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KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD
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- KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM000704
- MACHlNE MODEL SERIAL NUMBER
HD325-6 (2WD) 5001 and up
HD325-6W (4WD) 5001 and up
HD405-6 1001 and up
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Description
KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL
KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use It to full effect at every opportunity.
This shop manual mainly contains the necessary technical Information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes’ are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component. as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU HD325-6 HD405-6 SERVICE REPAIR MANUAL
COVER................................................................................................................................................................................ 1 CONTENTS............................................................................................................................................................................. 2 01 GENERAL........................................................................................................................................................................... 24 DIMENSIONS....................................................................................................................................................................... 25 SPECIFICATIONS................................................................................................................................................................... 27 WEIGHT TABLE..................................................................................................................................................................... 33 TABLE OF OIL COOLANT QUANTITIES.................................................................................................................................................. 35 10 STRUCTURE AND FUNCTION............................................................................................................................................................ 37 RADIATOR,TORQUE CONVERTER,BRAKE OIL COOLER,AFTER COOLER.......................................................................................................................... 39 POWER TRAIN SKELETON............................................................................................................................................................. 40 OUTPUT SHAFT..................................................................................................................................................................... 43 DRIVE SHAFT...................................................................................................................................................................... 44 TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING HYDRAULIC PIPING................................................................................................................. 45 HYDRAULIC CIRCUIT DIAGRAM FOR TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING.................................................................................................... 46 TORQUE CONVERTER,TRANSMISSION AND BRAKE COOLING HYDRAULIC CIRCUIT SCHEMATICS..................................................................................................... 47 TORQUE CONVERTER................................................................................................................................................................. 48 TORQUE CONVERTER VALVE........................................................................................................................................................... 51 LOCKUP SOLENOID VALVE............................................................................................................................................................ 56 TRANSMISSION..................................................................................................................................................................... 57 TRANSMISSION VALVE............................................................................................................................................................... 60 ECMV(ELECTRONIC CONTROL MODULATION VALVE)........................................................................................................................................ 61 FRONT AXLE....................................................................................................................................................................... 66 REAR AXLE........................................................................................................................................................................ 68 DIFFERENTIAL..................................................................................................................................................................... 69 FINAL DRIVE...................................................................................................................................................................... 73 FRONT BRAKE...................................................................................................................................................................... 74 REAR BRAKE....................................................................................................................................................................... 75 PARKING BRAKE.................................................................................................................................................................... 76 WHEELS........................................................................................................................................................................... 77 AXLE SUPPORT..................................................................................................................................................................... 78 STEERING SYSTEM.................................................................................................................................................................. 79 STEERING WHEEL................................................................................................................................................................... 80 STEERING LINKAGE................................................................................................................................................................. 81 SUSPENSION SYSTEM................................................................................................................................................................ 83 SUSPENSION CYLINDER.............................................................................................................................................................. 85 AIR PIPING....................................................................................................................................................................... 92 AIR CIRCUIT DIAGRAM.............................................................................................................................................................. 96 AIR GOVERNOR..................................................................................................................................................................... 100 AIR DRIER........................................................................................................................................................................ 102 SAFETY VALVE..................................................................................................................................................................... 104 CHECK VALVE...................................................................................................................................................................... 104 DOUBLE-CHECK VALVE............................................................................................................................................................... 105 PROTECTION VALVE................................................................................................................................................................. 106 HAND BRAKE VALVE(RETARDER CONTROL VALVE)......................................................................................................................................... 107 BRAKE VALVE...................................................................................................................................................................... 109 2-WAY CONTROL VALVE(PARKING BRAKE VALVE,EMERGENCY BRAKE VALVE)................................................................................................................... 112 EMERGENCY BRAKE CONTROL VALVE(VARIABLE CONTROL TYPE)............................................................................................................................. 114 RELAY VALVE(ACTS ALSO AS EMERGENCY RELAY)........................................................................................................................................ 117 PARKING BRAKE RELAY VALVE........................................................................................................................................................ 120 FRONT BRAKE CHAMBER.............................................................................................................................................................. 122 REAR BRAKE CHAMBER............................................................................................................................................................... 123 BRAKE CHAMBER.................................................................................................................................................................... 123 PARKING BRAKE CHAMBER............................................................................................................................................................ 126 SLACK ADJUSTER................................................................................................................................................................... 127 HYDRAULIC CIRCUIT DIAGRAM(FRONT DRIVE)........................................................................................................................................... 129 HYDRAULIC PIPING DIAGRAM(FRONT DRIVE)............................................................................................................................................ 130 PISTON PUMP(FRONT DRIVE)......................................................................................................................................................... 132 PISTON MOTOR(FRONT DRIVE)........................................................................................................................................................ 134 CHARGE PUMP OIL FILTER........................................................................................................................................................... 136 HYDRAULIC PIPING(STEERING AND HOIST)............................................................................................................................................. 137 HYDRAULIC CIRCUIT DIAGRAM(STEERING AND HOIST).................................................................................................................................... 138 HYDRAULIC CIRCUIT SCHEMATICS..................................................................................................................................................... 139 DUMP BODY CONTROL................................................................................................................................................................ 140 HYDRAULIC TANK,FILTER............................................................................................................................................................ 141 DEMAND VALVE..................................................................................................................................................................... 142 STEERING CONTROL VALVE........................................................................................................................................................... 146 CROSS-OVER RELIEF VALVE.......................................................................................................................................................... 150 HOIST VALVE...................................................................................................................................................................... 151 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................................................... 152 FRONT BRAKE CUT-OFF VALVE........................................................................................................................................................ 160 AUTOMATIC RETARDER VALVE......................................................................................................................................................... 161 EXHAUST BRAKE VALVE.............................................................................................................................................................. 161 HORN VALVE....................................................................................................................................................................... 162 WIPER SWITCH..................................................................................................................................................................... 162 WIPER RELAY...................................................................................................................................................................... 163 AIR CONDITIONER.................................................................................................................................................................. 164 PIPING DIAGRAM............................................................................................................................................................... 164 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................... 165 REFRIGERANT CIRCUIT DIAGRAM.................................................................................................................................................. 165 UNIT......................................................................................................................................................................... 166 RECEIVER DRYER............................................................................................................................................................... 166 CONDENSER.................................................................................................................................................................... 167 COMPRESSOR................................................................................................................................................................... 167 ENGINE CONTROL SYSTEM............................................................................................................................................................ 168 EXHAUST BRAKE.................................................................................................................................................................... 169 SYSTEM DIAGRAM............................................................................................................................................................... 169 AUTOMATIC SHIFT CONTROL SYSTEM................................................................................................................................................... 