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Komatsu HM350-1L Dump Truck Service Manual CEBM015400 – PDF DOWNLOAD
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Komatsu HM350-1L Dump Truck Service Manual
SERIAL NUMBERS : HM350-1L A10001 and UP
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Description
Komatsu HM350-1L Dump Truck Service Manual
FILE DETAILS:
Komatsu HM350-1L Dump Truck Service Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model:HM350-1L
Serial Number:A10001 and up
Book Code: CEBM015400
Language: English
Pages: 1220
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM350-1L Dump Truck Service Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate 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 workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
TABLE OF CONTENTS:
Komatsu HM350-1L Dump Truck Service Manual
COVER............................................................................................................................... 1 FOREWORD............................................................................................................................ 2 CONTENTS........................................................................................................................ 2 SAFETY.......................................................................................................................... 3 SAFETY NOTICE............................................................................................................... 3 IMPORTANT SAFETY NOTICE................................................................................................. 3 GENERAL PRECAUTIONS..................................................................................................... 3 PREPARATIONS FOR WORK................................................................................................... 3 PRECAUTIONS DURING WORK................................................................................................. 3 GENERAL......................................................................................................................... 5 HOW TO READ THE SHOP MANUAL..................................................................................................... 6 VOLUMES..................................................................................................................... 6 DISTRIBUTION AND UPDATING................................................................................................... 6 FILING METHOD............................................................................................................... 6 REVISED EDITION MARK........................................................................................................ 6 REVISIONS................................................................................................................... 6 SYMBOLS..................................................................................................................... 6 HOISTING INSTRUCTIONS........................................................................................................... 7 HOISTING.................................................................................................................... 7 WIRE ROPES.................................................................................................................. 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................. 8 Disconnection........................................................................................................... 8 Connection.............................................................................................................. 8 COATING MATERIALS............................................................................................................... 10 STANDARD TIGHTENING TORQUE...................................................................................................... 12 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................................ 12 TIGHTENING TORQUE OF HOSE NUTS.............................................................................................. 13 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS..................................................................................... 13 TIGHTENING TORQUE FOR FLARED NUTS........................................................................................... 13 TIGHTENING TORQUE FOR 102 ENGINE SERIES..................................................................................... 14 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...................................................... 14 ELECTRIC WIRE CODE.............................................................................................................. 16 CLASSIFICATION BY THICKNESS................................................................................................. 16 CLASSIFICATION BY COLOR AND CODE............................................................................................ 16 CONVERSION TABLES............................................................................................................... 17 METHOD OF USING THE CONVERSION TABLE........................................................................................ 17 TEMPERATURE............................................................................................................. 22 01 GENERAL.......................................................................................................................... 23 SPECIFICATION DRAWING........................................................................................................... 24 SPECIFICATIONS.................................................................................................................. 25 WEIGHT TABLE.................................................................................................................... 28 FUEL, COOLANT AND LUBRICANTS.................................................................................................... 29 ENGINE OIL SPECIFICATIONS................................................................................................... 30 NORMAL OPERATION........................................................................................................ 30 ARCTIC OPERATION........................................................................................................ 30 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.... 31 FINAL DRIVE OIL SPECIFICATIONS.......................................................................................... 31 DRIVE AXLE OIL SPECIFICATIONS........................................................................................... 31 DIESEL FUEL SPECIFICATIONS.................................................................................................. 31 COOLANT SPECIFICATIONS...................................................................................................... 32 GENERAL................................................................................................................. 32 WATER................................................................................................................... 32 ANTIFREEZE.............................................................................................................. 32 SUPPLEMENTAL COOLANT ADDITIVES.......................................................................................... 34 COOLING SYSTEM TEST KIT................................................................................................. 38 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD..................................................................................... 39 COOLING SYSTEMS................................................................................................................. 43 SPECIFICATIONS.............................................................................................................. 43 POWER TRAIN..................................................................................................................... 44 LOCKING DIFFERENTIAL........................................................................................................ 44 TORQUE DAMPER................................................................................................................... 46 FUNCTION.................................................................................................................... 46 TORQUE CONVERTER AND TRANSMISSION............................................................................................... 48 HYDRAULIC PIPING............................................................................................................ 48 TORQUE CONVERTER............................................................................................................ 49 SPECIFICATIONS.......................................................................................................... 49 TRANSMISSION POWER FLOW......................................................................................................... 53 OIL FLOW.................................................................................................................... 54 TRANSMISSION.................................................................................................................... 55 OUTLINE..................................................................................................................... 59 FL - R CLUTCH............................................................................................................... 60 FH - 1ST CLUTCH............................................................................................................. 61 2ND - 3RD CLUTCH............................................................................................................ 62 DIFFERENTIAL LOCK........................................................................................................... 63 CLUTCH AND TRANSMISSION OPERATIONS.............................................................................................. 65 FORWARD 1ST................................................................................................................. 66 OPERATION............................................................................................................... 66 FORWARD 2ND................................................................................................................. 67 OPERATION............................................................................................................... 67 FORWARD 3RD................................................................................................................. 68 OPERATION............................................................................................................... 68 FORWARD 4TH................................................................................................................. 69 OPERATION............................................................................................................... 69 FORWARD 5TH................................................................................................................. 70 OPERATION............................................................................................................... 