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Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual SEN01081-18 – PDF DOWNLOAD
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Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual
SERIAL NUMBERS:
HD465- 10001-10037
HD465-10101 and up
HD605- 8001-8032
HD605-10101 and up
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Description
Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual
FILE DETAILS:
Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD465-7E0, HD605-7E0
Serial Number: 10001-10037, 10101 and up, 8001-8032, 10101 and up
Book Code: SEN01081-18
Issued: Printed in Japan 1995
Language: English
Pages: 1646
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu HD465-7E0 HD605-7E0 Dump Truck Shop Manual
COVER ................................................................................................................................................................ 0 00 Index and foreword................................................................................................................................................. 0 Index............................................................................................................................................................. 3 Composition of shop manual.................................................................................................................................... 4 Table of contents............................................................................................................................................. 6 Foreword and general information.................................................................................................................................. 21 Safety notice................................................................................................................................................. 22 How to read the shop manual................................................................................................................................... 27 Explanation of terms for maintenance standard................................................................................................................. 29 Handling of electric equipment and hydraulic component........................................................................................................ 31 Handling of connectors newly used for engines................................................................................................................. 40 How to read electric wire code................................................................................................................................ 43 Precautions when carrying out operation....................................................................................................................... 46 Method of disassembling and connecting push-pull type coupler................................................................................................. 49 Standard tightening torque table.............................................................................................................................. 52 Conversion table.............................................................................................................................................. 56 01 Specification...................................................................................................................................................... 0 Specification and technical data.................................................................................................................................. 63 Specification drawing......................................................................................................................................... 64 Specifications................................................................................................................................................ 66 Weight table.................................................................................................................................................. 74 Fuel, coolant and lubricants.................................................................................................................................. 75 10 Structure, function and maintenance standard....................................................................................................................... 0 Engine and cooling system......................................................................................................................................... 79 Radiator, torque converter oil cooler, after cooler, work equipment oil cooler, fuel cooler................................................................... 80 Fuel system................................................................................................................................................... 82 Brake oil cooler.............................................................................................................................................. 83 Output shaft.................................................................................................................................................. 84 Power train, Part 1............................................................................................................................................... 87 Power train skeleton.......................................................................................................................................... 88 Drive shaft................................................................................................................................................... 90 Torque converter and transmission hydraulic piping............................................................................................................ 92 Brake cooling oil control valve (BCV)......................................................................................................................... 94 Torque converter.............................................................................................................................................. 96 Torque converter valve........................................................................................................................................ 103 Transmission.................................................................................................................................................. 105 Transmission control valve.................................................................................................................................... 121 ECMV.......................................................................................................................................................... 122 Power train, Part 2............................................................................................................................................... 131 Axle.......................................................................................................................................................... 132 Differential.................................................................................................................................................. 134 Final drive................................................................................................................................................... 135 Wheels........................................................................................................................................................ 136 Steering system................................................................................................................................................... 139 Steering column............................................................................................................................................... 140 Steering linkage.............................................................................................................................................. 141 Brake system...................................................................................................................................................... 145 Brake piping.................................................................................................................................................. 146 Brake valve................................................................................................................................................... 148 Secondary brake valve......................................................................................................................................... 151 Relay valve................................................................................................................................................... 152 Front brake off valve......................................................................................................................................... 153 Accumulator charge valve...................................................................................................................................... 154 Accumulator................................................................................................................................................... 158 Slack adjuster................................................................................................................................................ 159 Brake......................................................................................................................................................... 161 Parking brake solenoid valve.................................................................................................................................. 165 Undercarriage and frame........................................................................................................................................... 167 Suspension.................................................................................................................................................... 168 Suspension cylinder........................................................................................................................................... 170 Rear axle support............................................................................................................................................. 178 Hydraulic system.................................................................................................................................................. 181 Steering and hoist hydraulic piping........................................................................................................................... 182 Dump body control............................................................................................................................................. 184 Hydraulic tank................................................................................................................................................ 185 Steering valve................................................................................................................................................ 186 Crossover relief valve........................................................................................................................................ 190 Steering cylinder............................................................................................................................................. 191 Steering control valve........................................................................................................................................ 192 Hoist valve................................................................................................................................................... 198 Dump control valve (EPC valve)................................................................................................................................ 204 Hoist cylinder................................................................................................................................................ 