172 TRANSMISSION CONTROLLER.......................................................................................................................................................... 174 SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES......................................................................................................................... 175 SHIFT LEVER SWITCH............................................................................................................................................................... 178 SENSORS,SWITCHES................................................................................................................................................................. 179 TRANSMISSION SPEED SENSOR.................................................................................................................................................... 179 TRANSMISSION OIL TEMPERATURE SENSOR.......................................................................................................................................... 179 FILL SWITCH.................................................................................................................................................................. 180 ACCELERATOR SENSOR........................................................................................................................................................... 180 SHIFT LIMIT SWITCH........................................................................................................................................................... 181 MODE SELECTOR SWITCH......................................................................................................................................................... 181 AUTOMATIC EMERGENCY STEERING SYSTEM.............................................................................................................................................. 182 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................... 183 FLOW SWITCH.................................................................................................................................................................. 184 RELAY TIMER.................................................................................................................................................................. 186 AUTOMATIC SUSPENSION SYSTEM...................................................................................................................................................... 187 STRUCTURE OF SYSTEM.......................................................................................................................................................... 187 AUTOMATIC SUSPENSION MODE SELECTION CONTROL.................................................................................................................................. 189 SUSPENSION CONTROLLER........................................................................................................................................................ 190 SENSORS,SWITCHES............................................................................................................................................................. 191 STEERING ANGLE SENSOR.................................................................................................................................................... 191 PRESSURE SENSOR.......................................................................................................................................................... 191 PAYLOAD METER.................................................................................................................................................................... 192 STRUCTURE OF SYSTEM.......................................................................................................................................................... 192 PRINCIPLE OF CALCULATION..................................................................................................................................................... 193 FEATURES OF EQUIPMENT........................................................................................................................................................ 195 ELECTRONIC MONITOR SYSTEM........................................................................................................................................................ 200 ELECTRONIC MONITOR PANEL..................................................................................................................................................... 201 ELECTRONIC MONITOR DISPLAYS,FUNCTIONS........................................................................................................................................ 202 SENSORS,SWITCHES............................................................................................................................................................. 206 ENGINE SPEED SENSOR...................................................................................................................................................... 206 ENGINE OIL PRESSURE SENSOR............................................................................................................................................... 206 ENGINE WATER TEMPERATURE SENSOR.......................................................................................................................................... 207 RETARDER OIL TEMPERATURE SENSOR.......................................................................................................................................... 207 TORQUE CONVERTER OIL TEMPERATURE SENSOR.................................................................................................................................. 207 AIR PRESSURE SENSOR...................................................................................................................................................... 207 FUEL LEVEL SENSOR........................................................................................................................................................ 208 RADIATOR WATER LEVEL SENSOR.............................................................................................................................................. 209 TRANSMISSION OIL FILTER SENSOR........................................................................................................................................... 209 TRANSMISSION FILTER OIL TEMPERATURE SWITCH............................................................................................................................... 210 BODY RAISE SWITCH,BODY FLOAT SWITCH...................................................................................................................................... 210 STOP LAMP SWITCH......................................................................................................................................................... 211 EXHAUST BRAKE SWITCH..................................................................................................................................................... 211 TILT SWITCH.............................................................................................................................................................. 211 PARKING BRAKE SWITCH..................................................................................................................................................... 212 BIMETAL TIMER............................................................................................................................................................ 212 DIODE.................................................................................................................................................................... 213 LAMP..................................................................................................................................................................... 214 LAMP CHECK SWITCH........................................................................................................................................................ 216 DIMMER SWITCH............................................................................................................................................................ 216 COMBINATION SWITCH....................................................................................................................................................... 217 RELAY SWITCH............................................................................................................................................................. 218 BUZZER................................................................................................................................................................... 219 MAINTENANCE MONITOR SYSTEM....................................................................................................................................................... 220 SYSTEM DIAGRAM............................................................................................................................................................... 220 MONITOR PANEL................................................................................................................................................................ 221 MAINTENACE MONITOR CIRCUIT DIAGRAM........................................................................................................................................... 222 MONITOR DISPLAY,FUNCTIONS.................................................................................................................................................... 223 FUNCTIONS OF SWITCHES........................................................................................................................................................ 225 SENSORS,SWITCHES............................................................................................................................................................. 227 ENGINE OIL LEVEL SENSOR.................................................................................................................................................. 227 TRANSMISSION OIL LEVEL SENSOR............................................................................................................................................ 227 HYDRAULIC OIL LEVEL SENSOR............................................................................................................................................... 228 AIR FILTER CLOGGING SENSOR............................................................................................................................................... 228 RETARDER BRAKE WEAR SENSOR............................................................................................................................................... 229 HYDRAULIC FILTER SENSOR ................................................................................................................................................. 229 TRANSMISSION OIL FILTER SENSOR........................................................................................................................................... 229 BATTERY ELECTROLYTE LEVEL SENSOR......................................................................................................................................... 230 FULL-FLOW FILTER SENSOR.................................................................................................................................................. 230 FRONT DRIVE SYSTEM............................................................................................................................................................... 231 SYSTEM DIAGRAM............................................................................................................................................................... 231 GERNERAL LOCATIONS FOR ELECTRICAL COMPONENTS................................................................................................................................. 232 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................................... 233 4-WHEEL DRIVE CONTROLLER..................................................................................................................................................... 234 ECMV......................................................................................................................................................................... 235 SENSORS,SWITCHES............................................................................................................................................................. 236 STEERING ANGLE SENSOR(POTENTIOMETER)..................................................................................................................................... 236 HIGH-PRESSURE OIL PRESSURE SENSOR........................................................................................................................................ 237 CLUTCH OIL PRESSURE SENSOR............................................................................................................................................... 237 WHEEL SPEED SENSOR....................................................................................................................................................... 238 20 TESTING AND ADJUSTING............................................................................................................................................................. 239 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.................................................................................................................................... 240 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................................................. 242 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....................................................................................................................................... 250 TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING.................................................................................................................................. 258 ADJUSTING VALVE CLEARANCE........................................................................................................................................................ 260 MEASURING COMPRESSION PRESSURE................................................................................................................................................... 261 MEASURING BLOW-BY................................................................................................................................................................ 262 ADJUTING TENSION OF ALTERNATOR DRIVE BELT........................................................................................................................................ 263 MEASURING ENGINE SPEED........................................................................................................................................................... 264 MEASURING ENGINE OIL PRESSURE.................................................................................................................................................... 265 MEASURING BOOST PRESSURE......................................................................................................................................................... 266 MEASURING EXHAUST TEMPERATURE.................................................................................................................................................... 267 MEASURING EXHAUST GAS COLOR...................................................................................................................................................... 268 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................................................................... 