70 FORWARD 6TH................................................................................................................. 71 OPERATION............................................................................................................... 71 REVERSE 1ST................................................................................................................. 72 OPERATION............................................................................................................... 72 TRANSMISSION VALVE OPERATIONS................................................................................................... 73 ECMV (ELECTRONIC CONTROL MODULATION VALVE)...................................................................................... 74 ECMV LOCK-UP CLUTCH......................................................................................................... 75 OUTLINE................................................................................................................. 75 OPERATION............................................................................................................... 75 DURING DIRECT TRAVEL........................................................................................................ 76 FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL........................................................................... 76 ECMV SPEED CLUTCH........................................................................................................... 77 ECMV OUTLINE............................................................................................................ 77 ECMV AND PROPORTIONAL SOLENOID.......................................................................................... 77 ECMV AND FILL SWITCH.................................................................................................... 77 ECMV OPERATION.......................................................................................................... 78 ECMV FOR DIFFERENTIAL LOCK.................................................................................................. 80 OPERATION............................................................................................................... 80 MAIN AND TORQUE CONVERTER RELIEF VALVE.......................................................................................... 81 VALVE OUTLINE AND OPERATIONS................................................................................................ 82 TORQUE CONVERTER RELIEF VALVE........................................................................................... 82 MAIN RELIEF VALVE....................................................................................................... 82 OPERATION............................................................................................................... 82 DRIVE SHAFT..................................................................................................................... 83 OUTLINE..................................................................................................................... 83 DRIVE AXLES..................................................................................................................... 84 FRONT....................................................................................................................... 84 CENTER...................................................................................................................... 85 REAR........................................................................................................................ 86 LOCKING DIFFERENTIAL............................................................................................................ 87 FRONT....................................................................................................................... 87 CENTER...................................................................................................................... 89 REAR........................................................................................................................ 91 OPERATION............................................................................................................... 93 TRAVELING IN A STRAIGHT LINE............................................................................................ 93 TURNING................................................................................................................. 93 WHEN DIFFERENTIAL LOCK IS ACTUATED...................................................................................... 93 FINAL DRIVE SYSTEM.............................................................................................................. 94 FRONT....................................................................................................................... 94 CENTER...................................................................................................................... 96 REAR........................................................................................................................ 98 FUNCTION................................................................................................................ 99 OPERATION............................................................................................................... 99 STEERING COLUMN................................................................................................................. 100 WHEEL BRAKING SYSTEM............................................................................................................ 101 PIPING LAY-OUT.............................................................................................................. 101 BRAKE VALVE................................................................................................................. 102 VALVE OPERATION......................................................................................................... 103 ACCUMULATOR CHARGE VALVE.................................................................................................... 105 FUNCTION................................................................................................................ 105 VALVE OPERATION......................................................................................................... 107 ACCUMULATOR................................................................................................................. 109 FUNCTION................................................................................................................ 109 SPECIFICATIONS.......................................................................................................... 109 SLACK ADJUSTER.............................................................................................................. 110 FUNCTION................................................................................................................ 111 OPERATION............................................................................................................... 111 FRONT BRAKE................................................................................................................. 112 CENTER, REAR BRAKE.......................................................................................................... 114 FUNCTION................................................................................................................ 116 OPERATIONS.............................................................................................................. 116 PROPORTIONAL REDUCING VALVE................................................................................................. 117 FUNCTION................................................................................................................ 117 BRAKE SYSTEM TANK........................................................................................................... 118 PARKING BRAKE................................................................................................................... 119 FUNCTION.................................................................................................................... 119 PARKING BRAKE CALIPER....................................................................................................... 121 OUTLINE................................................................................................................. 121 SPRING CYLINDER............................................................................................................. 122 OUTLINE................................................................................................................. 122 PARKING BRAKE SOLENOID...................................................................................................... 123 FUNCTION................................................................................................................ 123 SUSPENSION SYSTEM............................................................................................................... 124 FRONT....................................................................................................................... 124 REAR........................................................................................................................ 126 OUTLINE................................................................................................................. 128 FUNCTION................................................................................................................ 128 SUSPENSION CYLINDER......................................................................................................... 129 STRUCTURE AND OPERATION................................................................................................. 130 OSCILLATION HITCH JOINT......................................................................................................... 131 OUTLINE..................................................................................................................... 133 STEERING, HOIST OIL PIPING DIAGRAM.............................................................................................. 134 DUMP BODY CONTROL............................................................................................................... 135 FUNCTION.................................................................................................................... 135 HYDRAULIC TANK AND FILTER....................................................................................................... 136 FLOW AMPLIFIER VALVE............................................................................................................ 137 OUTLINE..................................................................................................................... 137 OPERATION................................................................................................................... 138 STEERING VALVE.................................................................................................................. 140 OUTLINE..................................................................................................................... 