208 Hydraulic pump................................................................................................................................................ 209 Work equipment (Body)............................................................................................................................................. 215 Auto greasing system.......................................................................................................................................... 216 Cab and its attachments........................................................................................................................................... 239 ROPS cab...................................................................................................................................................... 240 Air conditioner............................................................................................................................................... 241 Rear view monitor............................................................................................................................................. 247 Electrical system, Part 1......................................................................................................................................... 251 Machine monitor system........................................................................................................................................ 252 Electrical system, Part 2......................................................................................................................................... 285 Automatic shift control system................................................................................................................................ 286 Transmission controller....................................................................................................................................... 290 External power supply heater.................................................................................................................................. 304 Automatic emergency steering system........................................................................................................................... 306 Automatic suspension system................................................................................................................................... 310 Retarder control system....................................................................................................................................... 313 Battery disconnector switch................................................................................................................................... 324 Dump control lever............................................................................................................................................ 330 Electrical system, Part 3......................................................................................................................................... 335 Payload meter II (Card type).................................................................................................................................. 336 Electrical system, Part 4......................................................................................................................................... 367 VHMS controller related....................................................................................................................................... 368 ASR system (If equipped)...................................................................................................................................... 392 Sensors, switches............................................................................................................................................. 398 20 Standard value table............................................................................................................................................... 0 Standard service value table...................................................................................................................................... 419 Standard value table for engine............................................................................................................................... 420 Standard value table for machine.............................................................................................................................. 422 30 Testing and adjusting.............................................................................................................................................. 0 Testing and adjusting, Part 1..................................................................................................................................... 433 Tools for testing, adjusting, and troubleshooting............................................................................................................. 435 Sketch of special tool........................................................................................................................................ 441 Testing engine speed.......................................................................................................................................... 442 Testing air supply pressure (boost pressure).................................................................................................................. 443 Testing exhaust temperature................................................................................................................................... 444 Testing exhaust gas color..................................................................................................................................... 446 Adjustment of valve clearance................................................................................................................................. 448 Testing of compression pressure............................................................................................................................... 450 Testing blow-by pressure...................................................................................................................................... 453 Testing engine oil pressure................................................................................................................................... 454 Testing EGR valve and bypass valve drive oil pressure......................................................................................................... 455 Handling of fuel system devices............................................................................................................................... 457 Releasing residual pressure from fuel system.................................................................................................................. 457 Testing of fuel pressure...................................................................................................................................... 458 Reduced cylinder mode operation............................................................................................................................... 459 No-injection cranking......................................................................................................................................... 459 Testing of fuel return rate and fuel leakage.................................................................................................................. 460 Bleeding air from fuel circuit................................................................................................................................ 462 Testing the fuel circuit for leakage.......................................................................................................................... 463 Replacement and adjustment of fan belt........................................................................................................................ 464 Replacement and adjustment of alternator and air conditioner compressor belt.................................................................................. 465 Testing and adjusting, Part 2..................................................................................................................................... 467 Testing torque converter stall speed.......................................................................................................................... 469 Testing power train oil pressure.............................................................................................................................. 470 Adjusting transmission speed sensor........................................................................................................................... 477 Testing and adjusting brake oil pressure...................................................................................................................... 478 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas......................................................... 481 Testing brake performance..................................................................................................................................... 487 Bleeding air from brake circuit............................................................................................................................... 489 Testing wear of front brake pad............................................................................................................................... 490 Testing wear of rear brake disc............................................................................................................................... 491 Method of releasing parking brake in an emergency............................................................................................................. 492 Testing and adjusting front suspension cylinder............................................................................................................... 493 Testing and adjusting rear suspension cylinder................................................................................................................ 497 Testing and adjusting front suspension cylinder (Automatic suspension specification).......................................................................... 501 Testing and adjusting hydraulic pressure in steering, hoist circuit........................................................................................... 502 Testing and adjusting oil pressure in dump EPC circuit........................................................................................................ 505 Air bleeding from steering cylinder........................................................................................................................... 506 Procedure for raising dump body in emergency.................................................................................................................. 507 Procedure for lowering dump body in emergency................................................................................................................. 508 Adjusting body positioner sensor.............................................................................................................................. 510 Handling of voltage circuit of engine controller.............................................................................................................. 511 Adjusting transmission controller............................................................................................................................. 511 Method for emergency escape at electrical system failure...................................................................................................... 512 Testing and adjusting, Part 3..................................................................................................................................... 517 Setting and adjusting of devices.............................................................................................................................. 518 Special functions of machine monitor (EMMS)................................................................................................................... 530 Testing and adjusting, Part 4..................................................................................................................................... 553 Special functions of machine monitor (EMMS)................................................................................................................... 