269 AIR BLEEDING FROM FUEL SYSTEM.................................................................................................................................................... 272 ADJUSTING ENGINE STOP MOTOR CABLE................................................................................................................................................ 273 ADJUSTING ACCELERATOR PEDAL...................................................................................................................................................... 274 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................................................... 275 TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE............................................................................................................................. 276 MEASURING FRONT DRIVE CLUTCH OIL PRESSURE........................................................................................................................................ 277 TESTING HYDRAULIC PRESSURE OF TRANSMISSION VALVE................................................................................................................................. 278 TESTING ECMV OIL PRESSURE........................................................................................................................................................ 279 TESTING TORQUE CONVERTER STALL SPEED............................................................................................................................................. 281 TESTING BRAKE PRESSURE........................................................................................................................................................... 282 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................. 284 TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE.................................................................................................................................. 285 TESTING WEAR OF FRONT BRAKE PAD.................................................................................................................................................. 286 TESTING WEAR OF FRONT BRAKE DISC................................................................................................................................................. 286 TESTING AND ADJUSTING SUSPENSION CYLINDER........................................................................................................................................ 288 TESTING AND ADJUSTING SET PRESSURE OF AIR GOVERNOR............................................................................................................................... 300 ADJUSTING HOIST LEVER LINKAGE.................................................................................................................................................... 301 ADJUSTING BODY POSITIONER........................................................................................................................................................ 302 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING,HOIST CIRCUIT............................................................................................................... 303 AIR BLEEDING FROM STEERING CYLINDER.............................................................................................................................................. 305 BLEEDING AIR FROM DRIVE HYDRAULIC CIRCUIT........................................................................................................................................ 306 ADJUSTING ELECTRONIC MONITOR..................................................................................................................................................... 308 METHOD FOR EMERGENCY OPERATION OF TRUCK WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM OF TRANSMISSION CONTROL SYSTEM................................................................ 309 PROCEDURE FOR OPERATING SHIFT CHECKER AND MODULATION CHECKER..................................................................................................................... 311 TROUBLESHOOTING.................................................................................................................................................................. 331 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................... 332 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................ 333 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................................................................... 334 HANDLING CONNECTORS.......................................................................................................................................................... 341 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................ 342 METHOD OF USING TROUBLESHOOTING CHARTS AND TABLES............................................................................................................................ 344 METHOD OF USING JUDGEMENT TABLE.............................................................................................................................................. 352 EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM(CONTROL MECHANISM)............................................................................................................... 355 METHOD OF SELF-DIAGNOSTIC DISPLAY FOR MONITOR PANEL AND EACH CONTROLLER...................................................................................................... 358 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(TRANSMISSION CONTROL SYSTEM)...................................................................................................... 365 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(SUSPENSION CONTROLLER SYSTEM)..................................................................................................... 371 ACTION BY SELF-TESTER AND MACHINE SYMPTOMS(FRONT DRIVE CONTROLLER SYSTEM).................................................................................................... 372 TYPE AND LOCATION OF CONNECTOR,SENSOR........................................................................................................................................ 376 LOCATION OF CONNECTOR,SENSOR................................................................................................................................................. 381 CONNECTION TABLE FOR CONNECTOR............................................................................................................................................... 384 TROUBLESHOOTING OF CHASSIS RELATED PARTS..................................................................................................................................... 395 D-1 STARTING PERFORMANCE IS POOR......................................................................................................................................... 396 D-2 ENGINE DOES NOT START................................................................................................................................................ 397 (1) ENGINE DOES NOT TURN............................................................................................................................................. 397 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL NOT BEING INJECTED)............................................................................................. 398 (3) EXHAUST SMOKE COMES OUT BUT ENGINE ENGINE DOES NOT START(FUEL IS BEING INJECTED)................................................................................. 399 D-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).................................................................................................................. 400 D-4 ENGINE STOPS DURING OPERATIONS....................................................................................................................................... 401 D-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)............................................................................................................................. 402 D-6 ENGINE LACKS OUTPUT(NO POWER)........................................................................................................................................ 403 D-7 EXHAUST SMOKE IS BLACK(INCOMPLATE COMBUSTION)........................................................................................................................ 404 D-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)............................................................................................................... 405 D-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................................................... 406 D-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................................................... 407 D-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN............................................................................................... 408 D-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE)................................................................................................................... 409 D-13 OIL LEVEL RISES..................................................................................................................................................... 410 D-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)..................................................................................................................... 411 D-15 ABNORMAL NOISE IS MADE.............................................................................................................................................. 412 D-16 VIBRATION IS EXCESSIVE.............................................................................................................................................. 413 TROUBLESHOOTING OF ENGINE ELECTRICAL SYSTEM FOR ENGINE START AND STOP........................................................................................................ 414 G-1 ENGINE DOES NOT START(FUEL INJECTION PUMP STOP LEVER STAYS AT STOP POSITION)......................................................................................... 415 G-2 ENGINE DOES NOT STOP(FUEL INJECTION PUMP STOP LEVER STAYS AT FULL POSITION).......................................................................................... 416 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE START AND STOP..................................................................................................................... 417 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM............................................................................................................................ 418 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM................................................................................... 420 JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER,TRANSMISSION RELATED PARTS................................................................................................... 421 A-1 ABNORMALITY IN POWER SOURCE.......................................................................................................................................... 422 a) [OFF] SELF TESTING DISPLAY OF CONTROLLER DOES NOT LIGHT UP........................................................................................................ 422 b) DROP IN VOLTAGE OF CONTROLLER POWER SOURCE DISPLAYED.............................................................................................................. 423 c) ABNORMALITY IN TRANSMISSION CUT RELAY POWER SOURCE DISPLAYED...................................................................................................... 424 A-2 ABNORMALITY IN NEUTRAL SAFETY SYSTEM DISPLAYED....................................................................................................................... 425 A-3 ABNORMALITY IN CONTROLLER SYSTEM..................................................................................................................................... 426 a) ONLY DOT LIGHT UP OR ABNORMALITY IN CONTROLLER DISPLAYED ABNORMALITY IN CONTROLLER DISPLAYED...................................................................... 426 b) DOUBLE SYSTEM FOR CLUTCH DISPLAYED................................................................................................................................ 427 A-4 ABNORMALITY IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED............................................................................................................. 428 A-5 ABNORMALITY IN AUTO-RETARDER BRAKE SOLENOID SYSTEM DISPLAYED......................................................................................................... 429 A-6 DISPLAYES ABNORMALITY IN EXHAUST BRAKE SOLENOID SYSTEM............................................................................................................... 430 A-7 ABNORMALITY IN SPEED SENSOR SYSTEM................................................................................................................................... 431 a) ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM DISPLAYED............................................................................................................... 431 b) ABNORMALITY IN INTERMEDIATE SHAFT SPEED SENSOR SYSTEM DISPLAYED................................................................................................... 432 c) DISCONNECTION IN TRAVEL SPEED SENSOR(TRANSMISSION OUTPUT SHAFT SPEED SENSOR)DISPLAYED............................................................................. 433 A-8 SPEED SENSOR SYSTEM,CLUTCH SLIPPING.................................................................................................................................. 434 a) INPUT SHAFT SENSOR OR H.L CLUTCH SYSTEM DISPLAYED................................................................................................................. 434 b) TRAVEL SPEED SENSOR OR SPEED CLUTCH(1,2,3,4,R)SYSTEM DISPLAYED.................................................................................................... 435 A-9 ABNORMALITY IN MODEL SELECTION DISPLAYED............................................................................................................................. 436 A-10 ABNORMALITY IN TRANSMISSION SHIFT LEVER SYSTEM...................................................................................................................... 437 a) SHORT CIRCUIT IN TRANSMISSION SHIFT LEVER ASSEMBLY POWER SOURCE DISPLAYED......................................................................................... 437 b) SHIFT LEVER POSITION SIGNAL DISPLAYS TWO OR MORE SYSTEMS.......................................................................................................... 438 c) TRANSMISSION SHIFT LEVER POSITION SIGNAL IS NOT INPUT............................................................................................................. 441 A-11 ABNORMALITY IN ACCELERATOR SIGNAL DISPLAYED......................................................................................................................... 442 A-12 ABNORMALITY IN TRANSMISSION OIL TEMPERATURE SENSOR DISPLAYED........................................................................................................ 444 A-13 ABNORMALITY IN PRESSURE CONTROL VALVE SYSTEM........................................................................................................................ 445 a) FILL SIGNAL DISPLAYES ON REGARDLESS OF COMMAND.................................................................................................................... 445 b) FILL SIGNAL IS NOT INPUT AND CLUTCH SLIPPING IS DISPLAYED......................................................................................................... 446 b-1)INSPECTION OF FILL SIGNAL SYSTEM............................................................................................................................. 446 b-2)TRANSMISSION INPUT SHAFT REVOLUTION SIGNAL SYSTEM,CHECK OF HI-LO CLUTCH SYSTEM............................................................................... 