141 STRUCTURE................................................................................................................... 141 HAND PUMP AND SLEEVE CONNECTION............................................................................................. 142 FUNCTION OF CENTER SPRING............................................................................................... 143 STEERING CYLINDER............................................................................................................... 144 HOIST VALVE..................................................................................................................... 145 HOIST VALVE AT HOLD POSITION................................................................................................ 147 HOIST VALVE AT RAISE POSITION............................................................................................... 148 HOIST VALVE AT FLOAT POSITION............................................................................................... 149 HOIST VALVE AT LOWER POSITION............................................................................................... 150 EPC VALVE....................................................................................................................... 151 FUNCTION.................................................................................................................... 151 PILOT CHECK VALVE............................................................................................................... 152 HOIST CYLINDER.................................................................................................................. 153 HYDRAULIC PUMP.................................................................................................................. 154 STEERING, HOIST + PILOT PUMP................................................................................................ 154 TRANSMISSION + DIFFERENTIAL LOCK PUMP....................................................................................... 155 BRAKE COOLING + BRAKE PUMP.................................................................................................. 156 AUXILIARY STEERING PUMP..................................................................................................... 157 DIFFERENTIAL LOCK PUMP...................................................................................................... 158 TRANSMISSION PUMP........................................................................................................... 159 CAB TILT SYSTEM VIEW............................................................................................................ 160 AIR CONDITIONING SYSTEM VIEW.................................................................................................... 161 FUNCTION.................................................................................................................... 161 AIR CONDITIONER UNIT........................................................................................................ 162 RECEIVER DRYER.............................................................................................................. 163 CONDENSER................................................................................................................... 164 REFRIGERANT COMPRESSOR...................................................................................................... 165 MACHINE MONITOR SYSTEM.......................................................................................................... 166 NETWORK DATA................................................................................................................ 166 OUTLINE................................................................................................................. 167 MACHINE MONITOR PANEL....................................................................................................... 169 OPTION SETTING CONNECTOR DIAGRAM............................................................................................ 171 ADJUSTING MACHINE MONITOR............................................................................................... 171 MACHINE MONITOR NORMAL DISPLAY FUNCTIONS.................................................................................... 172 SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH................................................................. 175 CHECK FUNCTION OF MONITOR LAMPS AND METERS...................................................................................... 176 SERVICE METER DISPLAY....................................................................................................... 176 ODOMETER.................................................................................................................... 176 SERVICE MODE................................................................................................................ 176 OUTLINE................................................................................................................. 176 OPERATION METHOD............................................................................................................ 178 AUTOMATIC SHIFT CONTROL SYSTEM.................................................................................................. 179 OUTLINE..................................................................................................................... 180 TRANSMISSION CONTROLLER......................................................................................................... 181 OUTLINE..................................................................................................................... 181 SHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE....................................................................... 184 GEARSHIFTING CHARACTERISTICS............................................................................................ 184 AUTOMATIC GEARSHIFTING GRAPH................................................................................................ 185 GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD........................................................................... 186 SHIFT HOLD FUNCTION..................................................................................................... 187 GEARSHIFTING TIME DELAY................................................................................................. 187 SAFETY FUNCTIONS........................................................................................................ 187 SELF-DIAGNOSTIC FUNCTION................................................................................................ 188 AUTO AUXILIARY STEERING SYSTEM.................................................................................................. 189 OUTLINE..................................................................................................................... 189 SENSORS AND SWITCHES............................................................................................................ 190 ENGINE SPEED SENSOR......................................................................................................... 190 FUNCTION................................................................................................................ 190 ACCELERATOR PEDAL SENSOR.................................................................................................... 190 OUTLINE................................................................................................................. 191 ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS............................................................................ 192 FUNCTION................................................................................................................ 192 STEERING OIL TEMPERATURE SENSOR............................................................................................. 192 FUNCTION................................................................................................................ 192 FUEL LEVEL SENSOR........................................................................................................... 193 FUNCTION................................................................................................................ 193 TILT SENSOR................................................................................................................. 194 FUNCTION................................................................................................................ 194 AIR CLEANER CLOGGING SENSOR................................................................................................. 195 FUNCTION................................................................................................................ 195 HYDRAULIC OIL LEVEL SENSOR.................................................................................................. 196 FUNCTION................................................................................................................ 196 BODY POSITIONER SENSOR...................................................................................................... 197 FUNCTION.................................................................................................................... 197 RETARDER CONTROL SYSTEM......................................................................................................... 198 RETARDER CONTROLLER UNIT.................................................................................................... 199 OUTLINE................................................................................................................. 199 RETARDER CONTROL FUNCTION................................................................................................... 203 SYSTEM DIAGRAM.......................................................................................................... 203 HOIST CONTROL FUNCTION...................................................................................................... 205 SYSTEM DIAGRAM.......................................................................................................... 205 DIFFERENTIAL LOCK CONTROL FUNCTION.......................................................................................... 207 SYSTEM DIAGRAM.......................................................................................................... 207 BRAKE CONTROL SYSTEM (E-SPEC)................................................................................................... 209 BRAKE CONTROLLER (E-SPEC) UNIT.............................................................................................. 210 OUTLINE................................................................................................................. 210 BRAKE CONTROL FUNCTION...................................................................................................... 214 SYSTEM DIAGRAM.......................................................................................................... 214 HOIST CONTROL SYSTEM............................................................................................................ 215 SYSTEM DIAGRAM.............................................................................................................. 