554 Testing and adjusting, Part 5..................................................................................................................................... 595 Request for opening ORBCOMM terminal.......................................................................................................................... 596 VHMS controller initial setting procedure..................................................................................................................... 598 Using method of KOMTRAX functions of ORBCOMM terminal......................................................................................................... 618 Precautions for replacing VHMS controller..................................................................................................................... 621 Pm Clinic check sheet......................................................................................................................................... 627 Initial setting of payload meter.............................................................................................................................. 631 Setting of payload meter built in VHMS........................................................................................................................ 632 Setting of card-type payload meter (PLM-II) after installation or replacement................................................................................. 640 40 Troubleshooting.................................................................................................................................................... 0 General information on troubleshooting............................................................................................................................ 647 Points to remember when troubleshooting....................................................................................................................... 648 Sequence of events in troubleshooting......................................................................................................................... 649 Check before troubleshooting.................................................................................................................................. 650 Classification and procedures for troubleshooting............................................................................................................. 651 Contents of troubleshooting table............................................................................................................................. 652 Connection table for connector pin numbers.................................................................................................................... 654 T-branch box and T-branch adapter table....................................................................................................................... 690 Failure code table and fuse locations............................................................................................................................. 695 Failure codes table........................................................................................................................................... 696 Fuse locations................................................................................................................................................ 707 Troubleshooting by failure code, Part 1........................................................................................................................... 713 Failure code [1500L0] (Dual engagement)....................................................................................................................... 715 Failure code [15B0NX] (Transmission oil filter: Clogging)..................................................................................................... 716 Failure code [15F0KM] (R → F shifting abuse 1: Mistake in operation).......................................................................................... 718 Failure code [15F0MB] (R → F shifting abuse 2: Mistake in operation).......................................................................................... 718 Failure code [15F7KM] (Forward clutch disk abuse: Mistake in operation or setting)............................................................................ 719 Failure code [15G0MW] (R clutch: Slipping).................................................................................................................... 720 Failure code [15G7KM] (Reverse clutch disk abuse: Mistake in operation or setting)............................................................................ 722 Failure code [15H0MW] (Hi clutch: Slipping)................................................................................................................... 724 Failure code [15J0MW] ( Lo clutch: Slipping).................................................................................................................. 726 Failure code [15K0MW] (1st clutch: Slipping).................................................................................................................. 728 Failure code [15L0MW] (2nd clutch: Slipping).................................................................................................................. 730 Failure code [15M0MW] (3rd clutch: Slipping).................................................................................................................. 732 Failure code [15N0MW] (4th clutch: Slipping).................................................................................................................. 734 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF)...................................................................... 736 Failure code [15SBMA] (R clutch solenoid: Malfunction)........................................................................................................ 738 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF)..................................................................... 739 Failure code [15SCMA] (Hi clutch solenoid: Malfunction)....................................................................................................... 742 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF)..................................................................... 743 Failure code [15SDMA] (Lo clutch solenoid: Malfunction)....................................................................................................... 746 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF).................................................................... 747 Failure code [15SEMA] (1st clutch solenoid: Malfunction)...................................................................................................... 750 Troubleshooting by failure code, Part 2........................................................................................................................... 753 Failure code [15SFL1] 2nd clutch solenoid: Fill signal is ON when command current is OFF...................................................................... 756 Failure code [15SFMA] 2nd clutch solenoid: Malfunction........................................................................................................ 759 Failure code [15SGL1] 3rd clutch solenoid: Fill signal is ON when command current is OFF...................................................................... 760 Failure code [15SGMA] 3rd clutch solenoid: Malfunction........................................................................................................ 763 Failure code [15SHL1] 4th clutch solenoid: Fill signal is ON when command current is OFF...................................................................... 764 Failure code [15SHMA] 4th clutch solenoid: Malfunction........................................................................................................ 767 Failure code [15SJMA] Lockup clutch solenoid: Malfunction..................................................................................................... 768 Failure code [2C4MNX] Retarder cooling oil filter: Clogging................................................................................................... 770 Failure code [2F00KM] Parking brake: Mistake in operation or setting.......................................................................................... 772 Failure code [2G42ZG] Accumulator: Oil pressure reduction (Front)............................................................................................. 775 Failure code [2G43ZG] Accumulator: Oil pressure reduction (Rear).............................................................................................. 775 Failure code [6014NX] Hydraulic oil filter: Clogging.......................................................................................................... 776 Failure code [989A00] Engine over run prevention command signal: Operating.................................................................................... 778 Failure code [989D00] Rear section tipping over alarm: Alarm is activated..................................................................................... 778 Failure code [A570NX] Engine oil filter: Clogging............................................................................................................. 779 Failure code [AA10NX] Air cleaner element: Clogging........................................................................................................... 780 Failure code [AB00MA] Alternator: Malfunction................................................................................................................. 782 Failure code [B@BAZG] Abnormal lowering of engine oil pressure: Lowering of oil pressure...................................................................... 784 Failure code [B@BAZK] Engine oil: Level too low............................................................................................................... 785 Failure code [B@BCNS] Engine: Overheat........................................................................................................................ 786 Failure code [B@BCZK] Lowering of radiator coolant: Lowering of level ........................................................................................ 788 Failure code [B@BFZK] Lowering of fuel level.................................................................................................................. 790 Failure code [B@C7NS] Brake cooling oil: Overheating (Rear)................................................................................................... 792 Failure code [B@CENS] Overheating of torque converter oil..................................................................................................... 794 Failure code [B@GAZK] Battery electrolyte level: Lowering of level............................................................................................ 795 Failure code [B@JANS] Steering oil temperature: Overheat...................................................................................................... 796 Troubleshooting by failure code, Part 3........................................................................................................................... 799 Failure code [CA111] Abnormality in engine controller......................................................................................................... 802 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................................................... 804 Failure code [CA122] Charge pressure sensor high error........................................................................................................ 806 Failure code [CA123] Charge pressure sensor low error......................................................................................................... 808 Failure code [CA131] Throttle sensor high error............................................................................................................... 810 Failure code [CA132] Throttle sensor low error................................................................................................................ 813 Failure code [CA135] Engine oil pressure sensor high error.................................................................................................... 814 Failure code [CA141] Engine oil pressure sensor low error..................................................................................................... 