CODE [DLE2LC] 651
ENGINE SPEED SENSOR OPEN OR SHORTED (LC) 651
(TM-72) FAILURE CODE [DLF1KA] 652
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 652
(TM-73) FAILURE CODE [DLF1LC] 653
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 653
(TM-74) FAILURE CODE [DLF2KA] 654
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 654
(TM-75) FAILURE CODE [DLF2LC] 655
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 655
(TM-76) FAILURE CODE [DLT3KA] 656
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 656
(TM-77) FAILURE CODE [DLT3LC] 658
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 658
(TM-78) FAILURE CODE [DXH0KA] 660
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA) 660
(TM-79) FAILURE CODE [DXH0KB] 662
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB) 662
(TM-80) FAILURE CODE [DXH1KA] 664
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA) 664
(TM-81) FAILURE CODE [DXH1KB] 666
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB) 666
(TM-82) FAILURE CODE [DXH2KA] 668
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA) 668
(TM-83) FAILURE CODE [DXH2KB] 670
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB) 670
(TM-84) FAILURE CODE [DXH3KA] 672
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA) 672
(TM-85) FAILURE CODE [DXH3KB] 674
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB) 674
(TM-86) FAILURE CODE [DXH4KA] 676
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA) 676
(TM-87) FAILURE CODE [DXH4KB] 678
1ST CLUTCH SYSTEM OPEN OR SHORTED (KB) 678
(TM-88) FAILURE CODE [DXH5KA] 680
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) 680
(TM-89) FAILURE CODE [DXH5KB] 682
2ND CLUTCH SYSTEM OPEN OR SHORTED (KB) 682
(TM-90) FAILURE CODE [DXH6KA] 684
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB) 684
(TM-91) FAILURE CODE [DXH6KB] 686
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB) 686
(TM-92) FAILURE CODE [DXH7KA] 688
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA) 688
(TM-93) FAILURE CODE [DXH7KB] 690
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB) 690
(TM-94) NO FAILURE CODE DISPLAYED 692
BACK-UP LIGHTS AND ALARM DO NOT OPERATE 692
CONNECTOR ARRANGEMENT AND LOCATIONS 697
BK CONTROL SYSTEM CIRCUIT DIAGRAM 703
CONTENT OF CODE DISPLAY (1) 710
CONTENT OF CODE DISPLAY (2) 712
CONTENT OF CODE DISPLAY (3) 714
CONTENT OF CODE DISPLAY (4) 716
CONTENT OF CODE DISPLAY (5) 718
CONTENT OF CODE DISPLAY (6) 720
CONTENT OF CODE DISPLAY (7) 722
INFORMATION CONTAINED IN TESTING PROCEDURES 724
(BK-1) FAILURE CODE [2A62L1] 726
FRONT DIFFERENTIAL CONTROL VALVE (L1) 726
(BK-2) FAILURE CODE [2A62LH] 728
FRONT DIFFERENTIAL CONTROL VALVE (LH) 728
(BK-3) FAILURE CODE [2B62L1] 730
REAR DIFFERENTIAL LOCK CONTROL VALVE (L1) 730
(BK-4) FAILURE CODE [2B62LH] 732
REAR DIFFERENTIAL LOCK CONTROL VALVE (LH) 732
(BK-5) FAILURE CODE [2C4MNX] 734
BRAKE COOLING FILTER CLOG INDICATED (NX) 734
(BK-6) FAILURE CODE [2D02CA] 736
LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) 736
(BK-7) FAILURE CODE [2D01CA] 737
RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) 737
(BK-8) FAILURE CODE [2D03CA] 738
CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) 738
(BK-9) FAILURE CODE [2D04CA] 739
CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA) 739
(BK-12) FAILURE CODE [2G42ZG] 740
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG) 740
(BK-13) FAILURE CODE [2G43ZG] 741
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG) 741
(BK-14) FAILURE CODE [D1C0KZ] 742
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ) 742