215 DIFFERENTIAL LOCK CONTROL SYSTEM................................................................................................ 217 SYSTEM DIAGRAM.............................................................................................................. 217 DUMP CONTROL LEVER.............................................................................................................. 220 FUNCTION.................................................................................................................... 221 OPERATION................................................................................................................... 222 DUMP CONTROL LEVER OPERATED TO FLOAT.................................................................................... 222 DUMP CONTROL LEVER FLOAT CANCELED....................................................................................... 222 DUMP CONTROL LEVER OPERATED TO LOWER.................................................................................... 222 DUMP CONTROL LEVER OPERATED TO RAISE.................................................................................... 223 DUMP CONTROL LEVER RAISE CANCELED....................................................................................... 223 20 TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................................... 225 STANDARD VALUE TABLE............................................................................................................ 227 FOR ENGINE.................................................................................................................. 227 STANDARD VALUE TABLE............................................................................................................ 228 FOR CHASSIS................................................................................................................. 228 STANDARD VALUE TABLE............................................................................................................ 232 FOR ELECTRICAL COMPONENTS................................................................................................... 232 TOOLS........................................................................................................................... 246 FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................. 246 ENGINE COMPONENTS............................................................................................................... 248 MEASURING EXHAUST SMOKE..................................................................................................... 248 MEASURING EXHAUST TEMPERATURE............................................................................................... 248 ADJUSTING VALVE CLEARANCE................................................................................................... 248 MEASURING COMPRESSION PRESSURE.............................................................................................. 248 MEASURING CRANKCASE PRESSURE................................................................................................ 248 MEASURING ENGINE OIL PRESSURE............................................................................................... 248 MEASURING BOOST PRESSURE.................................................................................................... 248 MEASURING FUEL PRESSURE..................................................................................................... 248 BLEEDING AIR FROM FUEL SYSTEM............................................................................................... 248 ADJUSTING ENGINE SPEED SENSOR................................................................................................... 249 ADJUSTING ALTERNATOR BELT................................................................................................... 251 ADJUSTING REFRIGERANT COMPRESSOR BELT....................................................................................... 252 TESTING TORQUE CONVERTER STALL SPEED............................................................................................ 253 MEASURING POWER TRAIN OIL PRESSURES............................................................................................. 254 MEASURING POWER TRAIN MAIN RELIEF PRESSURE.................................................................................. 255 MEASURING TORQUE CONVERTER “INLET” OIL PRESSURE............................................................................. 255 MEASURING TORQUE CONVERTER “OUTLET” OIL PRESSURE............................................................................ 255 MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE........................................................................ 256 MEASURING TRANSMISSION “LO” CLUTCH PRESSURE................................................................................. 257 MEASURING TRANSMISSION “HI” CLUTCH PRESSURE................................................................................. 257 MEASURING TRANSMISSION “1ST” CLUTCH PRESSURE................................................................................ 257 MEASURING TRANSMISSION “2ND” CLUTCH PRESSURE................................................................................ 258 MEASURING TRANSMISSION “3RD” CLUTCH PRESSURE................................................................................ 258 MEASURING TRANSMISSION “R” CLUTCH PRESSURE.................................................................................. 259 MEASURING INTER-AXLE “DIFFERENTIAL LOCK” CLUTCH PRESSURE.................................................................... 259 TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE.................................................................... 260 TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE........................................................................... 260 TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE.......................................................................... 261 TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE............................................................................ 261 ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE......................................................................... 262 ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE........................................................................ 263 ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE.......................................................................... 263 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................. 264 TESTING AND ADJUSTING BRAKE OIL PRESSURE........................................................................................ 266 MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 266 MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP........................................................................... 266 MEASURING ACTUATION PRESSURE ON PARKING BRAKE............................................................................... 267 MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID...................................................................... 268 ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 269 TESTING BRAKE PERFORMANCE....................................................................................................... 270 TESTING BRAKING PERFORMANCE OF FOOT BRAKE................................................................................... 270 TESTING BRAKING PERFORMANCE OF RETARDER BRAKE............................................................................... 270 TESTING PARKING BRAKE BRAKING PERFORMANCE................................................................................... 271 TESTING OVERRUN PROTECTION BRAKING PERFORMANCE.............................................................................. 271 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................................. 272 BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE..................................................................... 272 BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT................................................................. 273 BLEEDING AIR FROM PARKING BRAKE CIRCUIT..................................................................................... 273 CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD................................................................................. 274 CHECKING BRAKE DISC......................................................................................................... 274 CHECKING BRAKE PAD.......................................................................................................... 275 ADJUSTING PAD CLEARANCE..................................................................................................... 276 RELEASING EMERGENCY PARKING BRAKE............................................................................................... 277 TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE ................................................................................ 278 MEASURING STEERING RELIEF OIL PRESSURE...................................................................................... 278 ADJUSTING STEERING RELIEF OIL PRESSURE...................................................................................... 279 TESTING AND ADJUSTING SUSPENSION CYLINDER....................................................................................... 280 CHECKING CYLINDER LENGTH.................................................................................................... 280 RELEASING NITROGEN GAS...................................................................................................... 280 ADJUSTING OIL LEVEL......................................................................................................... 281 CHARGING WITH NITROGEN GAS.................................................................................................. 282 ADJUSTING CYLINDER LENGTH................................................................................................... 283 TILTING THE CAB UP.............................................................................................................. 284 PREPARATORY WORK............................................................................................................ 284 TILTING CAB UP.............................................................................................................. 284 USING EXTERNAL CRANE........................................................................................................ 285 HOLDING CAB IN POSITION..................................................................................................... 285 LOWERING CAB DOWN........................................................................................................... 285 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE..................................................................................... 286 TESTING DUMP MAIN RELIEF OIL PRESSURE....................................................................................... 286 ADJUSTING DUMP MAIN RELIEF OIL PRESSURE..................................................................................... 