Service Manual for Komatsu HM300-1L Articulated Truck CEBM015200 PDF

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Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200 – PDF DOWNLOAD

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Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200 – PDF DOWNLOAD

Language : English
Pages :1236
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200 – PDF DOWNLOAD

SERIAL NUMBERS HM300-1L A10001 and UP

COVER 1
FOREWORD 2
SAFETY 3
SAFETY NOTICE 3
IMPORTANT SAFETY NOTICE 3
GENERAL PRECAUTIONS 3
PREPARATIONS FOR WORK 3
PRECAUTIONS DURING WORK 3
CONTENTS 2
GENERAL 5
GENERAL 5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 5
TESTING, ADJUSTING AND TROUBLESHOOTING 5
DISASSEMBLY AND ASSEMBLY 5
DRAWINGS AND SCHEMATICS 5
HOW TO READ THE SHOP MANUAL 6
Volumes 6
Distribution And Updating 6
Filing Method 6
Revised Edition Mark 6
Revisions 6
Symbols 6
HOISTING INSTRUCTIONS 7
HOISTING 7
Wire Ropes 7
PUSH PULL COUPLER 8
Type 1 8
Disconnection 8
Connection 8
Type 2 9
Disconnection 9
Connection 9
Type 3 10
Disconnection 10
Connection 10
COATING MATERIALS 11
STANDARD TIGHTENING TORQUE 13
Torque For Bolts And Nuts 13
Torque For Hose Nuts 14
Torque For Split Flange Bolts 14
Torque For Flared Nuts 14
Torques For O-ring Boss Piping Joints 15
Tightening Torques For O-ring Boss Plugs 15
Torque Table For Hoses (Taper Seal Type And Face Seal Type) 15
ELECTRIC WIRE CODE 16
Classification By Thickness 16
Classification By Color And Code 16
CONVERSION TABLES 17
Method Of Using The Conversion Table 17
01 GENERAL 23
SPECIFICATION DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 29
ENGINE OIL SPECIFICATIONS 30
NORMAL OPERATION 30
ARCTIC OPERATION 30
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS 31
FINAL DRIVE OIL SPECIFICATIONS 31
DRIVE AXLE OIL SPECIFICATIONS 31
DIESEL FUEL SPECIFICATIONS 31
COOLANT SPECIFICATIONS 32
GENERAL 32
WATER 32
ANTIFREEZE 32
SUPPLEMENTAL COOLANT ADDITIVES 34
COOLING SYSTEM TEST KIT 38
10 STRUCTURE AND FUNCTION 39
COOLING SYSTEMS 42
POWER TRAIN 43
DRIVE SYSTEM 43
OUTPUT SHAFT 45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING 47
TORQUE CONVERTER 48
TRANSMISSION POWER FLOW 52
WHEN LOCK-UP CLUTCH IS DISENGAGED 52
WHEN LOCK-UP CLUTCH IS ENGAGED 52
OIL FLOW 53
TRANSMISSION 54
FL – R CLUTCH 59
FH – 1ST CLUTCH 60
2ND – 3RD CLUTCH 61
DIFFERENTIAL LOCK 62
CLUTCH AND TRANSMISSION OPERATIONS 64
FORWARD 1ST 65
FORWARD 2ND 66
FORWARD 3RD 67
FORWARD 4TH 68
FORWARD 5TH 69
FORWARD 6TH 70
REVERSE 1ST 71
TRANSMISSION VALVE 72
ECMV (ELECTRONIC CONTROL MODULATION VALVE) 73
ECMV LOCK-UP CLUTCH 74
DURING DIRECT TRAVEL 75
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL 75
ECMV SPEED CLUTCH 76
ECMV OUTLINE 76
ECMV AND PROPORTIONAL SOLENOID 76
ECMV AND FILL SWITCH 76
ECMV OPERATION 77
ECMV FOR DIFFERENTIAL LOCK 79
MAIN AND TORQUE CONVERTER RELIEF VALVE 80
TORQUE CONVERTER RELIEF VALVE 81
MAIN RELIEF VALVE 81
DRIVE SHAFT 82
DRIVE AXLE 83
FRONT 83
CENTER 84
REAR 85
LOCKING DIFFERENTIAL 86
FRONT 86
CENTER 88
REAR 90
LIMITED SLIP DIFFERENTIAL 92
FINAL DRIVE SYSTEM 96
FRONT 96
CENTER 98
REAR 100
STEERING COLUMN 102
WHEEL BRAKING SYSTEM 103
PIPING DIAGRAM 103
BRAKE VALVE 105
ACCUMULATOR CHARGE VALVE 108
ACCUMULATOR 112
SLACK ADJUSTER 113
FRONT BRAKE 115
CENTER, REAR BRAKE 117
PROPORTIONAL REDUCING VALVE 120
BRAKE SYSTEM TANK 121
PARKING BRAKE 122
PARKING BRAKE CALIPER 124
SPRING CYLINDER 125
PARKING BRAKE SOLENOID 126
SUSPENSION SYSTEM 128
FRONT 128
REAR 130
SUSPENSION CYLINDER 134
OSCILLATION HITCH JOINT 136
STEERING, HOIST OIL PIPING DIAGRAM 139
DUMP BODY CONTROL 140
HYDRAULIC TANK AND FILTER 141
FLOW AMPLIFIER VALVE 142
STEERING VALVE 145
HAND PUMP AND SLEEVE CONNECTION 147
FUNCTION OF CENTER SPRING 148
STEERING CYLINDER 149
HOIST VALVE 150
HOIST VALVE AT HOLD POSITION 152
HOIST VALVE AT RAISE POSITION 153
HOIST VALVE AT FLOAT POSITION 154
HOIST VALVE AT LOWER POSITION 155
EPC VALVE 156
PILOT CHECK VALVE 157
HOIST CYLINDER 158
HYDRAULIC PUMP 159
STEERING, HOIST + PILOT PUMP 159
TRANSMISSION + FRONT BRAKE COOLING PUMP 160
BRAKE COOLING + BRAKE PUMP 161
AUXILIARY STEERING PUMP 162
CAB TILT SYSTEM VIEW 163
