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Komatsu HM350-1 Service Workshop Manual 1001 and up – PDF DOWNLOAD
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Komatsu HM350-1 Service Workshop Manual
Machine model
HM350-1
Serial number
1001 and up
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Description
Komatsu HM350-1 Service Workshop Manual 1001 and up
FILE DETAILS:
Komatsu HM350-1 Service Workshop Manual
Brands: Komatsu
Manuals Type: Shop Manual
Machine Model: HM350-1
Serial Number: 1001 and up
Book Code: SEBM024912
Language: English
Pages: 1050
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM350-1 Service Workshop Manual
FOREWORD:
General :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu- rate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service work- shop. For ease of understanding. the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function:
This section explains the structure and function of each component It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. in addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems‘ with “Causes‘ are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each compo- nent, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. in addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu HM350-1 Service Workshop Manual
COVER ........................................................................................................................................................... 1 CONTENTS......................................................................................................................................................... 2 01 GENERAL....................................................................................................................................................... 27 SPECIFICATION DRAWINGS....................................................................................................................................... 28 SPECIFICATIONS............................................................................................................................................... 29 WEIGHT TABLE................................................................................................................................................. 32 FUEL, COOLANT AND LUBRICANTS................................................................................................................................. 33 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.................................................................................................................. 35 RADIATOR, OIL COOLER, AFTERCOOLER............................................................................................................................ 36 POWER TRAIN SKELETON......................................................................................................................................... 37 OUTPUT SHAFT................................................................................................................................................. 41 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING........................................................................................................... 43 TORQUE CONVERTER............................................................................................................................................. 45 TRANSMISSION................................................................................................................................................. 51 TRANSMISSION VALVE........................................................................................................................................... 69 ECMV (ELECTRONIC CONTROL MODULATION VALVE)................................................................................................................... 70 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE................................................................................................................... 77 DRIVE SHAFT.................................................................................................................................................. 79 AXLE......................................................................................................................................................... 80 DIFFERENTIAL................................................................................................................................................. 83 LIMITED SLIP DIFFERENTIAL.................................................................................................................................... 96 FINAL DRIVE.................................................................................................................................................. 100 STEERING COLUMN.............................................................................................................................................. 105 BRAKE PIPING................................................................................................................................................. 106 BRAKE VALVE.................................................................................................................................................. 108 ACCUMULATOR CHARGE VALVE..................................................................................................................................... 111 PROPORTIONAL REDUCING VALVE.................................................................................................................................. 113 BRAKE SYSTEM TANK............................................................................................................................................ 114 PARKING BRAKE................................................................................................................................................ 115 PARKING BRAKE CALIPER........................................................................................................................................ 117 SPRING CYLINDER.............................................................................................................................................. 118 PARKING BRAKE SOLENOID....................................................................................................................................... 119 SUSPENSION................................................................................................................................................... 120 SUSPENSION CYLINDER.......................................................................................................................................... 125 OSCILLATION HITCH............................................................................................................................................ 127 STEERING, HOIST OIL PRESSURE PIPING DIAGRAM.................................................................................................................. 130 DUMP BODY CONTROL............................................................................................................................................ 131 HYDRAULIC TANK AND FILTER.................................................................................................................................... 132 FLOW AMP VALVE............................................................................................................................................... 133 STEERING VALVE............................................................................................................................................... 136 STEERING CYLINDER............................................................................................................................................ 140 HOIST VALVE.................................................................................................................................................. 141 EPC VALVE.................................................................................................................................................... 147 PILOT CHECK VALVE............................................................................................................................................ 148 HOIST CYLINDER............................................................................................................................................... 149 HYDRAULIC PUMP............................................................................................................................................... 150 CAB TILT..................................................................................................................................................... 156 AIR CONDITIONER.............................................................................................................................................. 157 MACHINE MONITOR SYSTEM....................................................................................................................................... 162 AUTOMATIC SHIFT CONTROL SYSTEM............................................................................................................................... 176 TRANSMISSION CONTROLLER...................................................................................................................................... 178 AUTO EMERGENCY STEERING SYSTEM............................................................................................................................... 184 SENSORS, SWITCHES............................................................................................................................................ 185 RETARDER CONTROL SYSTEM...................................................................................................................................... 193 BRAKE CONTROL SYSTEM (E-SPEC)................................................................................................................................ 203 DUMP CONTROL LEVER........................................................................................................................................... 213 20 TESTING AND ADJUSTING......................................................................................................................................... 218 STANDARD VALUE TABLE FOR ENGINE.............................................................................................................................. 219 STANDARD VALUE TABLE FOR CHASSIS............................................................................................................................. 220 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................... 224 TESTING AND ADJUSTING........................................................................................................................................ 238 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................ 239 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)........................................................................................................... 241 MEASURING EXHAUST TEMPERATURE............................................................................................................................ 242 MEASURING EXHAUST COLOR.................................................................................................................................. 244 MEASURING COMPRESSION PRESSURE........................................................................................................................... 245 ADJUSTING VALVE CLEARANCE................................................................................................................................ 246 MEASURING BLOW-BY PRESSURE............................................................................................................................... 247 MEASURING ENGINE OIL PRESSURE............................................................................................................................ 248 HANDING EQUIPMENT IN FUEL CIRCUIT........................................................................................................................ 249 RELEASING REMAINING PRESSURE IN FUEL SYSTEM.............................................................................................................. 249 MEASURING FUEL PRESSURE.................................................................................................................................. 250 BLEEDING AIR FROM FUEL CIRCUIT........................................................................................................................... 251 REDUCED CYLINDER MODE OPERATION.......................................................................................................................... 252 CHECKING FOR LEAKAGE IN FUEL CIRCUIT..................................................................................................................... 