(BK-15) FAILURE CODE [D5ZFKZ] 744
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) 744
(BK-16) FAILURE CODE [D5ZGKZ] 746
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) 746
(BK-17) FAILURE CODE [DB10KK] 748
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 748
(BK-18) FAILURE CODE [DB11KK] 750
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 750
(BK-19) FAILURE CODE [DB12KK] 752
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK) 752
(BK-20) FAILURE CODE [DB13KK] 754
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 754
(BK-21) FAILURE CODE [DB19KM] 756
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM) 756
(BK-22) FAILURE CODE [DB1SKQ] 757
RETARDER CONTROL S-NET LINE MISMATCHED (KQ) 757
(BK-23) FAILURE CODE [DHU2KX] 758
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX) 758
(BK-24) FAILURE CODE [DHU3KX] 760
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX) 760
(BK-25) FAILURE CODE [DK51L5] 762
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB) 762
(BK-26) FAILURE CODE [DK52KX] 764
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX) 764
(BK-27) FAILURE CODE [DK53L8] 766
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8) 766
(BK-28) FAILURE CODE [DK54KX] 768
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX) 768
(BK-29) FAILURE CODE [DLF4KA] 770
TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA) 770
(BK-30) FAILURE CODE [DLT3KA] 771
TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA) 771
(BK-31) FAILURE CODE [DW71KZ] 773
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ) 773
(BK-32) FAILURE CODE [DK72KX] 774
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ) 774
(BK-33) FAILURE CODE [DW73KZ] 776
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ) 776
(BK-34) FAILURE CODE [DX11KA] 778
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) 778
(BK-35) FAILURE CODE [DX11KB] 779
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) 779
(BK-36) FAILURE CODE [DX11KY] 780
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY) 780
(BK-37) FAILURE CODE [DX12KA] 781
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) 781
(BK-38) FAILURE CODE [DX12KB] 782
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) 782
(BK-39) FAILURE CODE [DX13KA] 783
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA) 783
(BK-40) FAILURE CODE [DX13KB] 785
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB) 785
(BK-41) FAILURE CODE [DX13KY] 787
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY) 787
(BK-42) FAILURE CODE [DX14KZ] 789
REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) 789
(BK-43) FAILURE CODE [DX15KZ] 790
FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) 790
(BK-44) NO FAILURE CODE DISPLAYED 792
PARKING BRAKE SYSTEM FAILURE 792
CONNECTOR ARRANGEMENT AND LOCATIONS 797
MON CONTROL SYSTEM CIRCUIT DIAGRAM 803
CONTENT OF CODE DISPLAY (1) 808
INFORMATION CONTAINED IN TESTING PROCEDURES 810
(MON-1) FAILURE CODE [B@C6NS] 812
FRONT BRAKE OIL OVERHEAT CONDITION (NS) 812
(MON-3) FAILURE CODE [B@C8NS] 813
CENTER BRAKE OIL OVERHEAT CONDITION (NS) 813
(MON-4) FAILURE CODE [B@CENS] 814
TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS) 814
(MON-5) FAILURE CODE [DAF0KM] 815
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) 815
(MON-6) FAILURE CODE [DAF9KM] 817
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) 817
(MON-7) FAILURE CODE [DAFSKQ] 818
MODEL SELECTION DOES NOT MATCH (KQ) 818
(MON-8) FAILURE CODE [AQSKR] 819
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 819
(MON-9) FAILURE CODE [DA1SKR] 821