AIR CONDITIONING SYSTEM VIEW 164
AIR CONDITIONER UNIT 165
RECEIVER DRYER 166
CONDENSER 167
REFRIGERANT COMPRESSOR 168
MACHINE MONITOR SYSTEM 169
NETWORK DATA 169
MACHINE MONITOR PANEL 172
OPTION SETTING CONNECTOR DIAGRAM 174
ADJUSTING MACHINE MONITOR 174
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS 175
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH 178
CHECK FUNCTION OF MONITOR LAMPS AND METERS 179
SERVICE METER DISPLAY 179
ODOMETER 179
SERVICE MODE 179
OPERATION METHOD 181
AUTOMATIC SHIFT CONTROL SYSTEM 182
TRANSMISSION CONTROLLER 184
SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGE 187
GEAR SHIFTING CHARACTERISTICS 187
AUTOMATIC GEAR SHIFTING GRAPH 188
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD 189
SHIFT HOLD FUNCTION 190
GEAR SHIFTING TIME DELAY 190
SAFETY FUNCTIONS 190
SELF-DIAGNOSTIC FUNCTION 191
EMERGENCY STEERING SYSTEM 192
SENSORS AND SWITCHES 193
ENGINE SPEED SENSOR 193
ACCELERATOR PEDAL SENSOR 193
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS 195
STEERING OIL TEMPERATURE SENSOR 195
FUEL LEVEL SENSOR 196
TILT SENSOR 197
AIR CLEANER CLOGGING SENSOR 198
HYDRAULIC OIL LEVEL SENSOR 199
BODY POSITIONER SENSOR 200
RETARDER CONTROL SYSTEM 201
RETARDER CONTROLLER UNIT 202
RETARDER CONTROL FUNCTION 206
HOIST CONTROL FUNCTION 208
DIFFERENTIAL LOCK CONTROL FUNCTION 210
BRAKE CONTROL SYSTEM (E-SPEC) 212
BRAKE CONTROLLER (E-SPEC) UNIT 213
BRAKE CONTROL FUNCTION 217
HOIST CONTROL SYSTEM 218
DIFFERENTIAL LOCK CONTROL SYSTEM 220
DUMP CONTROL LEVER 222
20 TESTING, ADJUSTING AND TROUBLESHOOTING 227
STANDARD VALUE TABLE FOR ENGINE 229
STANDARD VALUE TABLE FOR CHASSIS 230
STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS 234
TOOLS FOR TESTING AND ADJUSTING 248
ENGINE COMPONENTS 249
MEASURING EXHAUST SMOKE 249
MEASURING EXHAUST TEMPERATURE 249
ADJUSTING VALVE CLEARANCE 249
MEASURING COMPRESSION PRESSURE 249
MEASURING CRANKCASE PRESSURE 249
MEASURING ENGINE OIL PRESSURE 249
MEASURING BOOST PRESSURE 249
MEASURING FUEL PRESSURE 249
BLEEDING AIR FROM FUEL SYSTEM 249
ADJUSTING ENGINE SPEED SENSOR 250
ADJUSTING ALTERNATOR BELT 252
TESTING TORQUE CONVERTER STALL SPEED 253
POWER TRAIN OIL PRESSURES 254
MEASURING POWER TRAIN MAIN RELIEF PRESSURE 255
MEASURING TORQUE CONVERTER INLET OIL PRESSURE 255
MEASURING TORQUE CONVERTER OUTLET OIL PRESSURE 255
MEASURING TORQUE CONVERTER LOCK-UP CLUTCH PRESSURE 256
MEASURING TRANSMISSION LO CLUTCH PRESSURE 257
MEASURING TRANSMISSION HI CLUTCH PRESSURE 257
MEASURING TRANSMISSION 1ST CLUTCH PRESSURE 257
MEASURING TRANSMISSION 2ND CLUTCH PRESSURE 258
MEASURING TRANSMISSION 3RD CLUTCH PRESSURE 258
MEASURING TRANSMISSION R CLUTCH PRESSURE 259
MEASURING INTER-AXLE DIFFERENTIAL LOCK CLUTCH PRESSURE 259
ADJUSTING TRANSMISSION SPEED SENSOR 260
BRAKE OIL PRESSURE 262
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE 262
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP 262
MEASURING ACTUATION PRESSURE ON PARKING BRAKE 263
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID 264
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE 265
TESTING BRAKE PERFORMANCE 266
TESTING BRAKING PERFORMANCE OF FOOT BRAKE 266
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE 266
TESTING PARKING BRAKE BRAKING PERFORMANCE 267
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE 267
BLEEDING AIR FROM BRAKE CIRCUIT 268
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE 268
BLEEDING AIR FROM WHEEL BRAKE 269
BLEEDING AIR FROM PARKING BRAKE CIRCUIT 269
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD 270
CHECKING BRAKE DISC 270
CHECKING BRAKE PAD 271
ADJUSTING PAD CLEARANCE 272
RELEASING EMERGENCY PARKING BRAKE 273
STEERING CIRCUIT PRESSURE 273
MEASURING STEERING RELIEF OIL PRESSURE 273
ADJUSTING STEERING RELIEF OIL PRESSURE 274
SUSPENSION CYLINDER 275
CHECKING CYLINDER LENGTH 275
RELEASING NITROGEN GAS 275
ADJUSTING OIL LEVEL 276
CHARGING WITH NITROGEN GAS 277
ADJUSTING CYLINDER LENGTH 278
TILTING THE CAB 279
PREPARATORY WORK 279
TILTING CAB UP 279
USING EXTERNAL CRANE 280
HOLDING CAB IN POSITION 280
LOWERING CAB DOWN 280
DUMP CIRCUIT PRESSURE 281
TESTING DUMP MAIN RELIEF OIL PRESSURE 281