253 ADJUSTING ENGINE SPEED SENSOR............................................................................................................................ 254 TESTING AND ADJUSTING FAN BELT TENSION................................................................................................................... 255 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................................ 256 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION............................................................................................ 256 ADJUSTING THE BODY MOUNT................................................................................................................................. 257 TESTING TORQUE CONVERTER STALL SPEED..................................................................................................................... 259 MEASURING POWER TRAIN OIL PRESSURE....................................................................................................................... 260 TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)........................................ 268 ADJUSTING TRANSMISSION SPEED SENSOR...................................................................................................................... 273 TESTING AND ADJUSTING BRAKE OIL PRESSURE................................................................................................................. 275 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS.................................................... 280 TESTING BRAKE PERFORMANCE................................................................................................................................ 284 BLEEDING AIR FROM BRAKE CIRCUIT.......................................................................................................................... 286 TESTING WEAR OF WHEEL BRAKE DISC......................................................................................................................... 288 TESTING WEAR OF PARKING BRAKE PAD........................................................................................................................ 289 METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE............................................................................................................ 291 TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE.......................................................................................................... 292 TESTING AND ADJUSTING SUSPENSION CYLINDER................................................................................................................ 294 METHOD OF TILTING CAB UP................................................................................................................................. 298 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE.............................................................................................................. 300 ADJUSTING BODY POSITIONER SENSOR......................................................................................................................... 303 PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT................................................................................. 304 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT.......................................................................................................... 304 ADJUSTING TRANSMISSION CONTROLLER........................................................................................................................ 305 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM................................................................................... 306 ADJUSTING MACHINE MONITOR................................................................................................................................ 310 SPECIAL FUNCTIONS OF MACHINE MONITOR..................................................................................................................... 314 PM-CLINIC INSPECTION SHEET............................................................................................................................... 350 TROUBLESHOOTING.............................................................................................................................................. 353 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................................. 354 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................... 355 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................................... 356 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................ 364 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................... 365 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................... 379 T-ADAPTER TABLE.......................................................................................................................................... 402 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................ 405 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)................................................................................................... 409 ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................... 411 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 414 ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1)).................................................................................................... 426 ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))........................................................................................ 427 ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))........................................................................................ 428 ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA)).................................................................................. 428 ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))................................................................................... 429 ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))............................................................................. 431 ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))................................................................................ 431 ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA)).................................................................. 432 ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB)).................................................................. 433 ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))................................................................. 434 ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))................................................................. 435 ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 436 ENG-13 FAILURE CODE [ADZKKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).................................................................. 437 ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 441 ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 442 ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 443 ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).................................................................. 444 ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 448 ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 449 ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))................................................................................. 450 ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))........................................................................................ 451 ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))......................................................................................... 452 ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))......................................................... 453 ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................................ 455 ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))......................................................... 456 ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))...................................................... 458 ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))................................................................. 459 ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))................................... 460 ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))..................................... 462 ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA)).................................... 463 ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))................................................................................... 464 ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))............................................................................... 465 ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))........................................................................ 467 ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))............................... 469 ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))............................................. 470 ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).............................................................. 471 ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 472 ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).......................................................... 474 ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 476 ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))............................................................................ 478 ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))............................................................................. 479 ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)............................................................................ 480 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE).............................................................................................. 483 TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM........................................................................................................... 486 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 492 TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))........................................................................................... 518 TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))................................................................................. 519 TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))................................................................................... 520 TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))................................................................................................. 521 TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))................................................................................................ 522 TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))................................................................................................ 523 TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))............................................................................................... 524 TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))............................................................................................... 525 TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))............................................................................................... 526 TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) ................................................................................. 527 TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))............................................................................ 528 TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))................................................................................. 529 TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))........................................................................... 530 TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))................................................................................. 531 TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))........................................................................... 532 TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))................................................................................ 533 TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 534 TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))................................................................................ 