286 MEASURING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 287 ADJUSTING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 287 ADJUSTING BODY POSITIONER SENSOR................................................................................................ 288 CHECKING SENSOR OUTPUT/INPUT VOLTAGE........................................................................................ 288 ADJUSTING LINK LENGTH....................................................................................................... 288 CALIBRATING SYSTEM.......................................................................................................... 289 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT................................................................................. 290 ADJUSTING TRANSMISSION CONTROLLER............................................................................................... 291 SETTING ROTARY SWITCH....................................................................................................... 291 ADJUSTING TRANSMISSION...................................................................................................... 291 ESCAPE METHOD FOR ELECTRICAL SYSTEM............................................................................................. 292 ADJUSTING MACHINE MONITOR....................................................................................................... 296 FUNCTIONS OF MACHINE MONITOR.................................................................................................... 300 NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR......................................................................... 300 FLOW OF MODES AND FUNCTIONS................................................................................................. 301 OPERATION AND DISPLAYS FOR OPERATOR MODE.................................................................................... 303 SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY.............................................................................. 311 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................... 332 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 334 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................................................................... 335 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.............................................................................. 335 HANDLING ELECTRONIC CONTROL UNIT............................................................................................ 340 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS................................................................. 341 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT........................................................................ 342 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 344 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................... 345 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.............................................................................. 346 TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS............................................................................... 348 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................... 350 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................... 358 T-ADAPTER TABLE................................................................................................................. 382 CONNECTOR LAYOUT DRAWING........................................................................................................ 385 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 393 ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM........................................................................................... 399 CONTENT OF CODE DISPLAY (1)..................................................................................................... 402 CONTENT OF CODE DISPLAY (2)..................................................................................................... 404 CONTENT OF CODE DISPLAY (3)..................................................................................................... 406 CONTENT OF CODE DISPLAY (4)..................................................................................................... 408 CONTENT OF CODE DISPLAY (5)..................................................................................................... 410 CONTENT OF CODE DISPLAY (6)..................................................................................................... 412 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 414 (ENG-1) FAILURE CODE [A000N1]................................................................................................... 416 ENGINE OVERSPEEDS (N1)...................................................................................................... 416 (ENG-2) FAILURE CODE [A570NX]................................................................................................... 417 ENGINE OIL FILTER CLOG SENSOR SYSTEM........................................................................................ 417 (ENG-3) FAILURE CODE [AD00L2]................................................................................................... 418 COMMON RAIL HIGHER THAN SET VALUE........................................................................................... 418 (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3].................................................................................. 419 COMMON RAIL PRESSURE HIGH OR LOW............................................................................................ 419 (ENG-6) FAILURE CODE [AD10MA]............................................................................................... 421 (ENG-7) FAILURE CODE [AD10MB]............................................................................................... 421 (ENG-8 OR 9) FAILURE CODE [AD11KA] OR [AD11KB].................................................................................. 422 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM............................................................................... 422 (ENG-10 OR 11) FAILURE CODE [AD51KA] OR [AD51KB]................................................................................ 424 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM............................................................................... 424 (ENG-12) FAILURE CODE [ADA1KA].................................................................................................. 425 OPEN IN NO. 1 INJECTOR SOLENOID VALVE....................................................................................... 425 (ENG-13) FAILURE CODE [ADZKKB].................................................................................................. 427 SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE........................................................................ 427 (ENG-14) FAILURE CODE [ADB1KA].................................................................................................. 430 OPEN IN NO. 2 INJECTOR SOLENOID VALVE....................................................................................... 430 (ENG-15) FAILURE CODE [ADC1KA].................................................................................................. 432 OPEN IN NO. 3 INJECTOR SOLENOID VALVE....................................................................................... 432 (ENG-16) FAILURE CODE [ADD1KA].................................................................................................. 434 OPEN IN NO. 4 INJECTOR SOLENOID VALVE....................................................................................... 434 (ENG-17) FAILURE CODE [ADDZKB].................................................................................................. 436 SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE........................................................................ 436 (ENG-18) FAILURE CODE [ADE1KA].................................................................................................. 439 OPEN IN NO. 5 INJECTOR SOLENOID VALVE....................................................................................... 439 (ENG-19) FAILURE CODE [ADF1KA].................................................................................................. 441 OPEN IN NO. 6 INJECTOR SOLENOID VALVE....................................................................................... 441 (ENG-20) FAILURE CODE [B@BAZG].................................................................................................. 443 ENGINE OIL PRESSURE DROP (ZG)............................................................................................... 443 (ENG-21) FAILURE CODE [B@BAZK].................................................................................................. 445 ENGINE OIL LEVEL DROP (ZK).................................................................................................. 445 (ENG-22) FAILURE CODE [B@BCNS].................................................................................................. 446 COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)....................................................................... 446 (ENG-23) FAILURE CODE [D181KZ].................................................................................................. 448 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)........................................................................ 448 (ENG-24) FAILURE CODE [D182KZ].................................................................................................. 450 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)........................................................................ 450 (ENG-25) FAILURE CODE [D1D0KB].................................................................................................. 452 SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)............................................................................. 452 (ENG-26) FAILURE CODE [D5ZAKX].................................................................................................. 454 ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX).............................................................................. 454 (ENG-27) FAILURE CODE [DB20KT].................................................................................................. 456 CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW................................................................................. 456 (ENG-28) FAILURE CODE [DB22KK].................................................................................................. 457 DROP IN VOLTAGE LOAD POWER SUPPLY (KK)...................................................................................... 457 (ENG-29) FAILURE CODE [DB29KQ].................................................................................................. 459 NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ).......................................... 459 (ENG-30) FAILURE CODE [DB2AMA].................................................................................................. 461 “Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA).................................................................. 