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE 282
MEASURING DUMP PILOT RELIEF OIL PRESSURE 282
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE 283
BODY POSITIONER SENSOR 284
CHECKING SENSOR OUTPUT/INPUT VOLTAGE 284
ADJUSTING LINK LENGTH 284
CALIBRATING SYSTEM 285
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT 286
TRANSMISSION CONTROLLER 287
SETTING ROTARY SWITCH 287
ADJUSTING TRANSMISSION 287
ESCAPE METHOD FOR ELECTRICAL SYSTEM 288
MACHINE MONITOR 292
FUNCTIONS OF MACHINE MONITOR 296
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR 296
FLOW OF MODES AND FUNCTIONs 297
OPERATION AND DISPLAYS FOR OPERATOR MODE 299
SWITCHING TO SERVICE MODE AND SCREEN DISPLAY 307
POINTS TO REMEMBER WHEN TROUBLESHOOTING 328
SEQUENCE OF EVENTS IN TROUBLESHOOTING 330
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 331
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT 331
HANDLING ELECTRONIC CONTROL UNIT 336
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS 337
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 338
CHECKS BEFORE TROUBLESHOOTING 340
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS 341
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS 342
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS 344
CONNECTOR TYPES AND MOUNTING LOCATIONS 346
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 354
T-ADAPTER TABLE 379
CONNECTOR LAYOUT DRAWING 382
CONNECTOR ARRANGEMENT AND LOCATIONS 391
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM 397
CONTENT OF CODE DISPLAY (1) 400
CONTENT OF CODE DISPLAY (2) 402
CONTENT OF CODE DISPLAY (3) 404
CONTENT OF CODE DISPLAY (4) 406
CONTENT OF CODE DISPLAY (5) 408
CONTENT OF CODE DISPLAY (6) 410
INFORMATION CONTAINED IN TESTING PROCEDURES 412
(ENG-1) FAILURE CODE [A000N1] 414
ENGINE OVERSPEEDS (N1) 414
(ENG-2) FAILURE CODE [A570NX] 415
ENGINE OIL FILTER CLOG SENSOR SYSTEM 415
(ENG-3) FAILURE CODE [AD00L2] 416
COMMON RAIL HIGHER THAN SET VALUE 416
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3] 417
COMMON RAIL PRESSURE HIGH OR LOW 417
(ENG-6) FAILURE CODE [AD10MA] 419
(ENG-7) FAILURE CODE [AD10MB] 419
(ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB] 420
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM 420
(ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB] 422
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC2 SYSTEM 422
(ENG-12) FAILURE CODE [ADA1KA] 423
OPEN IN NO 1 INJECTOR SOLENOID VALVE 423
(ENG-13) FAILURE CODE [ADZKKB] 424
SHORT CIRCUIT IN NO 1, 2, 3 INJECTOR SOLENOID VALVE 424
(ENG-14) FAILURE CODE [ADB1KA] 428
OPEN IN NO 2 INJECTOR SOLENOID VALVE 428
(ENG-15) FAILURE CODE [ADC1KA] 430
OPEN IN NO 3 INJECTOR SOLENOID VALVE 430
(ENG-16) FAILURE CODE [ADD1KA] 432
OPEN IN NO 4 INJECTOR SOLENOID VALVE 432
(ENG-17) FAILURE CODE [ADDZKB] 434
SHORT CIRCUIT IN NO 4, 5, 6 INJECTOR SOLENOID VALVE 434
(ENG-18) FAILURE CODE [ADE1KA] 438
OPEN IN NO 5 INJECTOR SOLENOID VALVE 438
(ENG-19) FAILURE CODE [ADF1KA] 440
OPEN IN NO 6 INJECTOR SOLENOID VALVE 440
(ENG-20) FAILURE CODE [B@BAZG] 442
ENGINE OIL PRESSURE DROP (ZG) 442
(ENG-21) FAILURE CODE [B@BAZK] 444
ENGINE OIL LEVEL DROP (ZK) 444
(ENG-22) FAILURE CODE [B@BCNS] 446
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS) 446
(ENG-23) FAILURE CODE [D181KZ] 448
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) 448
(ENG-24) FAILURE CODE [D182KZ] 450
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) 450
(ENG-25) FAILURE CODE [D1D0KB] 452
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB) 452
(ENG-26) FAILURE CODE [D5ZAKX] 454
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX) 454
(ENG-27) FAILURE CODE [DB20KT] 456
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW 456
(ENG-28) FAILURE CODE [DB22KK] 458
DROP IN VOLTAGE LOAD POWER SUPPLY (KK) 458
(ENG-29) FAILURE CODE [DB29KQ] 460
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ) 460
(ENG-30) FAILURE CODE [DB2AMA] 462
“Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA) 462
(ENG-31) FAILURE CODE [KK11KB] 463
TROUBLE IN INPUT OF ignition switch C (KB) 463
(ENG-32) FAILURE CODE [DDA1L5] 464
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5) 464