535 TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 536 TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))................................................................................ 537 TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 538 TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))............................................................................ 539 TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))...................................................................... 540 TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))....................................................... 541 TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................. 542 TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))..................................................................... 543 TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) ........................................................... 544 TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX)).................................................................................... 546 TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))................................................................ 547 TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)).......................................... 548 TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00)).................................................................................... 549 TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))....................................................................................... 551 TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))................................................................................... 552 TM-34 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))............................................................................. 553 TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))................................................................................. 554 TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))............................................................................................ 555 TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................................ 556 TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))........................................... 558 TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 559 TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))....................................................................... 560 TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)).................................................................... 562 TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...................................................... 563 TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............................... 564 TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............................... 565 TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))..................... 566 TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))............................................. 567 TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP)).................................... 568 TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))....................................... 569 TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))........................................ 570 TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))...................................................................... 570 TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))................................................ 571 TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))..................................................................... 572 TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA)).......................................................................... 573 TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA)).......................................................................... 574 TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))......................................................................... 575 TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))......................................................................... 576 TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))......................................................................... 577 TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))........................................................................... 578 TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA)).................................................................................... 579 TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB)).................................................................................... 581 TM-62 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))............................................. 583 TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8)).............................................................. 584 TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))............................................................... 585 TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))............................................... 586 TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).................................................. 587 TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))............................................................... 589 TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6)).................................................................................. 590 TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................. 591 TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))................................................................................ 593 TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))................................................................................ 594 TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)).............................................................. 595 TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)).............................................................. 596 TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))....................................................... 597 TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))....................................................... 598 TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))............................................................. 599 TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))............................................................. 600 TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA)).......................................................... 601 TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB)).......................................................... 602 TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))........................................................................ 603 TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))........................................................................ 604 TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))............................................................................. 605 TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))............................................................................. 606 TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))............................................................................. 607 TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))............................................................................. 608 TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))............................................................................ 609 TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))............................................................................ 610 TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))............................................................................ 611 TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))............................................................................ 612 TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))............................................................................ 613 TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))............................................................................ 614 TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA)).............................................................................. 615 TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB)).............................................................................. 616 TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY................................................................................................ 617 TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)............................................................................................. 620 BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM........................................................................................................... 622 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 628 BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................ 642 BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................ 643 BK-3 FAILURE CODE [2A62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................. 644 BK-4 FAILURE CODE [2A62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: * SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................. 645 BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX))...................................................................................... 646 BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA)).......................................................................................... 647 BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))........................................................................................... 648 BK-8 FAILURE CODE [2D03CA] (FRONT BRAKE (RIGHT): WEAR (CA)).......................................................................................... 649 BK-9 FAILURE CODE [2D04CA] (FRONT BRAKE (LEFT): WEAR (CA))........................................................................................... 650 BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))......................................................................... 651 BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)).......................................................................... 651 BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))................................................................... 652 BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................................. 653 BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................................. 654 BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)........................................................... 655 BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).................................... 656 BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).................................... 657 BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).......................... 658 BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))........................................ 659 BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))................................................... 660 BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))............................................... 661 BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))................................................ 663 BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))................................................................. 665 BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))............................................................ 668 BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))......................................................................... 670 BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 671 BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))........................................................... 673 BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))........................................................... 674 BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)............................... 675 BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 676 BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 677 BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))........................................................ 