461 (ENG-31) FAILURE CODE [KK11KB].................................................................................................. 462 TROUBLE IN INPUT OF IGNITION SWITCH C (KB).................................................................................. 462 (ENG-32) FAILURE CODE [DDA1L5].................................................................................................. 463 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)....................................................................... 463 (ENG-33) FAILURE CODE [DDE2L6].................................................................................................. 465 ENGINE OIL PRESSURE DROP (L6)............................................................................................... 465 (ENG-34) FAILURE CODE [DGE2KX].................................................................................................. 467 COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)......................................................................... 467 (ENG-35) FAILURE CODE [DGE3LC].................................................................................................. 468 COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6).......................................................................... 468 (ENG-36) FAILURE CODE [DGE4KX].................................................................................................. 469 TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX).............................................................................. 469 (ENG-37) FAILURE CODE [DH30KX].................................................................................................. 470 TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)................................................................................ 470 (ENG-38) FAILURE CODE [DH40KX].................................................................................................. 472 TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)..................................................................... 472 (ENG-39) FAILURE CODE [DK10KX].................................................................................................. 474 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)....................................................................... 474 (ENG-40) FAILURE CODE [DLE3LC].................................................................................................. 476 TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM.................................................................................... 476 (ENG-41) FAILURE CODE [DLE1LC].................................................................................................. 477 TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)................................................................................ 477 (ENG-42) NO FAILURE CODE DISPLAYED.............................................................................................. 478 ENGINE DOES NOT CRANK....................................................................................................... 478 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 485 TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM.......................................................................................... 491 CONTENT OF CODE DISPLAY (1)..................................................................................................... 498 CONTENT OF CODE DISPLAY (2)..................................................................................................... 500 CONTENT OF CODE DISPLAY (3)..................................................................................................... 502 CONTENT OF CODE DISPLAY (4)..................................................................................................... 504 CONTENT OF CODE DISPLAY (5)..................................................................................................... 506 CONTENT OF CODE DISPLAY (6)..................................................................................................... 508 CONTENT OF CODE DISPLAY (7)..................................................................................................... 510 CONTENT OF CODE DISPLAY (8)..................................................................................................... 512 CONTENT OF CODE DISPLAY (9)..................................................................................................... 514 CONTENT OF CODE DISPLAY (10).................................................................................................... 516 CONTENT OF CODE DISPLAY (11).................................................................................................... 518 CONTENT OF CODE DISPLAY (12).................................................................................................... 520 CONTENT OF CODE DISPLAY (13).................................................................................................... 522 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 524 (TM-1) FAILURE CODE [1380MW].................................................................................................... 526 LOCK-UP CLUTCH SLIPPING (MW)................................................................................................ 526 (TM-2) FAILURE CODE [1500LO].................................................................................................... 528 TRANSMISSION CLUTCH (LO).................................................................................................... 528 (TM-3) FAILURE CODE [15BONX].................................................................................................... 529 TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)................................................................. 529 (TM-4) FAILURE CODE [15GOMW].................................................................................................... 531 “R” CLUTCH SLIPPING (MW).................................................................................................... 531 (TM-5) FAILURE CODE [15HOMW].................................................................................................... 533 “HI” CLUTCH SLIPPING (MW)................................................................................................... 533 (TM-6) FAILURE CODE [15JOMW].................................................................................................... 535 “LO” CLUTCH SLIPPING (MW)................................................................................................... 535 (TM-7) FAILURE CODE [15KOMW].................................................................................................... 537 1ST. CLUTCH SLIPPING (MW)................................................................................................... 537 (TM-8) FAILURE CODE [15LOMW].................................................................................................... 539 2ND. CLUTCH SLIPPING (MW)................................................................................................... 539 (TM-9) FAILURE CODE [15MOMW].................................................................................................... 541 3RD. CLUTCH SLIPPING (MW)................................................................................................... 541 (TM-10) FAILURE CODE [15SBL1]................................................................................................... 543 ECMV FOR “R” CLUTCH NOT DISENGAGING (L1).................................................................................... 543 (TM-11) FAILURE CODE [15SBMA]................................................................................................... 545 ECMV FOR “R” CLUTCH NOT ENGAGING (MA)....................................................................................... 545 (TM-12) FAILURE CODE [15SCL1]................................................................................................... 547 ECMV “HI” CLUTCH NOT DISENGAGING (L1)....................................................................................... 547 (TM-13) FAILURE CODE [15SCMA]................................................................................................... 549 ECMV “HI” CLUTCH NOT DISENGAGING (MA)....................................................................................... 549 (TM-14) FAILURE CODE [15SDL1]................................................................................................... 551 ECMV “LO” CLUTCH NOT DISENGAGING (L1)....................................................................................... 551 (TM-15) FAILURE CODE [15SDMA]................................................................................................... 553 ECMV “LO” CLUTCH NOT ENGAGING (MA).......................................................................................... 553 (TM-16) FAILURE CODE [15SEL1]................................................................................................... 555 ECMV “1ST.” CLUTCH NOT DISENGAGING (L1)..................................................................................... 555 (TM-17) FAILURE CODE [15SEMA]................................................................................................... 557 ECMV “1ST.” CLUTCH NOT ENGAGING (MA)........................................................................................ 557 (TM-18) FAILURE CODE [15SFL1]................................................................................................... 559 ECMV “2ND.” CLUTCH NOT DISENGAGING (L1)..................................................................................... 559 (TM-19) FAILURE CODE [15SFMA]................................................................................................... 561 ECMV “2ND.” CLUTCH NOT ENGAGING (MA)........................................................................................ 561 (TM-20) FAILURE CODE [15SGL1]................................................................................................... 563 ECMV “3RD.” CLUTCH NOT DISENGAGING (L1)..................................................................................... 563 (TM-21) FAILURE CODE [15SGMA]................................................................................................... 565 ECMV “3RD.” CLUTCH NOT ENGAGING (MA)........................................................................................ 565 (TM-22) FAILURE CODE [15SJL1]................................................................................................... 567 ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1).................................................................................. 567 (TM-23) FAILURE CODE [15SJMA]................................................................................................... 569 ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA)..................................................................................... 569 (TM-24) FAILURE CODE [15SKL1]................................................................................................... 571 ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1)............................................................................... 