448 b-3)TRANSMISSION OUTPUT SHAFT REVOLUTION SIGNAL SYSTEM,CHECK OF F,R CLUTCH SYSTEM................................................................................ 448 A-14 WHEN FILL SIGNAL IS NOT INPUT (FLOW DETEDTOR VALVE SYSTEM).......................................................................................................... 449 A-15 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED OR DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID SYSTEM DISPLAYED.............................. 450 ELECTRICAL CIRCUIT DIAGRAM .............................................................................................................................................. 452 TROUBLESHOOTING OF SUSPENSION CONTROLLER SYSTEM.............................................................................................................................. 453 JUDGMENT TABLE FOR SUSPENSION CONTROLLER,SUSPENSION RELATED PARTS........................................................................................................ 454 S-1 ABNORMALITY IN POWER SOURCE SYSTEM................................................................................................................................... 455 S-2 ABNORMALITY IN PRESSURE SENSOR [RIGHT] SYSTEM........................................................................................................................ 456 S-3 ABNORMALITY IN PRESSURE SENSOR [LEFT] SYSTEM......................................................................................................................... 457 S-4 ABNORMALITY IN TRAVEL SPEED SENSOR SYSTEM............................................................................................................................ 458 S-5 ABNORMALITY IN STEERING SENSOR SYSTEM................................................................................................................................ 459 S-6 ABNORMALITY IN MODEL SENSOR SYSTEM................................................................................................................................... 460 S-7 ABNORMALITY IN SOLENOID [I] SYSTEM................................................................................................................................... 461 S-8 ABNORMALITY IN SOLENOID [II] SYSTEM.................................................................................................................................. 462 S-9 ABNORMALITY IN SOLENOID [III] SYSTEM................................................................................................................................. 463 S-10 ABNORMALITY IN CONTROLLER SYSTEM.................................................................................................................................... 464 ELECTRICAL CIRCUIT DIAGRAM FOR SUSPENSION CONTROL SYSTEM................................................................................................................. 465 TROUBLESHOOTING OF PAYLOAD METER SYSTEM...................................................................................................................................... 466 L-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY APPEARS............................................................................................................. 467 L-2 AFTER THE STARTING SWITCH IS TURNED ON,THE DEMAND FOR CALIBRATION(CAL FLASHES)CONTINUES TO BE GIVEN.................................................................. 467 L-3 CALIBRATION CANNOT BE CARRIED OUT.................................................................................................................................... 468 L-4 AFTER THE STARTING SWITCH IS TURNED ON,THE EXTERNAL DISPLAY LAMPS DO NOT ALL LIGHT UP................................................................................ 470 L-5 EXTERNAL DISPLAY LAMPS LIGHT UP EVEN WHEN IT IS NOT THE CONDITION FOR LIGHTING UP.................................................................................... 470 L-6 THE LEVEL OF LIGHTING UP OF THE EXTERNAL DISPLAY LAMPS IS NOT CORRECT................................................................................................ 471 L-7 THERE IS ABNORMALITY IN THE DISPLAY LOGIC............................................................................................................................ 472 a) EVEN WHEN THE DUMP BODY IS OPERATED,THE DISPLAY DOES NOT BECOME 0 TON............................................................................................. 472 b) THE DISPLAY STAYS AT 0 TON AND DOES NTO CHANGE.................................................................................................................... 472 c) WHEN THE TRANSMISSION LEVER IS AT NEUTRAL,THE WEIGHT DISPLAY IS NOT GIVEN(TIME DISPLAY IS GIVEN).................................................................. 473 d) WHEN THE TRANSMISSION LEVER IS AT A POSITION OTHER THAN NEUTRAL,THE TIME DISPLAY IS NOT GIVEN..................................................................... 475 L-8 E01-E04 IS DISPLAYED................................................................................................................................................. 476 L-9 E11-E14 IS DISPLAYED................................................................................................................................................. 477 L-10 E21-E28 IS DISPLAYED BY SENSOR CHECK................................................................................................................................ 477 L-11 E31 IS DISPLAYED.................................................................................................................................................... 478 L-12 E32 IS DISPLAYED.................................................................................................................................................... 480 L-13 E41 IS DISPLAYED.................................................................................................................................................... 480 L-14 E42 IS DISPLAYED.................................................................................................................................................... 481 L-15 THE PRINTER DOES NOT PRINT ANYTHING(ONLY BLANK PAPER COMES OUT)..................................................................................................... 481 L-16 THE PRINTER ONLY PRINTS NO DATA..................................................................................................................................... 482 L-17 EVEN WHEN THE [PRT]SWITCH IS PRESSED,NOTHING IS PRINTED OUT......................................................................................................... 482 L-18 PAPE FLASHES........................................................................................................................................................ 483 L-19 THE TIME IS WRONG................................................................................................................................................... 483 L-20 E33 IS DISPLAYED.................................................................................................................................................... 483 RELATED ELECTRICAL CIRCUIT DIAGRAMS...................................................................................................................................... 484 ELECTRICAL CIRCUIT DIAGRAMS FOR PAYLOAD METER SYSTEM..................................................................................................................... 487 TROUBLESHOOTING OF MONITOR PANEL SYSTEM...................................................................................................................................... 488 P-1 MONITOR PANEL DOES NOT WORK AT ALL................................................................................................................................... 490 P-2 PART OF MONITOR PANEL DOES NOT WORK.................................................................................................................................. 491 a) SPEEDOMETER DISPLAY DOES NOT WORK................................................................................................................................. 491 b) SPEEDOMETER DISPLAY WORKS,BUT OTHER PARTS DO NOT WORK............................................................................................................. 491 c) SUSPENSION DISPLAY DOES NOT WORK.................................................................................................................................. 491 d) (MECHATRONICS)CAUTION,FUEL GAUGE DISPLAYS DO NOT WORK............................................................................................................. 492 P-3 ENGINE(MECHATRONICS)DISPLAY FLASHES.................................................................................................................................. 493 P-4 AUTOMATIC SHIFT DISPLAY (MECHATRONICS)FLASHES........................................................................................................................ 494 P-5 SUSPENSION(MECHATRONIC)DISPLAY FLASHES............................................................................................................................... 494 P-6 ABNORMALITY IN POWER MODE DISPLAY.................................................................................................................................... 495 HIGH POWER DISPLAY LIGHTS UP......................................................................................................................................... 495 P-7 ABNORMALITY IN SUSPENSION DISPLAY.................................................................................................................................... 496 a) HARD DISPLAY DOES NOT LIGHT UP.................................................................................................................................... 496 b) MEDIUM DISPLAY DOES NOT LIGHT UP.................................................................................................................................. 496 c) SOFT DISPLAY DOES NOT LIGHT UP.................................................................................................................................... 497 d) SUSPENSIO MODE DISPLAYS ALL LIGHT UP.............................................................................................................................. 497 P-8 ABNORMALITY IN SHIFT POSITION DISPLAY................................................................................................................................ 498 a) R DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 498 b) N DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 498 c) D DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 499 d) 5 DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 499 e) 4 DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 500 f) 3 DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 500 g) L DISPLAY DOES NOT LIGHT UP....................................................................................................................................... 501 P-9 SHIFT LIMITER DISPLAY DOES NOT LIGHT UP.............................................................................................................................. 502 P-10 LOCK-UP DISPLAY DOES NOT LIGHT UP................................................................................................................................... 502 P-11 HI BEAM DISPLAY DOES NOT LIGHT UP................................................................................................................................... 503 P-12 ABNORMALITY IN TURN SIGNAL.......................................................................................................................................... 504 a) RIGHT TURN SIGNAL LAMP DOES NOT LIGHT UP.......................................................................................................................... 504 b) LEFT TURN SIGNAL LAMP DOES NOT LIGHT UP........................................................................................................................... 504 P-13 ABNORMALITY IN SHIFT INDICATOR DISPLAY.............................................................................................................................. 505 a) WHEN 1,2,4,6,R IS DISPLAYED,DISPLAY CHANGES TO E.................................................................................................................. 505 b) WHEN 3,5,7 IS DISPLAYED,DISPLAY CHANGES TO E...................................................................................................................... 505 c) WHEN 1 IS DISPLAYED,DISPLAY CHANGES TO E.......................................................................................................................... 506 d) WHEN 2,3 IS DISPLAYED,DISPLAY CHANGES TO E........................................................................................................................ 506 e) WHEN 4,5 IS DISPLAYED,DISPLAY CHANGES TO E........................................................................................................................ 507 f) WHEN 6,7 IS DISPLAYED,DISPLAY CHANGES TO E........................................................................................................................ 507 g) WHEN R IS DISPLAYED,DISPLAY CHANGES TO E.......................................................................................................................... 508 P-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY.......................................................................................................................... 509 P-15 TACHOMETER DOES NOT WORK NORMALLY................................................................................................................................... 509 P-16 SERVICE METER DOES NOT WORK......................................................................................................................................... 510 P-17 ODOMETER DOES NOT WORK.............................................................................................................................................. 510 P-18 ABNORMALITY IN ALARM BUZZER......................................................................................................................................... 511 a) CAUTION DISPLAY IS FLASHING (LIGHTED UP),BUT ALARM BUZZER DOES NOT SOUND.......................................................................................... 511 b) ALARM BUZZER CONTINUES TO SOUND................................................................................................................................... 511 P-19 ABNORMALITY IN WARNING LAMP......................................................................................................................................... 512 a) CAUTION DISPLAY IS FLASHING(LIGHTED UP),BUT WARNING LAMP DOES NOT FLASH........................................................................................... 512 b) WARNING LAMP STAYS ON............................................................................................................................................. 512 P-20 CAUTION DISPLAY DOES NOT FLASH(DOES NOT LIGHT UP),BUT WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS.................................................................. 513 a) WARNING LAMP FLASHES AND ALARM BUZZER SOUNDS...................................................................................................................... 513 b) WARNING LAMP FLASHES WHEN ENGINE STOPS............................................................................................................................ 513 c) WARNING LAMP FLASHES WHEN ENGINE IS RUNNIGN....................................................................................................................... 513 P-21 ABNORMALITY IN AIR PRESSURE GAUGE................................................................................................................................... 