(ENG-33) FAILURE CODE [DDE2L6] 466
ENGINE OIL PRESSURE DROP (L6) 466
(ENG-34) FAILURE CODE [DGE2KX] 468
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX) 468
(ENG-35) FAILURE CODE [DGE3LC] 469
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6) 469
(ENG-36) FAILURE CODE [DGE4KX] 470
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX) 470
(ENG-37) FAILURE CODE [DH30KX] 471
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX) 471
(ENG-38) FAILURE CODE [DH40KX] 472
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX) 472
(ENG-39) FAILURE CODE [DK10KX] 474
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX) 474
(ENG-40) FAILURE CODE [DLE3LC] 476
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM 476
(ENG-41) FAILURE CODE [DLE1LC] 477
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC) 477
(ENG-42) NO FAILURE CODE DISPLAYED 478
ENGINE DOES NOT CRANK 478
CONNECTOR ARRANGEMENT AND LOCATIONS 486
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM 492
CONTENT OF CODE DISPLAY (1) 498
CONTENT OF CODE DISPLAY (2) 500
CONTENT OF CODE DISPLAY (3) 502
CONTENT OF CODE DISPLAY (4) 504
CONTENT OF CODE DISPLAY (5) 506
CONTENT OF CODE DISPLAY (6) 508
CONTENT OF CODE DISPLAY (7) 510
CONTENT OF CODE DISPLAY (8) 512
CONTENT OF CODE DISPLAY (9) 514
CONTENT OF CODE DISPLAY (10) 516
CONTENT OF CODE DISPLAY (11) 518
CONTENT OF CODE DISPLAY (12) 520
CONTENT OF CODE DISPLAY (13) 522
INFORMATION CONTAINED IN TESTING PROCEDURES 524
(TM-1) FAILURE CODE [1380MW] 526
LOCK-UP CLUTCH SLIPPING (MW) 526
(TM-2) FAILURE CODE [1500LO] 528
TRANSMISSION CLUTCH (LO) 528
(TM-3) FAILURE CODE [15BONX] 530
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX) 530
(TM-4) FAILURE CODE [15GOMW] 532
“R” CLUTCH SLIPPING (MW) 532
(TM-5) FAILURE CODE [15HOMW] 534
“HI” CLUTCH SLIPPING (MW) 534
(TM-6) FAILURE CODE [15JOMW] 536
“LO” CLUTCH SLIPPING (MW) 536
(TM-7) FAILURE CODE [15KOMW] 538
1ST CLUTCH SLIPPING (MW) 538
(TM-8) FAILURE CODE [15LOMW] 540
2ND CLUTCH SLIPPING (MW) 540
(TM-9) FAILURE CODE [15MOMW] 542
3RD CLUTCH SLIPPING (MW) 542
(TM-10) FAILURE CODE [15SBL1] 544
ECMV FOR “R” CLUTCH NOT DISENGAGING (L1) 544
(TM-11) FAILURE CODE [15SBMA] 546
ECMV FOR “R” CLUTCH NOT ENGAGING (MA) 546
(TM-12) FAILURE CODE [15SCL1] 548
ECMV “HI” CLUTCH NOT DISENGAGING (L1) 548
(TM-13) FAILURE CODE [15SCMA] 550
ECMV “HI” CLUTCH NOT DISENGAGING (MA) 550
(TM-14) FAILURE CODE [15SDL1] 552
ECMV “LO” CLUTCH NOT DISENGAGING (L1) 552
(TM-15) FAILURE CODE [15SDMA] 554
ECMV “LO” CLUTCH NOT ENGAGING (MA) 554
(TM-16) FAILURE CODE [15SEL1] 556
ECMV “1ST” CLUTCH NOT DISENGAGING (L1) 556
(TM-17) FAILURE CODE [15SEMA] 558
ECMV “1ST” CLUTCH NOT ENGAGING (MA) 558
(TM-18) FAILURE CODE [15SFL1] 560
ECMV “2ND” CLUTCH NOT DISENGAGING (L1) 560
(TM-19) FAILURE CODE [15SFMA] 562
ECMV “2ND” CLUTCH NOT ENGAGING (MA) 562
(TM-20) FAILURE CODE [15SGL1] 564
ECMV “3RD” CLUTCH NOT DISENGAGING (L1) 564
(TM-21) FAILURE CODE [15SGMA] 566
ECMV “3RD” CLUTCH NOT ENGAGING (MA) 566
(TM-22) FAILURE CODE [15SJL1] 568
ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1) 568
(TM-23) FAILURE CODE [15SJMA] 570
ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA) 570
(TM-24) FAILURE CODE [15SKL1] 572
ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1) 572
(TM-25) FAILURE CODE [15SKMA] 574
ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA) 574
(TM-26) FAILURE CODE [2B61MW] 576
ECMV “INTER-AXLE” CLUTCH SLIPPING (MW) 576
(TM-27) FAILURE CODE [2F00KM] 578
PARKING BRAKE SYSTEM INDICATING FAILURE (KM) 578
(TM-28) FAILURE CODE [6014NX] 580
HYDRAULIC TANK FILTER CLOGGED (NX) 580
(TM-29) FAILURE CODE [989A00] 582
POSSIBLE ENGINE OVER SPEED CONDITION (00) 582
(TM-30) FAILURE CODE [989AKZ] 584
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ) 584
(TM-31)FAILURE CODE [989D00] 586
REAR OVERTURN SIGNAL OUT OF RANGE (00) 586
(TM-32)FAILURE CODE [AA10NX] 588
AIR CLEANER CLOG INDICATION (NX) 588
(TM-33) FAILURE CODE [AB00MA] 590
ALTERNATOR NOT CHARGING PROPERLY (MA) 590
(TM-34) FAILURE CODE [B@BCZK] 592
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK) 592
(TM-35) FAILURE CODE [B@HAZK] 594
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK) 594