571 (TM-25) FAILURE CODE [15SKMA]................................................................................................... 573 ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA).................................................................................. 573 (TM-26) FAILURE CODE [2B61MW]................................................................................................... 575 ECMV “INTER-AXLE” CLUTCH SLIPPING (MW)...................................................................................... 575 (TM-27) FAILURE CODE [2F00KM]................................................................................................... 577 PARKING BRAKE SYSTEM INDICATING FAILURE (KM)................................................................................ 577 (TM-28) FAILURE CODE [6014NX]................................................................................................... 579 HYDRAULIC TANK FILTER CLOGGED (NX).......................................................................................... 579 (TM-29) FAILURE CODE [989A00]................................................................................................... 581 POSSIBLE ENGINE OVER SPEED CONDITION (00)................................................................................... 581 (TM-30) FAILURE CODE [989AKZ]................................................................................................... 582 OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ)...................................................................... 582 (TM-31)FAILURE CODE [989D00].................................................................................................... 584 REAR OVERTURN SIGNAL OUT OF RANGE (00)...................................................................................... 584 (TM-32)FAILURE CODE [AA10NX].................................................................................................... 586 AIR CLEANER CLOG INDICATION (NX)............................................................................................ 586 (TM-33) FAILURE CODE [AB00MA]................................................................................................... 588 ALTERNATOR NOT CHARGING PROPERLY (MA)....................................................................................... 588 (TM-34) FAILURE CODE [B@BCZK]................................................................................................... 589 COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)......................................................................... 589 (TM-35) FAILURE CODE [B@HAZK]................................................................................................... 591 LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)................................................................................. 591 (TM-36) FAILURE CODE [B@JANS]................................................................................................... 592 STEERING OIL OVERHEAT CONDITION INDICATED (ZK).............................................................................. 592 (TM-37) FAILURE CODE [D1B0KZ]................................................................................................... 593 POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)................................................................ 593 (TM-38) FAILURE CODE [D5ZBKX]................................................................................................... 595 DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX)............................................................................. 595 (TM-39) FAILURE CODE [D5ZCKZ]................................................................................................... 597 OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ).......................................................................... 597 (TM-40) FAILURE CODE [DF10KA]................................................................................................... 599 FORCED NEUTRAL DEMAND SIGNAL (L4)........................................................................................... 599 (TM-41) FAILURE CODE [D5ZEKX]................................................................................................... 601 ENGINE LOAD SIGNAL OUT OF RANGE (KX)........................................................................................ 601 (TM-42) FAILURE CODE [DAQ0KK]................................................................................................... 603 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 603 (TM-43) FAILURE CODE [DAQ1KK]................................................................................................... 605 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 605 (TM-44) FAILURE CODE [DAQ2KK]................................................................................................... 607 POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK).................................................................. 607 (TM-45) FAILURE CODE [DAQ3KK]................................................................................................... 609 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 609 (TM-46) FAILURE CODE [DAQ5KP]................................................................................................... 611 TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)............................................................................ 611 (TM-47) FAILURE CODE [DAQ9KM]................................................................................................... 613 MISTAKEN OPERATION SETTING (KP)............................................................................................. 613 (TM-48) FAILURE CODE [DAQ9KM]................................................................................................... 614 NO MATCH IN MODEL SELECTION SIGNAL (KP)..................................................................................... 614 (TM-49) FAILURE CODE [DAQAKQ]................................................................................................... 615 TRANSMISSION CONTROLLER ROTARY SWITCH....................................................................................... 615 (TM-50) FAILURE CODE [DAQSMA]................................................................................................... 615 TRANSMISSION FUNCTION INOPERABLE............................................................................................ 615 (TM-51) FAILURE CODE [DDTFKA]................................................................................................... 616 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA).................................................................... 616 (TM-52) FAILURE CODE [DDTFKA]................................................................................................... 618 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA).................................................................... 618 (TM-53) FAILURE CODE [DDTHKA]................................................................................................... 620 “HI” CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 620 (TM-54) FAILURE CODE [DDTJKA]................................................................................................... 622 “LO” CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 622 (TM-55) FAILURE CODE [DDTKKA]................................................................................................... 624 1ST. CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 624 (TM-56) FAILURE CODE [DDTLKA]................................................................................................... 626 2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 626 (TM-57) FAILURE CODE [DDTMKA]................................................................................................... 628 3RD. CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 628 (TM-58) FAILURE CODE [DDTNKA]................................................................................................... 630 “R” CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 630 (TM-59) FAILURE CODE [DF10KA]................................................................................................... 632 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)...................................................................... 632 (TM-60) FAILURE CODE [DF10KB]................................................................................................... 634 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)...................................................................... 634 (TM-61) FAILURE CODE [DGF1KX]................................................................................................... 636 TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)....................................................................... 636 (TM-63) FAILURE CODE [DGR3L8]................................................................................................... 637 CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)....................................................................... 637 (TM-64) FAILURE CODE [DGR4L8]................................................................................................... 639 FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)........................................................................ 639 (TM-65) FAILURE CODE [DGT1LX]................................................................................................... 641 TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)....................................................................... 641 (TM-66) FAILURE CODE [DHT5KX]................................................................................................... 642 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX)...................................................................... 642 (TM-67) FAILURE CODE [DHT5L6]................................................................................................... 644 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6)...................................................................... 644 (TM-68) FAILURE CODE [DJF1KA]................................................................................................... 646 FUEL LEVEL SENSOR OUT OF RANGE (L6)......................................................................................... 646 (TM-69) FAILURE CODE [DK11KX]................................................................................................... 648 THROTTLE ANGLE SENSOR OUT OF RANGE (KX)..................................................................................... 648 (TM-70) FAILURE CODE [DLE2KA]................................................................................................... 650 ENGINE SPEED SENSOR OPEN OR SHORTED (KA).................................................................................... 650 (TM-71) FAILURE CODE [DLE2LC]................................................................................................... 651 ENGINE SPEED SENSOR OPEN OR SHORTED (LC).................................................................................... 651 (TM-72) FAILURE CODE [DLF1KA]................................................................................................... 