514 a) NO DISPLAY GIVEN IN DISPLAY AREA.................................................................................................................................. 514 b) DISPLAY SHOWS HIGHEST LEVEL AND DOES NOT MOVE..................................................................................................................... 514 P-22 ABNORMALITY IN COOLANT TEMPERATURE GAUGE............................................................................................................................ 515 a) NO DISPLAY GIVEN IN DISPLAY AREA.................................................................................................................................. 515 b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE...................................................................................................................... 515 P-23 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE............................................................................................................... 516 a) NO DISPLAY GIVEN IN DISPLAY AREA.................................................................................................................................. 516 b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE...................................................................................................................... 516 P-24 ABNORMALITY IN RETARDER OIL TEMPERATURE GAUGE....................................................................................................................... 517 a) NO DISPLAY GIVEN IN DISPLAY AREA.................................................................................................................................. 517 b) DISPLAY SHOWS LOWEST LEVEL AND DOES NOT MOVE...................................................................................................................... 517 P-25 ABNORMALITY IN FUEL GAUGE........................................................................................................................................... 518 a) NO DISPLAY GIVEN IN DISPLAY AREA.................................................................................................................................. 518 b) DISPLAY SHOWS FULL AND DOES NOT MOVE.............................................................................................................................. 518 P-26 ABNORMALITY IN NIGHT LIGHTING....................................................................................................................................... 519 a) NONE OF PANEL LAMPS LIGHT UP...................................................................................................................................... 519 b) SERVICE METER AND ODOMETER LIGHT UP,BUT OTHER PARTS DO NOT LIGHT UP............................................................................................... 520 c) SERVICE METER AND ODOMETER DO NOT LIGHT UP........................................................................................................................ 520 RELATED ELECTRICAL CIRCUIT DIAGRAMS...................................................................................................................................... 521 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM...................................................................................................................... 529 TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM................................................................................................................................ 530 M-1 MAINTENANACE MONITOR DOES NOT WOEK................................................................................................................................... 531 a) WHEN NOTHING WORKS................................................................................................................................................ 531 b) WHEN CHECK DISPLAY DOES NOT WORK.................................................................................................................................. 531 M-2 WHEN ENGINE IS STOPPED,ENGINE OIL LEVEL DISPLAY FLASHES.............................................................................................................. 532 M-3 WHEN ENGINE IS STOPPED,TRANSMISSION OIL LEVEL DISPLAY FLASHES........................................................................................................ 533 M-4 WHEN ENGINE IS STOPPED,HYDRAULIC OIL LEVEL DISPLAY FLASHES........................................................................................................... 534 M-5 WHEN ENGINE IS STOPPED,RETARDER OIL LEVEL DISPLAY FLASHES............................................................................................................ 535 M-6 WHEN ENGINE IS STOPPED,BRAKE OIL LEVEL DISPLAY FLASHES............................................................................................................... 536 M-7 WHEN ENGINE IS STOPPED,BATTERY ELECTROLYTE LEVEL DISPLAY FLASHES..................................................................................................... 537 M-8 RETARDER WEAR DISPLAY FLASHES........................................................................................................................................ 538 M-9 WHEN ENGINE IS RUNNIGN,AIR CLEANER CLOGGING DISPLAY FLASHES.......................................................................................................... 539 M-10 WHEN ENGINE IS RUNNING,FULL-FLOW FILTER CLOGGING DISPLAY FLASHES.................................................................................................... 540 M-11 WHEN ENGINE IS RUNNIGN,TRANSMISSION FILTER CLOGGING DISPLAY FLASHES................................................................................................. 541 M-12 WHEN ENGINE IS RUNNIGN,HYDRAULIC FILTER CLOGGING DISPLAY FLASHES.................................................................................................... 542 M-13 WHEN ENGINE IS RUNNIGN,RETARDER FILTER CLOGGING DISPLAY FLASHES..................................................................................................... 543 M-14 MAINTENACE TIMER DOES NOT WORK...................................................................................................................................... 544 M-15 ABNORMALITY IN SWITCH............................................................................................................................................... 545 a) CONFIRMATION SWITCH FOR OIL OR FILTER REPLACEMENT TIME DOES NOT WORK.............................................................................................. 545 b) REPLACEMENT SWITCH,MISOPERATION CANCEL SWITCH DO NOT WORK......................................................................................................... 545 M-16 NIGHT LIGHTING DOES NOT LIGHT UP.................................................................................................................................... 546 ELECTRICAL CIRCUIT DIAGRAM OF MAINTENACE MONITOR SYSTEM.................................................................................................................. 547 TROUBLESHOOTING OF PILOT LAMP SYSTEM......................................................................................................................................... 548 F-1 ABNORMALITY IN LIGHTING UP OF REAR BRAKE LAMP........................................................................................................................ 549 a) BRAKE IS NOT BEING APPLIED,BUT PILOT LAMP LIGHTS UP............................................................................................................... 549 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN BRAKE IS APPLIED........................................................................................................... 550 F-2 ABNORMALITY IN LIGHTING UP OF BODY FLOAT PILOT LAMP.................................................................................................................. 551 a) HOIST LEVER IS AT FLOAT POSITION,BUT PILOT LAMP LIGHTS UP......................................................................................................... 551 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN HOIST LEVER IS OPERATED.................................................................................................... 552 F-3 ABNORMAL LIGHTING UP OF EXHAUST BRAKE PILOT LAMP..................................................................................................................... 553 a) PILOT LAMP LIGHTS UP EVEN WHEN EXHAUST BRAKE IS NOT BEING OPERATED................................................................................................ 553 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN EXHAUST BRAKE IS BEING OPERATED............................................................................................ 554 F-4 ABNORMALITY IN LIGHTING UP OF PARKING BRAKE PILOT LAMP............................................................................................................... 555 a) PARKING BRAKE IS NOT BEING APPLIED,BUT PILOT LAMP LIGHTS UP....................................................................................................... 555 b) PILOT LAMP DOES NOT LIGHT UP EVEN WHEN PARKING BRAKE IS APPLIED................................................................................................... 556 ELECTRICAL CIRCUIT DIAGRAM FOR PILOT LAMP CIRCUIT........................................................................................................................ 557 TROUBLESHOOTING OF AIR SYSTEM ON MACHINE AIR COMPRESSOR...................................................................................................................... 558 BASIC AIR CIRCUIT OF AIR COMPRESSOR...................................................................................................................................... 559 C-1 AIR PRESSURE DOES NOT RISE AT ALL.................................................................................................................................... 560 C-2 AIR PRESSURE DOES NOT RISE TO SPECIFIED RANGE........................................................................................................................ 562 C-3 AIR PRESSURE RISE,BUT TAKES A LONG TIME TO CHARGE.................................................................................................................... 563 C-4 WHEN AIR PRESSURE REACHES TOP OF GREEN RANGE ON AIR GAUGE,AIR PRESSURE SUDDENLY DROPS TO BOTTOM OF GREEN RANGE ON AIR GAUGE EVEN WHEN NO AIR IS USED................. 563 C-5 AIR BLOWS OUT FROM SAFETY VALVE...................................................................................................................................... 564 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM........................................................................................................................... 565 H-1:MACHINE DOES NOT MOVE................................................................................................................................................ 566 H-2:MACHINE DOES NOT TRAVEL SMOOTHLY..................................................................................................................................... 568 H-3:LOCK-UP CLUTCH CANNOT BE DISENGAGED.................................................................................................................................. 568 H-4:LARGE SHOCK WHEN STARTING OF SHIFTING................................................................................................................................ 569 H-5:TRANSMISSION DOES NOT SHIFT UP....................................................................................................................................... 569 H-6:MACHINE LACKS POWER OR SPEED WHEN TRAVELING.......................................................................................................................... 570 H-7:TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR................................................................................................................. 576 H-8:TORQUE CONVERTER OIL TEMPERATURE IS HIGHT............................................................................................................................ 578 H-9:TORQUE CONVERTER OIL PRESSURE IS LOW................................................................................................................................. 579 H-10:FRONT BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE.................................................................................................................... 580 H-11:REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ONE SIDE..................................................................................................................... 582 H-12:STEERING WHEEL IS HEAVY............................................................................................................................................. 583 H-13:STEERING WHEEL DOES NOT FUNCTION.................................................................................................................................... 584 H-14:STEERING WHEEL VIBRATES............................................................................................................................................. 584 H-15:HOIST CYLINDER LACKS LIFTING FORCE(LIFTING SPEED)................................................................................................................... 585 H-16:HOIST CYLINDER DOES NOT WORK........................................................................................................................................ 586 H-17:EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.............................................................................................................................. 587 TROUBLESHOOTING OF FRONT DRIVE SYSTEM(HD325-6W).............................................................................................................................. 588 W-1 SELF-DIAGNOSTIC DISPLAY UNIT OF CONTROLLER DOES NOT LIGHT UP......................................................................................................... 589 W-2 (DROP IN CONTROLLER INPUT VOLTAGE)IS DISPLAYED....................................................................................................................... 590 W-3 (ABNORMALITY IN ANALOG POWER SOURCE CUT RELAY)IS DISPLAYED........................................................................................................... 591 W-4 (DISCONNECTION IN CLUTCH CONTROL VALVE OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN CLUTCH CONTROL VALVE OUTPUT WIRING)IS DISPLAYED.................................. 592 W-5 (DEFECTIVE CLUTCH CONTROL VALVE SYSTEM)IS DISPLAYED (DEFECTIVE FILL SIGNAL INPUT SYSTEM)IS DIAPLAYED................................................................. 593 W-6 (DISCONNECTION IN PUMP OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED............................................................ 594 W-7 (DISCONNECTION IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUIT IN LEFT MOTOR OUTPUT WIRING)IS DISPLAYED...................................................... 595 W-8 (DISCONNECTION IN RIGHT MOTOR OUTPUT WIRING)IS DISPLAYED (SHORT CIRCUTI IN RIGHT MOTOR OUTPUT WIRING)IS DISPLAYED.................................................... 596 W-9 (ABNORMALITY(DISCONNECTION)IN PRESSURE SENSOR[A])IS DISPLAYED (ABNORMALITY(DISCONNECTION)IN PRESSURE SENSOR[B])IS DISPLAYED.......................................... 597 W-10 (SHORT CIRCUIT IN PRESSURE SENSOR[A])IS DISPLAYED (SHORT CIRCUIT IN PRESSURE SENSOR[B])IS DISPLAYED................................................................. 598 W-11 (ABNORMALITY IN HST HYDRAULIC SYSTEM)IS DISPLAYED................................................................................................................... 599 W-12 (DISCONNECTION IN STEERING ANGLE SENSOR)IS DISPLAYED (SHORT CIRCUIT IN STEERING ANGLE SENSOR)IS DISPLAYED (DEFECTIVE MOUNT OF STEERING ANGLE SENSOR)IS DISPLAYED.... 600 W-13 (DISCONNECTION IN ENGINE SPEED SENSOR)IS DISPLAYED.................................................................................................................. 601 W-14 (DISCONNECTION IN TRANSMISSION INPUT SHAFT SPEED SENSOR)IS DISPLAYED................................................................................................ 