(TM-36) FAILURE CODE [B@JANS] 595
STEERING OIL OVERHEAT CONDITION INDICATED (ZK) 595
(TM-37) FAILURE CODE [D1B0KZ] 596
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ) 596
(TM-38) FAILURE CODE [D5ZBKX] 598
DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX) 598
(TM-39) FAILURE CODE [D5ZCKZ] 600
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ) 600
(TM-40) FAILURE CODE [DF10KA] 602
FORCED NEUTRAL DEMAND SIGNAL (L4) 602
(TM-41) FAILURE CODE [D5ZEKX] 604
ENGINE LOAD SIGNAL OUT OF RANGE (KX) 604
(TM-42) FAILURE CODE [DAQ0KK] 606
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 606
(TM-43) FAILURE CODE [DAQ1KK] 608
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 608
(TM-44) FAILURE CODE [DAQ2KK] 610
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK) 610
(TM-45) FAILURE CODE [DAQ3KK] 612
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) 612
(TM-46) FAILURE CODE [DAQ5KP] 614
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP) 614
(TM-47) FAILURE CODE [DAQ9KM] 616
MISTAKEN OPERATION SETTING (KP) 616
(TM-48) FAILURE CODE [DAQ9KM] 617
NO MATCH IN MODEL SELECTION SIGNAL (KP) 617
(TM-49) FAILURE CODE [DAQAKQ] 618
TRANSMISSION CONTROLLER ROTARY SWITCH 618
(TM-50) FAILURE CODE [DAQSMA] 618
TRANSMISSION FUNCTION INOPERABLE 618
(TM-51) FAILURE CODE [DDTFKA] 620
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) 620
(TM-52) FAILURE CODE [DDTFKA] 622
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) 622
(TM-53) FAILURE CODE [DDTHKA] 624
“HI” CLUTCH SYSTEM OPEN OR SHORTED (KA) 624
(TM-54) FAILURE CODE [DDTJKA] 626
“LO” CLUTCH SYSTEM OPEN OR SHORTED (KA) 626
(TM-55) FAILURE CODE [DDTKKA] 628
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA) 628
(TM-56) FAILURE CODE [DDTLKA] 630
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) 630
(TM-57) FAILURE CODE [DDTMKA] 632
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA) 632
(TM-58) FAILURE CODE [DDTNKA] 634
“R” CLUTCH SYSTEM OPEN OR SHORTED (KA) 634
(TM-59) FAILURE CODE [DF10KA] 636
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) 636
(TM-60) FAILURE CODE [DF10KB] 638
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) 638
(TM-61) FAILURE CODE [DGF1KX] 640
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX) 640
(TM-63) FAILURE CODE [DGR3L8] 642
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) 642
(TM-64) FAILURE CODE [DGR4L8] 644
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) 644
(TM-65) FAILURE CODE [DGT1LX] 646
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX) 646
(TM-66) FAILURE CODE [DHT5KX] 648
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX) 648
(TM-67) FAILURE CODE [DHT5L6] 650
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6) 650
(TM-68) FAILURE CODE [DJF1KA] 652
FUEL LEVEL SENSOR OUT OF RANGE (L6) 652
(TM-69) FAILURE CODE [DK11KX] 654
THROTTLE ANGLE SENSOR OUT OF RANGE (KX) 654
(TM-70) FAILURE CODE [DLE2KA] 656
ENGINE SPEED SENSOR OPEN OR SHORTED (KA) 656
(TM-71) FAILURE CODE [DLE2LC] 657
ENGINE SPEED SENSOR OPEN OR SHORTED (LC) 657
(TM-72) FAILURE CODE [DLF1KA] 658
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 658
(TM-73) FAILURE CODE [DLF1LC] 659
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 659
(TM-74) FAILURE CODE [DLF2KA] 660
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 660
(TM-75) FAILURE CODE [DLF2LC] 661
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 661
(TM-76) FAILURE CODE [DLT3KA] 662
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) 662
(TM-77) FAILURE CODE [DLT3LC] 664
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) 664
(TM-78) FAILURE CODE [DXH0KA] 666
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA) 666
(TM-79) FAILURE CODE [DXH0KB] 668
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB) 668
(TM-80) FAILURE CODE [DXH1KA] 670
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA) 670
(TM-81) FAILURE CODE [DXH1KB] 672
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB) 672
(TM-82) FAILURE CODE [DXH2KA] 674
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA) 674
(TM-83) FAILURE CODE [DXH2KB] 676