816 Failure code [CA144] Coolant temperature sensor high error.................................................................................................... 818 Failure code [CA145] Coolant temperature sensor low error..................................................................................................... 820 Failure code [CA153] Charge temperature sensor high error..................................................................................................... 822 Failure code [CA154] Charge temperature sensor low error...................................................................................................... 824 Failure code [CA187] Sensor power supply 2 low error.......................................................................................................... 824 Failure code [CA212] Engine oil temperature sensor high error................................................................................................. 826 Failure code [CA213] Engine oil temperature sensor low error.................................................................................................. 828 Failure code [CA221] Atmospheric pressure sensor high error................................................................................................... 830 Failure code [CA222] Atmospheric pressure sensor low error.................................................................................................... 832 Failure code [CA227] Sensor power supply 2 high error......................................................................................................... 834 Failure code [CA234] Engine overspeed......................................................................................................................... 836 Failure code [CA238] Ne speed sensor power supply error....................................................................................................... 838 Failure code [CA263] Fuel temperature sensor high error....................................................................................................... 840 Failure code [CA265] Fuel temperature sensor low error........................................................................................................ 842 Failure code [CA271] PCV1 short circuit....................................................................................................................... 844 Failure code [CA272] PCV1 disconnection....................................................................................................................... 846 Failure code [CA273] PCV2 short circuit....................................................................................................................... 848 Failure code [CA274] PCV2 disconnection....................................................................................................................... 850 Failure code [CA322] Injector #1 system disconnection or short circuit........................................................................................ 852 Failure code [CA323] Injector #5 system disconnection or short circuit........................................................................................ 854 Failure code [CA324] Injector #3 system disconnection or short circuit........................................................................................ 856 Failure code [CA325] Injector #6 system disconnection or short circuit........................................................................................ 858 Failure code [CA331] Injector #2 system disconnection or short circuit........................................................................................ 860 Failure code [CA332] Injector #4 system disconnection or short circuit........................................................................................ 862 Failure code [CA342] Engine controller data inconsistency..................................................................................................... 864 Failure code [CA351] Injectors drive circuit error............................................................................................................ 864 Failure code [CA352] Sensor power supply 1 low error.......................................................................................................... 865 Failure code [CA386] Sensor power supply 1 high error......................................................................................................... 866 Troubleshooting by failure code, Part 4........................................................................................................................... 869 Failure code [CA431] Idle validation switch error............................................................................................................. 872 Failure code [CA432] Idle validation action error............................................................................................................. 876 Failure code [CA441] Battery voltage low error................................................................................................................ 876 Failure code [CA442] Battery voltage high error............................................................................................................... 877 Failure code [CA449] Common rail pressure high error 2........................................................................................................ 877 Failure code [CA451] Common rail pressure sensor high error................................................................................................... 878 Failure code [CA452] Common rail pressure sensor low error.................................................................................................... 880 Failure code [CA553] Common rail pressure high error 1........................................................................................................ 881 Failure code [CA554] Common rail pressure sensor: In-range error.............................................................................................. 882 Failure code [CA559] Supply pump no-pressure feed error 1..................................................................................................... 883 Failure code [CA689] Engine Ne speed sensor error............................................................................................................. 886 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................................................... 888 Failure code [CA757] All engine controller data lost error.................................................................................................... 889 Failure code [CA778] Engine Bkup speed sensor error........................................................................................................... 890 Failure code [CA1228] EGR valve servo error 1................................................................................................................. 892 Failure code [CA1625] EGR valve servo error 2................................................................................................................. 893 Failure code [CA1626] Short circuit in bypass valve solenoid drive system..................................................................................... 894 Failure code [CA1627] Disconnection in bypass valve solenoid drive system..................................................................................... 896 Failure code [CA1628] Bypass valve servo error 1.............................................................................................................. 897 Failure code [CA1629] Bypass valve servo error 2.............................................................................................................. 898 Failure code [CA1631] Bypass valve lift sensor high error..................................................................................................... 900 Failure code [CA1632] Bypass valve lift sensor low error...................................................................................................... 902 Failure code [CA1633] KOMNET (datalink timeout) error......................................................................................................... 903 Failure code [CA2185] Throttle sensor supply voltage high error............................................................................................... 904 Failure code [CA2186] Throttle sensor power supply low error.................................................................................................. 906 Failure code [CA2249] Supply pump no-pressure feed error 2.................................................................................................... 907 Failure code [CA2271] EGR valve lift sensor high error........................................................................................................ 908 Failure code [CA2272] EGR valve lift sensor low error......................................................................................................... 910 Failure code [CA2351] Short circuit in EGR valve solenoid drive system........................................................................................ 912 Failure code [CA2352] Disconnection in EGR valve solenoid drive system........................................................................................ 914 Failure code [CA2555] Intake heater relay voltage low error................................................................................................... 915 Failure code [CA2556] Intake heater relay voltage high error.................................................................................................. 916 Troubleshooting by failure code, Part 5........................................................................................................................... 919 Failure code [D19HKB] Stop lamp relay output system: Short circuit............................................................................................ 921 Failure code [D5ZKKZ] Front brake cut-off solenoid valve: Disconnection, short circuit or short circuit to power supply line.................................. 922 Failure code [DAF9KM] Wrong connection of connector........................................................................................................... 924 Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication.................................................................... 925 Failure code [DAQ0KK] Transmission controller direct power supply: Lowering of power supply voltage........................................................... 926 Failure code [DAQ0KT] Transmission controller nonvolatile memory: Abnormality in controller................................................................... 928 Failure code [DAQ2KK] Transmission controller solenoid power supply: Power supply voltage too low............................................................. 930 Failure code [DAQ9KQ] Transmission controller: Disagreement of model selection................................................................................ 932 Failure code [DAQRKR] Abnormality in CAN communication (Transmission)......................................................................................... 933 Failure code [DAQRMA] Transmission controller option setting: Malfunction..................................................................................... 938 Failure code [DB10KT] Retarder controller nonvolatile memory: Abnormality in controller....................................................................... 938 Failure code [DB12KK] Retarder controller solenoid power supply: Power supply system trouble.................................................................. 939 Failure code [DB13KK] Retarder controller battery direct power supply: Power supply voltage too low........................................................... 941 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)................................................................................... 943 Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled......................................................................... 945 Failure code [DB1RMA] Disagreement of option setting (Retarder controller).................................................................................... 949 Failure code [DB2RKR] CAN communication (engine controller): Communication disabled........................................................................... 