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 821
(MON-10) FAILURE CODE [DA2SKR] 823
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 823
(MON-11) FAILURE CODE [DV00KB] 825
DEFECTIVE ALARM BUZZER (KB) 825
(MON-12) NO FAILURE CODE DISPLAYED 827
WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL 827
(MON-13) NO FAILURE CODE DISPLAYED 829
WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL 829
(MON-14) NO FAILURE CODE DISPLAYED 831
ALARM BUZZER DOES NOT SOUND 831
(MON-15) NO FAILURE CODE DISPLAYED 833
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL 833
(MON-16) NO FAILURE CODE DISPLAYED 834
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED 834
(MON-17) NO FAILURE CODE DISPLAYED 835
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE 835
(MON-18) NO FAILURE CODE DISPLAYED 837
POWER MODE SWITCH DOES NOT WORK PROPERLY 837
(MON-19) NO FAILURE CODE DISPLAYED 838
AISS FUNCTION DOES NOT WORK PROPERLY 838
(MON-20) NO FAILURE CODE DISPLAYED 839
RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROPERLY 839
(MON-20) NO FAILURE CODE DISPLAYED 841
LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK PROPERLY 841
(MON-21) NO FAILURE CODE DISPLAYED 843
INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY 843
(MON-22) NO FAILURE CODE DISPLAYED 844
EXHAUST BRAKE DOES NOT WORK PROPERLY 844
(MON-23) NO FAILURE CODE DISPLAYED 846
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY 846
(MON-24) NO FAILURE CODE DISPLAYED 847
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY 847
(MON-25) NO FAILURE CODE DISPLAYED 850
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY 850
(H-1) 856
THE MACHINE DOES NOT MOVE 856
(H-2) AND (H-3) 857
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY) 857
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING) 857
(H-4) AND (H-5) 858
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS 858
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE 858
(H-6) 859
MACHINE LACKS POWER OR SPEED WHEN TRAVELING 859
(H-6) 860
ABNORMAL OPERATION AT SOME SPEED RANGES 860
(H-6) 861
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE 861
(H-7) 862
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES 862
(H-8) 863
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH) 863
(H-9) 864
TORQUE CONVERTER OIL PRESSURE LOW 864
(H-10) 865
FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY 865
(H-11) 866
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE 866
(H-12) 867
STEERING EFFORT SEeMS HEAVY 867
(H-13) 868
STEERING SYSTEM DOES NOT OPERATE 868
(H-14) 869
STEERING WHEEL VIBRATES 869
(H-15) 870
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER 870
(H-16) 871
DUMP OPERATIONS DO NOT WORK 871
(H-17) 872
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY 872
30 DISASSEMBLY AND ASSEMBLY 873
HOW TO USE MANUAL 876
PRECAUTIONS WHEN CARRYING OUT REPAIR 877
SPECIAL TOOL LIST 880
SKETCHES OF SPECIAL TOOLS 885
CONNECTOR REPAIR PROCEDURES 897
CONTACT TERMINAL REMOVAL (HD30 TYPE) 897
STRIPING INSULATION 898
CRIMPING CONTACT TERMINAL (HD30 TYPE) 899
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 900
CONTACT TERMINAL REMOVAL (DT TYPE) 901
STRIPING INSULATION 902
CRIMPING CONTACT TERMINAL (DT TYPE) 903
INSERTION OF CONTACT TERMINAL (DT TYPE) 904
ENGINE REMOVAL AND INSTALLATION PROCEDURES 905
REMOVAL 905
INSTALLATION 908
RADIATOR REMOVAL AND INSTALLATION PROCEDURES 910
REMOVAL 910
INSTALLATION 912
OUTPUT SHAFT SYSTEM 913
REMOVAL 913
INSTALLATION 915
OUTPUT SHAFT DIAGRAM 917
OUTPUT SHAFT ASSEMBLY PROCEDURES 918
TRANSMISSION AND FRONT DIFFERENTIAL 921
REMOVAL 921