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB) 676
(TM-84) FAILURE CODE [DXH3KA] 678
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA) 678
(TM-85) FAILURE CODE [DXH3KB] 680
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB) 680
(TM-86) FAILURE CODE [DXH4KA] 682
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA) 682
(TM-87) FAILURE CODE [DXH4KB] 684
1ST CLUTCH SYSTEM OPEN OR SHORTED (KB) 684
(TM-88) FAILURE CODE [DXH5KA] 686
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) 686
(TM-89) FAILURE CODE [DXH5KB] 688
2ND CLUTCH SYSTEM OPEN OR SHORTED (KB) 688
(TM-90) FAILURE CODE [DXH6KA] 690
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB) 690
(TM-91) FAILURE CODE [DXH6KB] 692
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB) 692
(TM-92) FAILURE CODE [DXH7KA] 694
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA) 694
(TM-93) FAILURE CODE [DXH7KB] 696
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB) 696
(TM-94) NO FAILURE CODE DISPLAYED 698
BACK-UP LIGHTS AND ALARM DO NOT OPERATE 698
CONNECTOR ARRANGEMENT AND LOCATIONS 704
BK CONTROL SYSTEM CIRCUIT DIAGRAM 710
CONTENT OF CODE DISPLAY (1) 716
CONTENT OF CODE DISPLAY (2) 718
CONTENT OF CODE DISPLAY (3) 720
CONTENT OF CODE DISPLAY (4) 722
CONTENT OF CODE DISPLAY (5) 724
CONTENT OF CODE DISPLAY (6) 726
INFORMATION CONTAINED IN TESTING PROCEDURES 728
(BK-1) FAILURE CODE [2G42ZG] 730
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG) 730
(BK-2) FAILURE CODE [2G43ZG] 731
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG) 731
(BK-3) FAILURE CODE [D1C0KZ] 732
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ) 732
(BK-4) FAILURE CODE [D5ZFKZ] 734
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) 734
(BK-5) FAILURE CODE [D5ZGKZ] 736
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) 736
(BK-6) FAILURE CODE [DB10KK] 738
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 738
(BK-7) FAILURE CODE [DB11KK] 740
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 740
(BK-8) FAILURE CODE [DB12KK] 742
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK) 742
(BK-9) FAILURE CODE [DB13KK] 744
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) 744
(BK-10) FAILURE CODE [DB19KM] 746
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM) 746
(BK-11) FAILURE CODE [DB1SKQ] 747
RETARDER CONTROL S-NET LINE MISMATCHED (KQ) 747
(BK-12) FAILURE CODE [DHU2KX] 748
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX) 748
(BK-13) FAILURE CODE [DHU3KX] 750
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX) 750
(BK-14) FAILURE CODE [DK51L5] 752
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB) 752
(BK-15) FAILURE CODE [DK52KX] 754
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX) 754
(BK-16) FAILURE CODE [DK53L8] 756
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8) 756
(BK-17) FAILURE CODE [DK54KX] 758
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX) 758
(BK-18) FAILURE CODE [DLF4KA] 760
TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA) 760
(BK-19) FAILURE CODE [DLT3KA] 762
TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA) 762
(BK-20) FAILURE CODE [DW71KZ] 764
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ) 764
(BK-21) FAILURE CODE [DK72KX] 766
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ) 766
(BK-22) FAILURE CODE [DW73KZ] 768
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ) 768
(BK-23) FAILURE CODE [DX11KA] 770
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) 770
(BK-24) FAILURE CODE [DX11KB] 771
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) 771
(BK-25) FAILURE CODE [DX11KY] 772
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY) 772
(BK-26) FAILURE CODE [DX12KA] 773
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) 773
(BK-27) FAILURE CODE [DX12KB] 774
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) 774
(BK-28) FAILURE CODE [DX12KY] 775
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) 775
(BK-29) FAILURE CODE [DX13KA] 776
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA) 776
(BK-30) FAILURE CODE [DX13KB] 778
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB) 778
(BK-31) FAILURE CODE [DX13KY] 780