950 Failure code [DBB0KK] or VHMS_LED display: "n9" → "01" VHMS controller: Low power supply voltage (input)...................................................... 956 Failure code [DBB0KQ] or VHMS_LED display: "nF" → "11" VHMS controller: Disagreement of model selection signals............................................... 958 Failure code [DBB3KK] or VHMS_LED display: "n9" → "05" VHMS controller battery power supply: Low power supply voltage (input)................................. 960 Failure code [DBB5KP] or VHMS_LED display: "n9" → "04" VHMS controller 5 V power supply output: Low output voltage............................................ 962 Failure code [DBB6KP] or VHMS_LED display: "n9" → "02" VHMS controller 24 V power supply output: Low output voltage........................................... 964 Failure code [DBB7KP] or VHMS_LED display: "n9" → "03" VHMS controller 12 V power supply output: Low output voltage........................................... 966 Failure code [DBBQKR] or VHMS_LED display: "n8" → "02" VHMS controller CAN communication: Defective communication (Abnormality in target component system).... 967 Failure code [DBBRKR] Abnormality in CAN communication (VHMS)................................................................................................. 967 Failure code [DBC2KK] ABS controller solenoid power supply: Power supply system trouble....................................................................... 968 Failure code [DBC3KK] ABS controller battery direct power supply: Power supply voltage too low................................................................ 970 Failure code [DBC9KQ] Disagreement of model selection (ABS controller)........................................................................................ 972 Failure code [DBCRKR] Abnormality in CAN communication (ABS).................................................................................................. 973 Failure code [DBCRMA] Disagreement of option setting (ABS controller)......................................................................................... 977 Failure code [DDD7KX] Trouble in travel speed setting switch system: Out of input signal range................................................................ 978 Failure code [DDD8KA] ARSC system switch system: Disconnection (If equipped).................................................................................. 980 Failure code [DDD8KB] ARSC system switch system: Short circuit (If equipped).................................................................................. 982 Failure code [DDD9KA] ABS system switch system: Disconnection................................................................................................. 984 Failure code [DDD9KB] ABS system switch system: Short circuit................................................................................................. 986 Failure code [DDDAKA] ASR system switch: Disconnection........................................................................................................ 988 Failure code [DDDAKB] ASR system switch: Short circuit........................................................................................................ 990 Failure code [DDP6L4] Service brake pressure switch trouble (Rear)............................................................................................ 992 Failure code [DDTHKA] Hi clutch fill switch: Disconnection.................................................................................................... 994 Failure code [DDTJKA] Lo clutch fill switch: Disconnection.................................................................................................... 996 Failure code [DDTKKA] 1st clutch fill switch: Disconnection................................................................................................... 998 Failure code [DDTLKA] 2nd clutch fill switch: Disconnection...................................................................................................1000 Failure code [DDTMKA] (3rd clutch fill switch: Disconnection).................................................................................................1002 Failure code [DDTNKA] R clutch fill switch: Disconnection.....................................................................................................1004 Failure code [DDTPKA] 4th clutch fill switch: Disconnection...................................................................................................1006 Failure code [DF10KA] Gear shift lever: Disconnection.........................................................................................................1008 Failure code [DF10KB] Gear shift lever: Short circuit.........................................................................................................1011 Failure code [DGE5KX] or VHMS_LED display: "n4" → "01" Atmospheric temperature sensor: Out of input signal range..............................................1016 Failure code [DGF1KX] Transmission oil temperature sensor: Out of input signal range..........................................................................1018 Failure code [DGR2KZ] Retarder oil temperature sensor system trouble: Ground fault (Rear wheel)...............................................................1020 Failure code [DGR6KX] Steering oil temperature sensor: Input signal out of range..............................................................................1022 Failure code [DGT1KX] Torque converter oil temperature sensor: Out of input signal range......................................................................1024 Troubleshooting by failure code, Part 6...........................................................................................................................1027 Failure code [DGT4KA] (or VHMS_LED display: “n3” → “12”) (Exhaust gas temperature sensor (F): Disconnection)..................................................1029 Failure code [DGT4KB] (or VHMS_LED display: “n3” → “11”) (Exhaust gas temperature sensor (F): Short circuit)..................................................1032 Failure code [DGT5KA] (or VHMS_LED display: “n3” → “22”) (Exhaust gas temperature sensor (R): Disconnection)..................................................1035 Failure code [DGT5KB] (or VHMS_LED display: “n3” → “21”) (Exhaust gas temperature sensor (R): Short circuit)..................................................1038 Failure code [DHE5KB] (or VHMS_LED display: “n3” → “32”) (Blow-by pressure sensor: Short circuit).............................................................1041 Failure code [DHE5KY] (or VHMS_LED display: “n3” → “31”) (Blow-by pressure sensor: Short circuit with power supply line)......................................1044 Failure code [DHP4KY] (or VHMS_LED display: “n5” → “44”) Short circuit in suspension pressure sensor system (Front right).....................................1046 Failure code [DHP4KZ] (or VHMS_LED display: “n5” → “43”) Disconnection or ground fault in suspension pressure sensor system (Front right).....................1048 Failure code [DHP5KY] (or VHMS_LED display: “n5” → “54”) Short circuit in suspension pressure sensor system (Front left)......................................1050 Failure code [DHP5KZ] (or VHMS_LED display: “n5” → “53”) Disconnection or ground fault in suspension pressure sensor system (Front left)......................1052 Failure code [DHP6KA] Trouble in suspension pressure sensor system (Right rear)...............................................................................1054 Failure code [DHP6KX] Trouble in suspension pressure sensor system (Right rear)...............................................................................1055 Failure code [DHP6KY] (or VHMS_LED display: “n5” → “64”) Short circuit in suspension pressure sensor system (Right rear)......................................1058 Failure code [DHP6KZ] (or VHMS_LED display: “n5” → “63”) Disconnection or ground fault in suspension pressure sensor system (Right rear)......................1060 Failure code [DHP7KA] Suspension pressure sensor system: Disconnection (Left rear)............................................................................1062 Failure code [DHP7KX] Failure in suspension pressure sensor system trouble: Out of input signal range (Left rear).............................................1064 Failure code [DHP7KY] or VHMS_LED display: "n5" → "74" Suspension pressure sensor system: Short circuit (Left rear)...........................................1066 Failure code [DHP7KZ] or VHMS_LED display: "n5" → "73" Suspension pressure sensor system: Disconnection or ground fault (Left rear)...........................1068 Failure code [DHT5KX] Torque converter oil pressure sensor: Out of input signal range.........................................................................1070 Failure code [DHT5L6] Torque converter oil pressure sensor: Disagreement of run and stop condition with signal................................................1072 Failure code [DHU2KX] Front accumulator oil pressure sensor: Out of input signal range........................................................................1074 Failure code [DHU3KX] Rear accumulator oil pressure sensor: Out of input signal range.........................................................................1076 Failure code [DHU6KX] Trouble in ABS control valve pressure sensor (Front right)..............................................................................1078 Failure code [DHU7KX] Trouble in ABS control valve pressure sensor (Front left)...............................................................................1080 Failure code [DHU8KX] Trouble in ABS control valve pressure sensor (Front right)..............................................................................1082 Failure code [DHU9KX] Trouble in ABS control valve pressure sensor (Front right)..............................................................................1084 Failure code [DJF1KA] Fuel level sensor: Disconnection........................................................................................................1086 Failure code [DK30KX] Steering angle potentiometer: Trouble (Disconnection)...................................................................................1088 Failure code [DK51L5] Retarder lever potentiometer: Potentiometer signal is inconsistent with swich signal....................................................1089 Failure code [DK52KX] Failure in hoist lever potentiometer 1: Out of input signal range.......................................................................1092 Failure code [DK53L8] Failure in hoist lever potentiometer 2: Disagreement of analog signal...................................................................1094 Failure code [DK54KX] Body positioner sensor: Out of input signal range.......................................................................................1096 Failure code [DKD0L6] Failure in steering speed sensor........................................................................................................1098 Failure code [DKH0KX] Clinometer sensor signal out of range...................................................................................................1100 Failure code [DKH1KX] or VHMS_LED display: "n4"→"33" Abnormality in clinometer sensor.........................................................................1102 Failure code [DLF1KA] Transmission input shaft speed sensor: Disconnection....................................................................................1104 Failure code [DLF1LC] Transmission input shaft speed sensor: Disagreement of revolution speed signal..........................................................1106 Failure code [DLF2KA] Transmission intermediate shaft speed sensor: Disconnection.............................................................................1108 Failure code [DLF2LC] Transmission intermediate shaft speed sensor: Disagreement of revolution speed signal...................................................1110 Troubleshooting by failure code, Part 7...........................................................................................................................1113 Failure code [DLF6KA] Disconnection in wheel speed sensor (Front right).......................................................................................1115 Failure code [DLF6L3] Trouble in wheel speed sensor (Front right).............................................................................................1116 