602 W-15 (ABNORMALITY IN LEFT FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED (ABNORMALITY IN RIGHT FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED................................ 603 W-16 (ABNORMALITY IN FRONT WHEEL SPEED SENSOR SYSTEM)IS DISPLAYED........................................................................................................ 603 W-17 (SHORT CIRCUIT IN 4-WHEEL DRIVE LAMP RELAY)IS DISPLAYED............................................................................................................. 604 W-18 (CLOGGING OF FRONT DRIVE OIL FILTER)IS DISPLAYED.................................................................................................................... 605 W-19 (RISE IN TEMPERATURE OF FRONT DRIVE OIL)IS DISPLAYED................................................................................................................ 606 W-20 (ABNORMALITY IN CLUTCH OIL PRESSURE SYSTEM)IS DISPLAYED............................................................................................................. 607 ELECTRICAL CIRCUIT DIAGRAM FOR FRONT DRIVE SYSTEM........................................................................................................................ 608 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................... 609 METHOD OF USING MANUAL........................................................................................................................................................... 611 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................... 612 SPECIAL TOOL LIST................................................................................................................................................................ 614 SKETCHES OF SPECIAL TOOLS........................................................................................................................................................ 618 STARTING MOTOR................................................................................................................................................................... 626 REMOVAL...................................................................................................................................................................... 626 INSTALLATION................................................................................................................................................................. 626 ALTERNATOR....................................................................................................................................................................... 627 REMOVAL...................................................................................................................................................................... 627 INSTALLATION................................................................................................................................................................. 627 ENGINE OIL COOLER................................................................................................................................................................ 628 REMOVAL...................................................................................................................................................................... 628 INSTALLATION................................................................................................................................................................. 628 FUEL INJECTION PUMP.............................................................................................................................................................. 629 REMOVAL...................................................................................................................................................................... 629 INSTALLATION................................................................................................................................................................. 631 AIR COMPRESSOR................................................................................................................................................................... 632 REMOVAL...................................................................................................................................................................... 632 INSTALLATION................................................................................................................................................................. 632 AIR CONDITIONER COMPRESSOR....................................................................................................................................................... 633 REMOVAL...................................................................................................................................................................... 633 INSTALLATION................................................................................................................................................................. 633 AIR CONDITIONER CONDENSER........................................................................................................................................................ 634 REMOVAL...................................................................................................................................................................... 634 INSTALLATION................................................................................................................................................................. 634 WATER PUMP....................................................................................................................................................................... 635 REMOVAL...................................................................................................................................................................... 635 INSTALLATION................................................................................................................................................................. 635 AFTERCOOLER CORE................................................................................................................................................................. 636 REMOVAL...................................................................................................................................................................... 636 INSTALLATION................................................................................................................................................................. 637 AFTERCOOLER...................................................................................................................................................................... 638 REMOVAL...................................................................................................................................................................... 638 INSTALLATION................................................................................................................................................................. 638 EXHAUST BRAKE CYLINDER........................................................................................................................................................... 639 REMOVAL...................................................................................................................................................................... 639 INSTALLATION................................................................................................................................................................. 639 TURBOCHARGER..................................................................................................................................................................... 640 REMOVAL...................................................................................................................................................................... 640 INSTALLATION................................................................................................................................................................. 640 NOZZLE HOLDER.................................................................................................................................................................... 642 REMOVAL...................................................................................................................................................................... 642 INSTALLATION................................................................................................................................................................. 642 CYLINDER HEAD.................................................................................................................................................................... 644 REMOVAL...................................................................................................................................................................... 644 INSTALLATION................................................................................................................................................................. 649 ENGINE........................................................................................................................................................................... 658 REMOVAL...................................................................................................................................................................... 658 INSTALLATION................................................................................................................................................................. 661 RADIATOR,TORQUE CONVERTER OIL COOLER............................................................................................................................................. 668 REMOVAL...................................................................................................................................................................... 668 INSTALLATION................................................................................................................................................................. 671 RADIATOR,FRONT DRIVE COOLER...................................................................................................................................................... 676 REMOVAL...................................................................................................................................................................... 676 INSTALLATION................................................................................................................................................................. 680 FRONT DRIVE OIL COOLER........................................................................................................................................................... 681 REMOVAL...................................................................................................................................................................... 681 INSTALLATION................................................................................................................................................................. 681 OUTPUT SHAFT..................................................................................................................................................................... 682 REMOVAL...................................................................................................................................................................... 682 INSTALLATION................................................................................................................................................................. 684 DISASSEMBLY.................................................................................................................................................................. 685 ASSEMBLY..................................................................................................................................................................... 686 TORQUE CONVERTER,TRANSMISSION.................................................................................................................................................... 688 REMOVAL...................................................................................................................................................................... 688 INSTALLATION................................................................................................................................................................. 690 TORQUE CONVERTER VALVE........................................................................................................................................................... 695 REMOVAL...................................................................................................................................................................... 695 INSTALLATION................................................................................................................................................................. 695 DISASSEMBLY.................................................................................................................................................................. 696 ASSEMBLY..................................................................................................................................................................... 696 TORQUE CONVERTER,TRANSMISSION.................................................................................................................................................... 697 DISCONNECTION................................................................................................................................................................ 697 CONNECTION................................................................................................................................................................... 698 TORQUE CONVERTER................................................................................................................................................................. 699 DISASSEMBLY.................................................................................................................................................................. 699 ASSEMBLY..................................................................................................................................................................... 704 PTO.............................................................................................................................................................................. 709 DISASSEMBLY.................................................................................................................................................................. 709 ASSEMBLY..................................................................................................................................................................... 710 TRANSMISSION..................................................................................................................................................................... 715 DISASSEMBLY.................................................................................................................................................................. 715 ASSEMBLY..................................................................................................................................................................... 733 TRANSMISSION CONTROL VALVE(ECMV ASSEMBLY)........................................................................................................................................ 751 REMOVAL...................................................................................................................................................................... 