INSTALLATION 928
SPLITTING DIFFERENTIAL AND TRANSMISSION ASSEMBLY 930
SEPARATING 930
REATTACHING 931
TORQUE CONVERTER OVERHAUL PROCEDURES 932
DISASSEMBLY 932
ASSEMBLY 937
TRANSMISSION OVERHAUL PROCEDURES 942
DISASSEMBLY 942
ASSEMBLY 960
FRONT DIFFERENTIAL OVERHAUL PROCEDURES 991
DISASSEMBLY 991
ASSEMBLY 1000
CENTER DIFFERENTIAL 1014
REMOVAL 1014
REMOVING DIFFERENTIAL COUPLING FLANGE 1016
INSTALLATION 1017
OVERHAUL PROCEDURES 1019
DISASSEMBLY 1019
ASSEMBLY 1026
REAR DIFFERENTIAL 1038
REMOVAL 1038
INSTALLATION 1039
OVERHAUL PROCEDURES 1040
DISASSEMBLY 1040
ASSEMBLY 1044
FRONT FINAL DRIVE AND BRAKE 1053
REMOVAL 1053
INSTALLATION 1055
OVERHAUL PROCEDURES 1056
DISASSEMBLY 1056
ASSEMBLY 1063
CENTER FINAL DRIVE AND BRAKE 1073
REMOVAL 1073
INSTALLATION 1074
OVERHAUL PROCEDURES 1075
DISASSEMBLY 1075
ASSEMBLY 1081
REAR FINAL DRIVE 1090
REMOVAL 1090
INSTALLATION 1091
OVERHAUL PROCEDURES 1092
DISASSEMBLY 1092
ASSEMBLY 1094
AXLE REMOVAL AND INSTALLATION PROCEDURES 1100
CENTER AXLE REMOVAL 1100
CENTER AXLE INSTALLATION 1103
REAR AXLE REMOVAL 1104
REAR AXLE INSTALLATION 1106
PARKING BRAKE SYSTEM 1107
REMOVAL 1107
INSTALLATION 1108
CALIPER OVERHAUL PROCEDURES 1109
DISASSEMBLY 1109
ASSEMBLY 1109
BRAKE PAD REPLACEMENT 1111
REMOVAL 1111
INSTALLATION 1111
SUSPENSION SYSTEM 1112
FRONT CYLINDER REMOVAL 1112
FRONT CYLINDER INSTALLATION 1113
REAR CYLINDER REMOVAL 1113
REAR CYLINDER INSTALLATION 1114
EQUALIZER BAR REMOVAL 1114
EQUALIZER BAR INSTALLATION 1116
TRUCK WHEELS 1117
FRONT WHEEL REMOVAL 1117
INSTALLATION OF FRONT WHEEL 1117
REAR TANDEM WHEELS 1118
CENTER WHEEL REMOVAL 1118
CENTER WHEEL INSTALLATION 1118
REAR WHEEL REMOVAL 1118
REAR WHEEL INSTALLATION 1118
ARTICULATED HITCH SYSTEM 1119
REMOVAL 1119
INSTALLATION 1124
OVERHAUL PROCEDURES 1126
DISASSEMBLY 1126
ASSEMBLY 1127
ORBITAL STEERING UNIT 1130
UNIT BREAKDOWN VIEW 1130
OVERHAUL PROCEDURES 1132
DISASSEMBLY 1132
ASSEMBLY 1135
FLOW AMPLIFIER VALVE 1141
REMOVAL 1141
INSTALLATION 1141
HOIST VALVE UNIT 1142
REMOVAL 1142
INSTALLATION 1142
OVERHAUL PROCEDURES 1143
DISASSEMBLY 1143
ASSEMBLY 1144
HYDRAULIC CYLINDER OVERHAUL PROCEDURES 1145
STEERING CYLINDER DISASSEMBLY 1145
STEERING CYLINDER ASSEMBLY 1146
HOIST CYLINDER DISASSEMBLY 1149
HOIST CYLINDER ASSEMBLY 1151
TRUCK BODY ASSEMBLY 1155
REMOVAL 1155
INSTALLATION 1156
OPERATOR’S SEAT 1157
DISASSEMBLY 1157
ASSEMBLY 1164
90 OTHERS 1171
CAB 1173
CLIMATE CONTROL SYSTEM 1173
CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER 1175
CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER 1177
LIGHTING WIPER AND RELAY BANK 1179
RELAY AND SWITCH CIRCUITS 1181
MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS 1183
DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS 1185
DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT 1187
RETARDER SYSTEM 1189
RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING 1191
TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL 1193
TRANSMISSION CONTROLLER 1195
TO HARNESS OUTSIDE OF CAB 1197
TO HARNESS OUTSIDE OF CAB AND TO ENGINE 1199
CHASSIS 1201
SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OF CAB 1201
TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS 1203
TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS 1205
CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS 1207
CHASSIS SENSOR SYSTEMS 1209
CONNECTORS OUTSIDE OF CAB 1211
ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS 1213
DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM 1215
BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR 1217
TRANSMISSION SELECTOR SYSTEM 1219

S.V 15/12/24