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY) 780
(BK-32) NO FAILURE CODE DISPLAYED 782
PARKING BRAKE SYSTEM FAILURE 782
CONNECTOR ARRANGEMENT AND LOCATIONS 788
MON CONTROL SYSTEM CIRCUIT DIAGRAM 794
CONTENT OF CODE DISPLAY (1) 798
INFORMATION CONTAINED IN TESTING PROCEDURES 801
(MON-1) FAILURE CODE [B@C6NS] 803
FRONT BRAKE OIL OVERHEAT CONDITION (NS) 803
(MON-2) FAILURE CODE [B@C8NS] 804
CENTER BRAKE OIL OVERHEAT CONDITION (NS) 804
(MON-3) FAILURE CODE [B@CENS] 805
TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS) 805
(MON-4) FAILURE CODE [DAF0KM] 806
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) 806
(MON-5) FAILURE CODE [DAF9KM] 808
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) 808
(MON-6) FAILURE CODE [DAFSKQ] 809
MODEL SELECTION DOES NOT MATCH (KQ) 809
(MON-7) FAILURE CODE [DAQSKR] 810
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 810
(MON-8) FAILURE CODE [DB1SKR] 812
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 812
(MON-9) FAILURE CODE [DB2SKR] 814
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) 814
(MON-10) FAILURE CODE [DV00KB] 816
DEFECTIVE ALARM BUZZER (KB) 816
(MON-11) NO FAILURE CODE DISPLAYED 818
WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL 818
(MON-12) NO FAILURE CODE DISPLAYED 820
WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL 820
(MON-13) NO FAILURE CODE DISPLAYED 822
ALARM BUZZER DOES NOT SOUND 822
(MON-14) NO FAILURE CODE DISPLAYED 824
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL 824
(MON-15) NO FAILURE CODE DISPLAYED 825
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED 825
(MON-16) NO FAILURE CODE DISPLAYED 826
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE 826
(MON-17) NO FAILURE CODE DISPLAYED 828
POWER MODE SWITCH DOES NOT WORK PROPERLY 828
(MON-18) NO FAILURE CODE DISPLAYED 829
AISS FUNCTION DOES NOT WORK PROPERLY 829
(MON-19) NO FAILURE CODE DISPLAYED 830
EXHAUST BRAKE DOES NOT WORK PROPERLY 830
(MON-20) NO FAILURE CODE DISPLAYED 832
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY 832
(MON-21) NO FAILURE CODE DISPLAYED 833
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY 833
(MON-22) NO FAILURE CODE DISPLAYED 836
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY 836
(H-1) 840
THE MACHINE DOES NOT MOVE 840
(H-2) AND (H-3) 841
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY) 841
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING) 841
(H-4) AND (H-5) 842
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS 842
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE 842
(H-6) 843
MACHINE LACKS POWER OR SPEED WHEN TRAVELING 843
(H-6) 844
ABNORMAL OPERATION AT SOME SPEED RANGES 844
(H-6) 845
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE 845
(H-7) 846
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES 846
(H-8) 847
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH) 847
(H-9) 848
TORQUE CONVERTER OIL PRESSURE LOW 848
(H-10) 849
FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY 849
(H-11) 850
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE 850
(H-12) 851
STEERING EFFORT SEAMS HEAVY 851
(H-13) 852
STEERING SYSTEM DOES NOT OPERATE 852
(H-14) 853
STEERING WHEEL VIBRATES 853
(H-15) 854
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER 854
(H-16) 855
DUMP OPERATIONS DO NOT WORK 855
(H-17) 856
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY 856
HYDRAULIC POWER TRAIN CIRCUIT DIAGRAM 857
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 858
USING TROUBLESHOOTING CHARTS 860
S-7 Exhaust gas is black (incomplete combustion) 862
(S-1) STARTING PERFORMANCE IS POOR 864
(S-2) ENGINE DOES NOT CRANK 865
(1) ENGINE DOES NOT TURN 865
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT OF STACK (FUEL IS NOT BEING INJECTED) 866
(3) EXHAUST SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 867
(S-3) ENGINE RPM DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 868
(S-4) ENGINE STOPS DURING OPERATIONS 869
(S-5) ENGINE DOES NOT RUN SMOOTHLY (HUNTING) 870
(S-6) ENGINE LACKS OUTPUT (OR LACKS POWER) 871
(S-7) EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 872