751 INSTALLATION................................................................................................................................................................. 751 DISASSEMBLY.................................................................................................................................................................. 752 ASSEMBLY..................................................................................................................................................................... 753 DIFFERENTIAL..................................................................................................................................................................... 754 REMOVAL...................................................................................................................................................................... 754 INSTALLATION................................................................................................................................................................. 754 DISASSEMBLY.................................................................................................................................................................. 755 ASSEMBLY..................................................................................................................................................................... 776 FRONT WHEEL...................................................................................................................................................................... 820 REMOVAL...................................................................................................................................................................... 820 INSTALLATION................................................................................................................................................................. 820 REAR WHEEL....................................................................................................................................................................... 822 REMOVAL...................................................................................................................................................................... 822 INSTALLATION................................................................................................................................................................. 823 FRONT BRAKE CALIPER PAD.......................................................................................................................................................... 824 REMOVAL...................................................................................................................................................................... 824 INSTALLATION................................................................................................................................................................. 824 FRONT BRAKE CALIPER.............................................................................................................................................................. 825 REMOVAL...................................................................................................................................................................... 825 INSTALLTION.................................................................................................................................................................. 825 DISASSEMBLY.................................................................................................................................................................. 826 ASSEMBLY..................................................................................................................................................................... 826 FRONT WHEEL HUB.................................................................................................................................................................. 827 DISASSEMBLY.................................................................................................................................................................. 827 ASSEMBLY..................................................................................................................................................................... 829 FRONT FINAL DRIVE CLUTCH CARRIER................................................................................................................................................. 832 DISASSEMBLY.................................................................................................................................................................. 832 ASSEMBLY..................................................................................................................................................................... 836 FRONT FINAL DRIVE BRAKE.......................................................................................................................................................... 841 DISASSEMBLY.................................................................................................................................................................. 841 ASSEMBLY..................................................................................................................................................................... 846 FRONT DRIVE SHAFT................................................................................................................................................................ 853 DISASSEMBLY.................................................................................................................................................................. 853 ASSEMBLY..................................................................................................................................................................... 857 REAR FINAL DRIVE CARRIER......................................................................................................................................................... 863 REMOVAL...................................................................................................................................................................... 863 INSTALLTION.................................................................................................................................................................. 864 DISASSEMBLY.................................................................................................................................................................. 865 ASSEMBLY..................................................................................................................................................................... 866 REAR FINAL DRIVE................................................................................................................................................................. 867 DISASSEMBLY.................................................................................................................................................................. 867 ASSEMBLY..................................................................................................................................................................... 869 REAR BRAKE....................................................................................................................................................................... 871 REMOVAL...................................................................................................................................................................... 871 INSTALLTION.................................................................................................................................................................. 871 DISASSEMBLY.................................................................................................................................................................. 872 ASSEMBLY..................................................................................................................................................................... 873 PARKING BRAKE PAD................................................................................................................................................................ 875 REMOVAL...................................................................................................................................................................... 875 INSTALLTION.................................................................................................................................................................. 876 PARKING BRAKE CALIPER............................................................................................................................................................ 877 REMOVAL...................................................................................................................................................................... 877 INSTALLTION.................................................................................................................................................................. 877 DISASSEMBLY.................................................................................................................................................................. 878 ASSEMBLY..................................................................................................................................................................... 878 FRONT SUSPENSION CYLINDER........................................................................................................................................................ 879 REMOVAL...................................................................................................................................................................... 879 INSTALLTION.................................................................................................................................................................. 880 DISASSEMBLY.................................................................................................................................................................. 883 ASSEMBLY..................................................................................................................................................................... 884 VARIABLE DAMPING SELECTOR VALVE.................................................................................................................................................. 885 DISASSEMBLY.................................................................................................................................................................. 885 ASSEMBLY..................................................................................................................................................................... 886 REAR SUSPENSION CYLINDER......................................................................................................................................................... 887 REMOVAL...................................................................................................................................................................... 887 INSTALLTION.................................................................................................................................................................. 888 DISASSEMBLY.................................................................................................................................................................. 889 ASSEMBLY..................................................................................................................................................................... 890 AIR GOVERNOR..................................................................................................................................................................... 893 REMOVAL...................................................................................................................................................................... 893 INSTALLTION.................................................................................................................................................................. 893 DISASSEMBLY.................................................................................................................................................................. 894 ASSEMBLY..................................................................................................................................................................... 894 BRAKE VALVE...................................................................................................................................................................... 895 REMOVAL...................................................................................................................................................................... 895 INSTALLTION.................................................................................................................................................................. 895 DISASSEMBLY.................................................................................................................................................................. 896 ASSEMBLY..................................................................................................................................................................... 898 PARKING BRAKE CHAMBER............................................................................................................................................................ 900 REMOVAL...................................................................................................................................................................... 900 INSTALLTION.................................................................................................................................................................. 900 DISASSEMBLY.................................................................................................................................................................. 901 ASSEMBLY..................................................................................................................................................................... 902 FRONT BRAKE CHAMBER.............................................................................................................................................................. 904 REMOVAL...................................................................................................................................................................... 904 INSTALLTION.................................................................................................................................................................. 904 REAR BRAKE CHAMBER............................................................................................................................................................... 907 REMOVAL...................................................................................................................................................................... 907 INSTALLTION.................................................................................................................................................................. 907 FRONT BRAKE CHAMBER.............................................................................................................................................................. 908 DISASSEMBLY.................................................................................................................................................................. 908 ASSEMBLY..................................................................................................................................................................... 