678 BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))........................................................ 679 BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))................................... 680 BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))....................................................... 681 BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))....................................................... 682 BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)).................................. 683 BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))............................................................................ 684 BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))............................................................................ 685 BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))....................................................... 686 BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)..... 687 BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL).... 688 BK-45 PARKING BRAKE DOES NOT WORK PROPERLY........................................................................................................... 690 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)..................................................................................................... 693 MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................... 694 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ........................................................................ 698 MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))......................................................................................... 700 MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))........................................................................................ 700 MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))........................................................................................ 700 MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))............................................................. 701 MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))............................................................. 702 MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))................................................................ 703 MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))............. 704 MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))............ 706 MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).................. 708 MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))...................................................................................... 710 MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY........................................................................... 711 MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED............................................................................... 712 MON-14 ALARM BUZZER DOES NOT SOUND................................................................................................................... 713 MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY....................................................... 714 MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY............................................................................... 716 MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY................................................................................................. 717 MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY........................................................................................... 720 MON-19 AISS FUNCTION DOES NOT WORK PROPERLY.......................................................................................................... 721 MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)......................................... 722 MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY........................................................................................... 725 MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)................................................................... 726 MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY.......................................................................................... 728 MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY............................................................................................ 729 MON-25 NIGHT LIGHTING IS NOT NORMAL.................................................................................................................. 734 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)................................................................................................. 740 H-1 MACHINE DOES NOT START........................................................................................................................... 741 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)................................................................................................. 742 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS).............................................................................................. 742 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING........................................................................................................ 743 H-5 TRANSMISSION DOES NOT SHIFT UP................................................................................................................... 743 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING...................................................................................................... 744 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR............................................................................................. 747 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH......................................................................................................... 748 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW............................................................................................................. 749 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE....................................................................................... 750 H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE...................................................................................... 751 H-12 STEERING WHEEL IS HEAVY......................................................................................................................... 752 H-13 STEERING WHEEL DOES NOT WORK.................................................................................................................... 753 H-14 STEERING WHEEL VIBRATES......................................................................................................................... 754 H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER................................................................................................. 755 H-16 DUMP DOES NOT WORK.............................................................................................................................. 756 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.......................................................................................................... 757 TROUBLESHOOTING OF THE ENGINE BODY (S MODE).............................................................................................................. 758 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................. 759 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................... 760 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................................ 763 S-2 ENGINE DOES NOT START............................................................................................................................ 764 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................................................................................. 767 S-4 ENGINE STOPS DURING OPERATIONS................................................................................................................... 768 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................................ 769 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)............................................................................................................. 770 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................................... 771 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).......................................................................................... 772 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................................................................................. 773 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................... 774 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)........................................................................ 775 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...................................................................................... 776 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)............................................................................................................ 777 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................................ 778 S-15 ABNORMAL NOISE IS MADE.......................................................................................................................... 779 S-16 VIBRATION IS EXCESSIVE.......................................................................................................................... 780 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................... 781 HOW TO READ THIS MANUAL...................................................................................................................................... 783 REMOVAL AND INSTALLATION OF ASSEMBLIES................................................................................................................... 783 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES................................................................................................................... 784 REECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................................... 785 SPECIAL TOOL LIST............................................................................................................................................ 787 SKETCHES OF SPECIAL TOOLS.................................................................................................................................... 792 REMOVAL OF FUEL SUPPLY PUMP.................................................................................................................................. 803 INSTALLATION OF FUEL SUPPLY PUMP............................................................................................................................. 804 REMOVAL OF ENGINE ASSEMBLY................................................................................................................................... 805 INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................. 810 REMOVAL OF CYLINDER HEAD ASSEMBLY............................................................................................................................ 811 INSTALLATION OF CYLINDER HEAD................................................................................................................................ 815 REMOVAL AND INSTALLATION OF NOZZLE TIP....................................................................................................................... 820 SPECIAL TOOL............................................................................................................................................. 820 REMOVAL.................................................................................................................................................. 820 INSTALLATION............................................................................................................................................. 821 SCHEMATIC DRAWING OF SPECIAL TOOL........................................................................................................................ 822 REMOVAL OF RADIATOR ASSEMBLY................................................................................................................................. 823 INSTALLATION OF RADIATOR ASSEMBLY............................................................................................................................ 825 REMOVAL OF OUTPUT SHAFT ASSEMBLY............................................................................................................................. 826 INSTALLATION OF OUTPUT SHAFT ASSEMBLY........................................................................................................................ 