Failure code [DLF7KA] Disconnection in wheel speed sensor (Front left)........................................................................................1117 Failure code [DLF7L3] Trouble in wheel speed sensor (Front left)..............................................................................................1118 Failure code [DLF8KA] Disconnection in wheel speed sensor (Right rear)........................................................................................1120 Failure code [DLF8L3] Trouble in wheel speed sensor (Right rear)..............................................................................................1122 Failure code [DLF8LC] Trouble in wheel speed sensor system (Right rear).......................................................................................1124 Failure code [DLF8MA] Disconnection in wheel speed sensor (Right rear)........................................................................................1125 Failure code [DLF9KA] Disconnection in wheel speed sensor (Left rear).........................................................................................1126 Failure code [DLF9L3] Trouble in wheel speed sensor (Left rear)...............................................................................................1128 Failure code [DLF9LC] Trouble in wheel speed sensor system (Left rear)........................................................................................1130 Failure code [DLF9MA] Disconnection in wheel speed sensor (Left rear).........................................................................................1131 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system..........................................................................1132 Failure code [DLT3LC] Trouble in transmission output shaft speed sensor.......................................................................................1134 Failure code [DLT4KA] Disconnection in transmission output shaft speed sensor.................................................................................1136 Failure code [DLT4MA] Disconnection in transmission output shaft speed sensor.................................................................................1138 Failure code [DV00KB] Short circuit in buzzer output..........................................................................................................1140 Failure code [DW2AKA] Disconnection in main pressure variable valve output....................................................................................1142 Failure code [DW2AKB] Ground fault in main pressure variable valve output circuit.............................................................................1144 Failure code [DW2AKY] Hot short in main pressure variable valve output circuit................................................................................1146 Failure code [DW2AL1] Defective reset of main pressure variable valve.........................................................................................1148 Failure code [DW2ALH] Malfunction of main pressure variable valve.............................................................................................1150 Failure code [DW35KZ] Trouble in output system of auto suspension solenoid 1 (Disconnection or short circuit).................................................1152 Failure code [DW36KZ] Trouble in output system of auto suspension solenoid 2 (Disconnection or short circuit).................................................1154 Failure code [DW72KZ] Trouble in kick-out solenoid output system (Disconnection or short circuit).............................................................1156 Failure code [DW73KZ] Trouble in hoist select valve output system (Disconnection or short circuit)............................................................1158 Failure code [DW78KZ] Trouble in brake cooling valve (BCV) (rear wheel) output system (Disconnection or short circuit)........................................1160 Failure code [DWNBK4] Trouble in ASR shut-off valve (Valve keeps operating)...................................................................................1162 Failure code [DWNBKA] Disconnection in ASR shut-off valve output circuit......................................................................................1164 Failure code [DWNBKB] Ground fault in ASR shut-off valve output circuit.......................................................................................1166 Failure code [DWNBKY] Short circuit in ASR shut-off valve output circuit......................................................................................1168 Failure code [DWNBMA] Trouble in ASR shut-off valve (Valve does not operate)..................................................................................1169 Failure code [DWNDKZ] Trouble in ABS cut-off valve (Front) system.............................................................................................1170 Failure code [DWNDMA] Defective ABS cut-off valve (Front).....................................................................................................1172 Failure code [DWNEKZ] Trouble in ABS cut-off valve (Rear) system..............................................................................................1174 Failure code [DWNEMA] Defective ABS cut-off valve (Rear)......................................................................................................1176 Troubleshooting by failure code, Part 8...........................................................................................................................1179 Failure code [DX11K4] Trouble in rear brake proportional pressure reducing solenoid valve (Valve keeps operating).............................................1182 Failure code [DX11KA] Disconnection in rear brake proportional pressure reducing solenoid valve output circuit................................................1184 Failure code [DX11KB] Short circuit in rear brake proportional pressure reducing solenoid valve...............................................................1185 Failure code [DX11KY] Short circuit in rear wheel proportional pressure reducing solenoid valve output circuit................................................1186 Failure code [DX11MA] Trouble in rear wheel proportional pressure reducing solenoid valve (Valve does not operate)............................................1187 Failure code [DX13KA] Disconnection in hoist EPC valve output circuit.........................................................................................1188 Failure code [DX13KB] Short circuit in hoist EPC valve output circuit.........................................................................................1190 Failure code [DX13KY] Short circuit in hoist EPC valve output circuit.........................................................................................1192 Failure code [DX17K4] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve keeps operating)............................................1194 Failure code [DX17KA] Disconnection in ASR proportional pressure reducing solenoid valve (right) output circuit...............................................1196 Failure code [DX17KB] Ground fault in ASR proportional pressure reducing solenoid valve (right) output circuit................................................1198 Failure code [DX17KY] Short circuit in ASR proportional pressure reducing solenoid valve (right) output circuit...............................................1200 Failure code [DX17MA] Trouble in ASR proportional pressure reducing solenoid valve (right) (Valve does not operate)...........................................1200 Failure code [DX18K4] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve keeps operating).............................................1202 Failure code [DX18KA] Disconnection in ASR proportional pressure reducing solenoid valve (left) output circuit................................................1204 Failure code [DX18KB] Ground fault in ASR proportional pressure reducing solenoid valve (left) output circuit.................................................1206 Failure code [DX18KY] Short circuit in ASR proportional pressure reducing solenoid valve (left) output circuit................................................1208 Failure code [DX18MA] Trouble in ASR proportional pressure reducing solenoid valve (left) (Valve does not operate)............................................1208 Failure code [DX21KA] Disconnection in ABS control valve output circuit (Front right).........................................................................1209 Failure code [DX21KB] Ground fault in ABS control valve output circuit (Front right)..........................................................................1210 Failure code [DX21KY] Hot short in ABS control valve output circuit (Front right).............................................................................1211 Failure code [DX21MA] Defective ABS control valve (Front right)...............................................................................................1212 Failure code [DX22KA] Disconnection in ABS control valve output circuit (Front left)..........................................................................1213 Failure code [DX22KB] Ground fault in ABS control valve output circuit (Front left)...........................................................................1214 Failure code [DX22KY] Hot short in ABS control valve output circuit (Front left)..............................................................................1215 Failure code [DX22MA] Defective ABS control valve (Front left)................................................................................................1216 Failure code [DX23KA] Disconnection in ABS control valve output circuit (Rear right)..........................................................................1217 Failure code [DX23KB] Ground fault in ABS control valve output circuit (Rear right)...........................................................................1218 Failure code [DX23KY] Hot short in ABS control valve output circuit (Rear right)..............................................................................1219 Failure code [DX23MA] Defective ABS control valve (Rear right)................................................................................................1220 Failure code [DX24KA] Disconnection in ABS control valve output circuit (Rear left)...........................................................................1221 Failure code [DX24KB] Ground fault in ABS control valve output circuit (Rear left)............................................................................1222 Failure code [DX24KY] Hot short in ABS control valve output circuit (Rear left)...............................................................................1223 Failure code [DX24MA] Defective ABS control valve (Rear left).................................................................................................1224 Failure code [DX25MA] Defective ABS front wheel system control valve..........................................................................................1225 Failure code [DX26MA] Defective ABS rear wheel system control valve...........................................................................................1225 Troubleshooting by failure code, Part 9...........................................................................................................................1227 Failure code [DXH1KA] Lockup clutch solenoid output circuit: Disconnection....................................................................................1230 Failure code [DXH1KB] Lockup clutch solenoid output circuit: Short circuit....................................................................................1232 Failure code [DXH1KY] Lockup clutch solenoid output circuit: Short circuitto power supply line................................................................1234 Failure code [DXH2KA] Hi clutch solenoid output circuit: Disconnection........................................................................................1236 Failure code [DXH2KB] Hi clutch solenoid output circuit: Short circuit........................................................................................1238 Failure code [DXH2KY] Hi clutch solenoid output circuit: Short circuit top ower supply line...................................................................1240 Failure code [DXH3KA] Lo clutch solenoid output circuit: Disconnection........................................................................................1244 Failure code [DXH3KB] Lo clutch solenoid output circuit: Short circuit........................................................................................1246 Failure code [DXH3KY] Lo clutch solenoid output circuit: Short circuit in power supply line...................................................................1248 Failure code [DXH4KA] 1st clutch solenoid output circuit: Disconnection.......................................................................................1252 Failure code [DXH4KB] 1st clutch solenoid output circuit: Short circuit.......................................................................................1254 Failure code [DXH4KY] 1st clutch solenoid output circuit: Short circuit to power supply line..................................................................1256 Failure code [DXH5KA] 2nd clutch solenoid output circuit: Disconnection.......................................................................................1260 Failure code [DXH5KB] 2nd clutch solenoid output circuit: Short circuit.......................................................................................1262 Failure code [DXH5KY] 2nd clutch solenoid output circuit: Short circuit in power supply line..................................................................1264 Failure code [DXH6KA] 3rd clutch solenoid output circuit: Disconnection.......................................................................................1268 Failure code [DXH6KB] 3rd clutch solenoid output circuit: Short circuit.......................................................................................1270 Failure code [DXH6KY] 3rd clutch solenoid output circuit: Short circuit to power supply line..................................................................1272 Failure code [DXH7KA] R clutch solenoid output circuit: Disconnection.........................................................................................1276 Failure code [DXH7KB] R clutch solenoid output circuit: Short circuit.........................................................................................1278 Failure code [DXH7KY] R clutch solenoid output circuit: Short circuit to power supply line....................................................................1280 Failure code [DXHHKA] 4th clutch solenoid output circuit: Disconnection.......................................................................................1282 Failure code [DXHHKB] 4th clutch solenoid output circuit: Short circuit.......................................................................................1284 Failure code [DXHHKY] 4th clutch solenoid output circuit: Short circuit to power supply line..................................................................1286 Failure code [F@BBZL] or VHMS_LED display: "n3"→"38" Blow-by pressure: High error.............................................................................1289 Failure code [F@BYNR] or VHMS_LED display: "n3"→"62" Exhaust gas temperature (F): Abnormal heat...............................................................1290 Failure code [F@BYNS] or VHMS_LED display: "n3"→"61" Exhaust gas temperature (F): Overheat....................................................................1292 Failure code [F@BZNR] or VHMS_LED display: "n3"→"72" Exhaust gas temperature (R): Abnormal heat...............................................................1294 Failure code [F@BZNS] or VHMS_LED display: "n3"→"71" Exhaust gas temperature (R): Overheat....................................................................1296 Troubleshooting of electrical system (E-mode).....................................................................................................................1299 Before troubleshooting of electric system.....................................................................................................................1301 Contents of troubleshooting table.............................................................................................................................1302 E-1 Engine does not start.....................................................................................................................................1303 E-2 Automatic preheating does not operate.....................................................................................................................1306 E-3 Machine monitor does not display all, when starting switch is turned ON...................................................................................1310 E-4 Machine monitor does not operate when starting switch is OFF..............................................................................................1312 E-5 Alarm buzzer does not sound...............................................................................................................................1314 E-6 Alarm buzzer does not stop sounding.......................................................................................................................1316 E-7 Gauges of machine monitor, caution lamps or character display section do not display properly.............................................................1318 E-8 A selection of the display in character display section cannot be changed.................................................................................1319 E-9 Power mode selecting function does not operate properly...................................................................................................1322 E-10 AISS function does not operate properly..................................................................................................................1323 E-11 Seat belt caution lamp does not display properly.........................................................................................................1324 E-12 Turn signal lamp or turning lamp (hazard lamp) do not work properly......................................................................................1325 E-13 Night illumination (lighting) does not work properly.....................................................................................................1328 E-14 Emergency steering does not operate......................................................................................................................1340 E-15 Hoist lever does not operate normally....................................................................................................................1346 E-16 Electric priming pump does not operate or does not stop automatically....................................................................................1348 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................................1351 Contents of troubleshooting table.............................................................................................................................1353 H-1 Machine does not start....................................................................................................................................1354 H-2 Machine does not travel smoothly (hunting)................................................................................................................1356 H-3 Lockup cannot be cancelled................................................................................................................................1356 H-4 Excessive shock when starting or shifting excessive.......................................................................................................1357 H-5 Transmission does not shift up............................................................................................................................1358 H-6 Machine lacks power or speed when traveling...............................................................................................................1360 H-7 Time lag is excessive when starting or shifting gear......................................................................................................1364 H-8 Torque converter oil temperature is high..................................................................................................................1366 H-9 Torque converter oil pressure is low......................................................................................................................1367 H-10 Front brake is ineffective...............................................................................................................................1368 H-11 Rear brake is ineffective................................................................................................................................1369 H-12 Steering wheel is heavy..................................................................................................................................1370 H-13 Steering wheel does not work.............................................................................................................................1371 H-14 Steering wheel vibrates..................................................................................................................................1372 H-15 Dump body lifting speed is slow..........................................................................................................................1373 H-16 Dump body does not work..................................................................................................................................1374 H-17 Excessive hydraulic drift of dump body...................................................................................................................1375 Troubleshooting of engine (S-mode)................................................................................................................................1377 Method of using troubleshooting chart.........................................................................................................................1380 S-1 Starting performance of engine is poor....................................................................................................................1384 S-2 Engine does not start.....................................................................................................................................1386 S-3 Engine does not pick up smoothly..........................................................................................................................1390 S-4 Engine stops during operation.............................................................................................................................1391 S-5 Engine does not rotate smoothly...........................................................................................................................1392 S-6 Engine lack output (or lacks power).......................................................................................................................1393 S-7 Exhaust gas is black (incomplete combustion)..............................................................................................................1394 S-8 Oil consumption is excessive (or exhaust gas is blue).....................................................................................................1396 S-9 Oil becomes dirty quickly.................................................................................................................................1397 S-10 Fuel consumption is excessive............................................................................................................................1398 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................................................................................1399 S-12 Oil pressure drops.......................................................................................................................................1400 S-13 Oil level rises (Entry of coolant or fuel)...............................................................................................................1402 S-14 Coolant temperature becomes too high (Overheating).......................................................................................................1404 S-15 Abnormal noise is made...................................................................................................................................1405 S-16 Vibration is excessive...................................................................................................................................1406 S-17 Air cannot be bled from fuel circuit.....................................................................................................................1408 50 Disassembly and assembly........................................................................................................................................... 