910 REAR BRAKE CHAMBER............................................................................................................................................................... 912 DISASSEMBLY.................................................................................................................................................................. 912 ASSEMBLY..................................................................................................................................................................... 914 SLACK ADJUSTER................................................................................................................................................................... 922 REMOVAL...................................................................................................................................................................... 922 INSTALLTION.................................................................................................................................................................. 922 DISASSEMBLY.................................................................................................................................................................. 923 ASSEMBLY..................................................................................................................................................................... 923 TRANSMISSION LUBRICATION,RETARDER BRAKE PUMP..................................................................................................................................... 924 REMOVAL...................................................................................................................................................................... 924 INSTALLTION.................................................................................................................................................................. 924 BRAKE COOLING PUMP............................................................................................................................................................... 926 REMOVAL...................................................................................................................................................................... 926 INSTALLTION.................................................................................................................................................................. 926 HOIST,STEERING PUMP.............................................................................................................................................................. 928 REMOVAL...................................................................................................................................................................... 928 INSTALLTION.................................................................................................................................................................. 928 FRONT DRIVE PUMP................................................................................................................................................................. 929 REMOVAL...................................................................................................................................................................... 929 INSTALLTION.................................................................................................................................................................. 930 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................... 931 EMERGENCY STEERING MOTOR PUMP.................................................................................................................................................... 937 REMOVAL...................................................................................................................................................................... 937 INSTALLTION.................................................................................................................................................................. 937 TRAVEL MOTOR..................................................................................................................................................................... 938 REMOVAL...................................................................................................................................................................... 938 INSTALLTION.................................................................................................................................................................. 939 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................... 940 STEERING VALVE................................................................................................................................................................... 943 REMOVAL...................................................................................................................................................................... 943 INSTALLTION.................................................................................................................................................................. 943 DISASSEMBLY.................................................................................................................................................................. 944 ASSEMBLY..................................................................................................................................................................... 948 DEMAND VALVE..................................................................................................................................................................... 954 REMOVAL...................................................................................................................................................................... 954 INSTALLTION.................................................................................................................................................................. 954 DISASSEMBLY.................................................................................................................................................................. 955 ASSEMBLY..................................................................................................................................................................... 955 RELIEF VALVE..................................................................................................................................................................... 956 DISASSEMBLY.................................................................................................................................................................. 956 ASSEMBLY..................................................................................................................................................................... 956 HOIST VALVE...................................................................................................................................................................... 957 REMOVAL...................................................................................................................................................................... 957 INSTALLTION.................................................................................................................................................................. 957 DISASSEMBLY.................................................................................................................................................................. 958 ASSEMBLY..................................................................................................................................................................... 959 STEERING CYLINDER................................................................................................................................................................ 960 REMOVAL...................................................................................................................................................................... 960 INSTALLTION.................................................................................................................................................................. 960 DISASSEMBLY.................................................................................................................................................................. 961 ASSEMBLY..................................................................................................................................................................... 963 HOIST CYLINDER................................................................................................................................................................... 965 REMOVAL...................................................................................................................................................................... 965 INSTALLTION.................................................................................................................................................................. 965 DISASSEMBLY.................................................................................................................................................................. 966 ASSEMBLY..................................................................................................................................................................... 968 BODY............................................................................................................................................................................. 972 REMOVAL...................................................................................................................................................................... 972 INSTALLTION.................................................................................................................................................................. 973 TRANSMISSION CONTROLLER.......................................................................................................................................................... 974 REMOVAL...................................................................................................................................................................... 974 INSTALLTION.................................................................................................................................................................. 974 SUSPENSION CONTROLLER............................................................................................................................................................ 974 REMOVAL...................................................................................................................................................................... 974 INSTALLTION.................................................................................................................................................................. 974 FRONT DRIVE CONTROLLER........................................................................................................................................................... 974 REMOVAL...................................................................................................................................................................... 974 INSTALLTION.................................................................................................................................................................. 974 40 MAINTENANCE STANDARD.............................................................................................................................................................. 975 OUTPUT SHAFT..................................................................................................................................................................... 976 TORQUE CONVERTER VALVE........................................................................................................................................................... 977 TORQUE CONVERTER................................................................................................................................................................. 978 TRANSMISSION..................................................................................................................................................................... 980 ECMV(ELECTRONIC CONTROL MODULATION VALVE)........................................................................................................................................ 984 FRONT AXLE ...................................................................................................................................................................... 985 DIFFERENTIAL..................................................................................................................................................................... 986 FINAL DRIVE...................................................................................................................................................................... 990 FRONT BRAKE...................................................................................................................................................................... 991 REAR BRAKE....................................................................................................................................................................... 992 PARKING BRAKE.................................................................................................................................................................... 993 REAR AXLE SUPPORT................................................................................................................................................................ 994 STEERING LINKAGE................................................................................................................................................................. 995 FRONT SUSPENSION CYLINDER........................................................................................................................................................ 997 REAR SUSPENSION CYLINDER......................................................................................................................................................... 998 PARKING BRAKE CHAMBER............................................................................................................................................................1000 SLACK ADJUSTER...................................................................................................................................................................1001 HYDRAULIC PUMP...................................................................................................................................................................1002 DEMAND VALVE.....................................................................................................................................................................1006 CROSS-OVER RELIEF VALVE..........................................................................................................................................................1006 HOIST VALVE......................................................................................................................................................................1007 STEERING CYLINDER................................................................................................................................................................1008 HOIST CYLINDER...................................................................................................................................................................1009
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