829 DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY......................................................................................................................... 830 ASSEMBLY OF OUTPUT SHAFT ASSEMBLY............................................................................................................................ 831 REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...................................................................................................... 833 INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY................................................................................................. 839 DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION......................................................................................................... 841 COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION.............................................................................................................. 841 DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY..................................................................................................................... 842 ASSEMBLY OF TORUE CONVERTER ASSEMBLY......................................................................................................................... 846 DISASSEMBLY OF TRANSMISSION ASSEMBLY......................................................................................................................... 850 ASSEMBLY OF TRANSMISSION ASSEMBLY............................................................................................................................ 869 DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY................................................................................................................... 895 ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY...................................................................................................................... 902 REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY...................................................................................................................... 914 INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY................................................................................................................. 916 DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY.................................................................................................................. 918 ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY..................................................................................................................... 924 REMOVAL OF REAR DIFFERENTIAL ASSEMBLY........................................................................................................................ 934 INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY................................................................................................................... 935 DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY.................................................................................................................... 935 ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY....................................................................................................................... 939 REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY.............................................................................................................. 947 INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY......................................................................................................... 948 DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY.......................................................................................................... 949 ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY............................................................................................................. 955 REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY............................................................................................................. 962 INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY........................................................................................................ 963 DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY......................................................................................................... 964 ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY............................................................................................................ 968 REMOVAL OF REAR FINAL DRIVE ASSEMBLY......................................................................................................................... 974 INSTALLATION OF REAR FINAL DRIVE ASSEMBLY.................................................................................................................... 975 DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY..................................................................................................................... 975 ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY........................................................................................................................ 977 REMOVAL OF CENTER AXLE ASSEMBLY.............................................................................................................................. 982 INSTALLATION OF CENTER AXLE ASSEMBLY......................................................................................................................... 984 REMOVAL OF REAR AXLE ASSEMBLY................................................................................................................................ 985 INSTALLATION OF REAR AXLE ASSEMBLY........................................................................................................................... 987 REMOVAL OD FRONT SUSPENSION CYLINDER ASSEMBLY................................................................................................................ 988 INSTALLATION OF FRONT SUSPENSION CYLIDER ASSEMBLY............................................................................................................ 989 REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY................................................................................................................. 989 INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY............................................................................................................ 990 REMOVAL OF EQUALIZER BAR ASSEMBLY............................................................................................................................ 990 INSTALLATION OF EQUALIZER BAR ASSEMBLY....................................................................................................................... 994 REMOVAL OF FRONT WHEEL ASSEMBLY.............................................................................................................................. 995 INSTALLATION OF FRONT WHEEL ASSEMBLY......................................................................................................................... 995 REMOVAL OF CENTER WHEEL ASSEMBLY............................................................................................................................. 996 INSTALLATION OF CENTER WHEEL ASSEMBLY........................................................................................................................ 996 REMOVAL OF REAR WHEEL ASSEMBLY............................................................................................................................... 996 INSTALLATION OF REAR WHEEL ASSEMBLY.......................................................................................................................... 996 REMOVAL OF HITCH FRAME ASSEMBLY.............................................................................................................................. 997 INSTALLATION OF HITCH FRAME ASSEMBLY.........................................................................................................................1001 DISASSEMBLY OF HITCH FRAME...................................................................................................................................1003 ASSEMBLY OF HITCH FRAME ASSEMBLY.............................................................................................................................1004 STANDARD INTEGRAL ORBIT-TOLL.................................................................................................................................1006 DISASSEMBLY OF STEERING VALVE................................................................................................................................1008 ASSEMBLY OF STEERING VALVE...................................................................................................................................1010 REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY.....................................................................................................................1015 INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY................................................................................................................1016 REMOVAL OF HOIST VALVE ASSEMBLY..............................................................................................................................1017 INSTALLATION OF HOIST VALVE ASSEMBLY.........................................................................................................................1018 DISASSEMBLY OF HOIST VALVE ASSEMBLY..........................................................................................................................1019 ASSEMBLY OF HOIST VALVE ASSEMBLY.............................................................................................................................1020 DISASSEMBLY OF STEERING CYLINDER ASSEMBLY....................................................................................................................1021 ASSEMBLY OF STEERING CYLINDER ASSEMBLY.......................................................................................................................1022 DISASSEMBLY OF HOIST CYLINDER ASSEMBLY.......................................................................................................................1024 ASSEMBLY OF HOIST CYLINDER ASSEMBLY..........................................................................................................................1025 REMOVAL OF BODY ASSEMBLY.....................................................................................................................................1027 INSTALLATION OF BODY ASSEMBLY................................................................................................................................1028 DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY.........................................................................................................1029 90 OTHERS........................................................................................................................................................1038 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................1039 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................1040 DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................1041 BRAKE HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................................1042 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................1043 DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER...............................................................................................................1044 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)..............................................................................................................1045 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)..............................................................................................................1046 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)..............................................................................................................1047 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)..............................................................................................................1048 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2).............................................................................................................1049 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2).............................................................................................................1050
KOMATSU HM350-1 SERVICE WORKSHOP MANUAL 1001 AND UP – PDF DOWNLOAD:
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