0 General information on disassembly and assembly...................................................................................................................1411 How to read this manual.......................................................................................................................................1412 Coating materials list........................................................................................................................................1414 Special tool list.............................................................................................................................................1417 Sketches of special tools.....................................................................................................................................1420 Engine and cooling system.........................................................................................................................................1425 Removal and installation of fuel supply pump assembly.........................................................................................................1426 Removal and installation of fuel injector assembly............................................................................................................1429 Removal and installation of cylinder head assembly............................................................................................................1433 Removal and installation of engine front seal.................................................................................................................1445 Removal and installation of engine rear seal..................................................................................................................1448 Removal and installation of engine assembly...................................................................................................................1452 Removal and installation of radiator assembly.................................................................................................................1459 Removal and installation of output shaft assembly.............................................................................................................1463 Disassembly and assembly of output shaft assembly.............................................................................................................1464 Removal and installation of brake and power train oil cooler assembly.........................................................................................1467 Power train, Part 1...............................................................................................................................................1471 Removal and installation of torque converter and transmission assembly........................................................................................1472 Separation and coupling of transmission assembly and torque converter assembly................................................................................1475 Disassembly and assembly of transmission assembly and torque converter assembly...............................................................................1476 Disassembly and assembly of torque converter assembly.........................................................................................................1478 Disassembly and assembly of transmission assembly.............................................................................................................1488 Removal and installation of transmission control valve assembly (ECMV assembly)...............................................................................1519 Disassembly and assembly of transmission control valve assembly (ECMV assembly)...............................................................................1520 Power train, Part 2...............................................................................................................................................1525 Removal and installation of differential assembly.............................................................................................................1526 Disassembly and assembly of differential assembly.............................................................................................................1528 Removal and installation of final drive carrier assembly......................................................................................................1540 Disassembly and assembly of final drive carrier assembly......................................................................................................1541 Disassembly and assembly of front wheel hub assembly..........................................................................................................1542 Steering system...................................................................................................................................................1547 Disassembly and assembly of steering cylinder assembly........................................................................................................1548 Brake system......................................................................................................................................................1553 Removal and installation of front brake caliper pads..........................................................................................................1554 Removal and installation of front brake calipers assembly.....................................................................................................1555 Disassembly and assembly of front brake calipers assembly.....................................................................................................1556 Removal and installation of final drive and rear brake assembly...............................................................................................1558 Removal and installation of final drive, rear brake, and parking brake assembly...............................................................................1561 Disassembly and assembly of final drive, rear brake, and parking brake assembly...............................................................................1562 Undercarriage and frame...........................................................................................................................................1575 Removal and installation of front wheel assembly..............................................................................................................1576 Removal and installation of rear wheel assembly...............................................................................................................1578 Removal and installation of front suspension cylinder assembly................................................................................................1580 Disassembly and assembly of front suspension cylinder assembly (Cylinder with buffer ring)....................................................................1582 Removal and installation of rear suspension cylinder assembly.................................................................................................1585 Disassembly and assembly of rear suspension cylinder assembly (Cylinder with buffer ring).....................................................................1586 Hydraulic system..................................................................................................................................................1591 Disassembly and assembly of hoist cylinder assembly...........................................................................................................1592 Body..............................................................................................................................................................1597 Removal and installation of body assembly.....................................................................................................................1598 Cab and its attachments...........................................................................................................................................1603 Disassembly and assembly of operator's seat assembly..........................................................................................................1604 Removal and installation of air conditioner unit assembly.....................................................................................................1613 Electrical system.................................................................................................................................................1617 Removal and installation of engine controller assembly........................................................................................................1618 Removal and installation of transmission controller assembly..................................................................................................1619 Removal and installation of retarder controller assembly......................................................................................................1620 90 Diagrams and drawings.............................................................................................................................................. 0 Hydraulic diagrams and drawings...................................................................................................................................1623 Power train hydraulic circuit diagram.........................................................................................................................1624 Steering and hoist hydraulic circuit diagram..................................................................................................................1625 Brake hydraulic circuit diagram...............................................................................................................................1627 Electrical diagrams and drawings..................................................................................................................................1631 Electrical circuit diagram inside cab (1/3)...................................................................................................................1633 Electrical circuit diagram inside cab (2/3)...................................................................................................................1634 Electrical circuit diagram inside cab (3/3)...................................................................................................................1635 Electrical circuit diagram outside cab (1/3)..................................................................................................................1636 Electrical circuit diagram outside cab (2/3)..................................................................................................................1637 Electrical circuit diagram outside cab (3/3)..................................................................................................................1638 Electrical circuit diagram for VHMS...........................................................................................................................1639 Electrical circuit diagram for ASR (If equipped)..............................................................................................................1640 Air conditioner electrical circuit diagram....................................................................................................................1641 Electrical circuit diagram for auto greasing (If equipped)....................................................................................................1642 Electrical circuit diagram of external power supply heater....................................................................................................1643 Connectors table and arrangement drawing .....................................................................................................................1644
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