(S-8) OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 873
(S-9) OIL BECOMES CONTAMINATED QUICKLY 874
(S-10) FUEL CONSUMPTION IS EXCESSIVE 875
(S-11) OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR LEVEL GOES DOWN 876
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 877
(S-13) OIL LEVEL RISES (COOLANT, FUEL IN OIL) 878
(S-14) COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 879
(S-15) ABNORMAL NOISE IS HEARD 880
(S-16) VIBRATION IS EXCESSIVE 881
30 DISASSEMBLY AND ASSEMBLY 883
HOW TO USE MANUAL 887
Removal and Installation of Assemblies 887
Disassembly and Assembly of Assemblies 889
PRECAUTIONS WHEN CARRYING OUT REPAIR OPERATION 891
SPECIAL TOOL LIST 894
SKETCHES OF SPECIAL TOOLS 898
CONNECTOR REPAIR PROCEDURES 910
Stripping Insulation 910
Wire Inspection 910
Contact Terminal Removal (HD30 Type) 911
Crimping Contact Terminal (HD30 Type) 912
Insertion Of Contact Terminal (HD30 Type) 913
Contact Terminal Removal (DT Type) 914
Crimping Contact Terminal (DT Type) 915
Insertion Of Contact Terminal (DT Type) 916
ENGINE 917
REMOVAL 917
INSTALLATION 922
RADIATOR 924
REMOVAL 924
INSTALLATION 926
OUTPUT SHAFT SYSTEM 927
REMOVAL 927
INSTALLATION 929
DISASSEMBLY 931
ASSEMBLY 933
TRANSMISSION AND FRONT DIFFERENTIAL 935
REMOVAL 935
INSTALLATION 941
SEPARATING FRONT DIFFERENTIAL FROM TRANSMISSION 944
REMOVAL 944
INSTALLATION 945
TORQUE CONVERTER 946
DISASSEMBLY 946
ASSEMBLY 950
TRANSMISSION 956
DISASSEMBLY 956
ASSEMBLY 981
FRONT DIFFERENTIAL1011
DISASSEMBLY1011
ASSEMBLY1017
CENTER AXLE AND DIFFERENTIAL1029
AXLE ASSEMBLY1029
REMOVAL1029
INSTALLATION1031
DIFFERENTIAL1032
REMOVAL1032
INSTALLATION1034
DISASSEMBLY1037
ASSEMBLY1044
REAR AXLE AND DIFFERENTIAL1058
AXLE ASSEMBLY1058
REMOVAL1058
INSTALLATION1060
DIFFERENTIAL ASSEMBLY1061
REMOVAL1061
INSTALLATION1063
DISASSEMBLY1064
ASSEMBLY1069
FRONT FINAL DRIVE AND BRAKE ASSEMBLY1080
REMOVAL1080
INSTALLATION1082
DISASSEMBLY1083
ASSEMBLY1089
CENTER FINAL DRIVE AND BRAKE ASSEMBLY1097
REMOVAL1097
INSTALLATION1099
DISASSEMBLY1100
ASSEMBLY1103
REAR FINAL DRIVE AND BRAKE ASSEMBLY1110
REMOVAL1110
INSTALLATION1111
DISASSEMBLY1112
ASSEMBLY1114
SUSPENSION SYSTEM1119
FRONT SUSPENSION1119
REMOVAL1119
INSTALLATION1121
REAR SUSPENSION1122
REMOVAL1122
INSTALLATION1122
EQUALIZER BEAM1123
REMOVAL1123
INSTALLATION1125
HITCH FRAME SYSTEM1126
REMOVAL1126
INSTALLATION1133
DISASSEMBLY1137
ASSEMBLY1139
ORBITAL STEERING UNIT1144
UNIT BREAKDOWN VIEW1144
DISASSEMBLY1146
ASSEMBLY1149
FLOW AMP VALVE1155
REMOVAL1155
INSTALLATION1156
HOIST VALVE1157
REMOVAL1157
INSTALLATION1158
HYDRAULIC CYLINDER1159
STEERING CYLINDER1159
DISASSEMBLY1159
ASSEMBLY1161
HOIST CYLINDER1164
DISASSEMBLY1164
ASSEMBLY1166
TRUCK BODY ASSEMBLY1170
REMOVAL1170
INSTALLATION1171
OPERATOR’S SEAT1172
DISASSEMBLY1172
ASSEMBLY1179
90 DIAGRAMS AND SCHEMATICS1185
CAB1187
CLIMATE CONTROL SYSTEM1187
CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER1189
CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER1191
LIGHTING WIPER AND RELAY BANK1193
RELAY AND SWITCH CIRCUITS1195
MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS1197
DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS1199
DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT1201
RETARDER SYSTEM1203
RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING1205
TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL1207
TRANSMISSION CONTROLLER1209
TO HARNESS OUTSIDE OF CAB1211
TO HARNESS OUTSIDE OF CAB AND TO ENGINE1213
CHASSIS1215
SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OD CAB1215
TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS1217
TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS1219
CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS1221
CHASSIS SENSOR SYSTEMS1223
CONNECTORS OUTSIDE OF CAB1225
ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS1227
DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM1229
BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR1231
TRANSMISSION SELECTOR SYSTEM1233
BRAKE HYDRAULIC CIRCUIT DIAGRAM1235

DESCRIPTION:

Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200 – PDF DOWNLOAD

SERIAL NUMBERS HM300-1L A10001 and UP

G.B 13/12/24