652 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA).................................................................. 652 (TM-73) FAILURE CODE [DLF1LC]................................................................................................... 653 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC).................................................................. 653 (TM-74) FAILURE CODE [DLF2KA]................................................................................................... 654 TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA)........................................................... 654 (TM-75) FAILURE CODE [DLF2LC]................................................................................................... 655 TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC)........................................................... 655 (TM-76) FAILURE CODE [DLT3KA]................................................................................................... 656 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)................................................................. 656 (TM-77) FAILURE CODE [DLT3LC]................................................................................................... 658 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)................................................................. 658 (TM-78) FAILURE CODE [DXH0KA]................................................................................................... 660 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA).................................................................... 660 (TM-79) FAILURE CODE [DXH0KB]................................................................................................... 662 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB).................................................................... 662 (TM-80) FAILURE CODE [DXH1KA]................................................................................................... 664 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 664 (TM-81) FAILURE CODE [DXH1KB]................................................................................................... 666 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 666 (TM-82) FAILURE CODE [DXH2KA]................................................................................................... 668 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 668 (TM-83) FAILURE CODE [DXH2KB]................................................................................................... 670 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 670 (TM-84) FAILURE CODE [DXH3KA]................................................................................................... 672 LOW CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 672 (TM-85) FAILURE CODE [DXH3KB]................................................................................................... 674 LOW CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 674 (TM-86) FAILURE CODE [DXH4KA]................................................................................................... 676 1ST. CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 676 (TM-87) FAILURE CODE [DXH4KB]................................................................................................... 678 1ST. CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 678 (TM-88) FAILURE CODE [DXH5KA]................................................................................................... 680 2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 680 (TM-89) FAILURE CODE [DXH5KB]................................................................................................... 682 2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 682 (TM-90) FAILURE CODE [DXH6KA]................................................................................................... 684 3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 684 (TM-91) FAILURE CODE [DXH6KB]................................................................................................... 686 3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 686 (TM-92) FAILURE CODE [DXH7KA]................................................................................................... 688 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 688 (TM-93) FAILURE CODE [DXH7KB]................................................................................................... 690 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 690 (TM-94) NO FAILURE CODE DISPLAYED............................................................................................... 692 BACK-UP LIGHTS AND ALARM DO NOT OPERATE..................................................................................... 692 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 697 BK CONTROL SYSTEM CIRCUIT DIAGRAM............................................................................................... 703 CONTENT OF CODE DISPLAY (1)..................................................................................................... 710 CONTENT OF CODE DISPLAY (2)..................................................................................................... 712 CONTENT OF CODE DISPLAY (3)..................................................................................................... 714 CONTENT OF CODE DISPLAY (4)..................................................................................................... 716 CONTENT OF CODE DISPLAY (5)..................................................................................................... 718 CONTENT OF CODE DISPLAY (6)..................................................................................................... 720 CONTENT OF CODE DISPLAY (7)..................................................................................................... 722 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 724 (BK-1) FAILURE CODE [2A62L1].................................................................................................... 726 FRONT DIFFERENTIAL CONTROL VALVE (L1)....................................................................................... 726 (BK-2) FAILURE CODE [2A62LH].................................................................................................... 728 FRONT DIFFERENTIAL CONTROL VALVE (LH)....................................................................................... 728 (BK-3) FAILURE CODE [2B62L1].................................................................................................... 730 REAR DIFFERENTIAL LOCK CONTROL VALVE (L1)................................................................................... 730 (BK-4) FAILURE CODE [2B62LH].................................................................................................... 732 REAR DIFFERENTIAL LOCK CONTROL VALVE (LH)................................................................................... 732 (BK-5) FAILURE CODE [2C4MNX].................................................................................................... 734 BRAKE COOLING FILTER CLOG INDICATED (NX).................................................................................... 734 (BK-6) FAILURE CODE [2D02CA].................................................................................................... 736 LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)......................................................................... 736 (BK-7) FAILURE CODE [2D01CA].................................................................................................... 737 RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)........................................................................ 737 (BK-8) FAILURE CODE [2D03CA].................................................................................................... 738 CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)................................................................. 738 (BK-9) FAILURE CODE [2D04CA].................................................................................................... 739 CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA)........................................................................ 739 (BK-12) FAILURE CODE [2G42ZG]................................................................................................... 740 ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG).............................................................................. 740 (BK-13) FAILURE CODE [2G43ZG]................................................................................................... 741 ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)............................................................................... 741 (BK-14) FAILURE CODE [D1C0KZ]................................................................................................... 742 OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)................................................................................... 742 (BK-15) FAILURE CODE [D5ZFKZ]................................................................................................... 744 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)......................................................................................... 744 (BK-16) FAILURE CODE [D5ZGKZ]................................................................................................... 746 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)......................................................................................... 746 (BK-17) FAILURE CODE [DB10KK]................................................................................................... 748 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 748 (BK-18) FAILURE CODE [DB11KK]................................................................................................... 750 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 750 (BK-19) FAILURE CODE [DB12KK]................................................................................................... 752 VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)................................................................................ 752 (BK-20) FAILURE CODE [DB13KK]................................................................................................... 754 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 754 (BK-21) FAILURE CODE [DB19KM]................................................................................................... 756 MISTAKEN OPERATION OF RETARDER CONTROLLER (KM).............................................................................. 756 (BK-22) FAILURE CODE [DB1SKQ]................................................................................................... 757 RETARDER CONTROL S-NET LINE MISMATCHED (KQ)................................................................................. 757 (BK-23) FAILURE CODE [DHU2KX]................................................................................................... 758 ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)..................................................................... 758 (BK-24) FAILURE CODE [DHU3KX]................................................................................................... 760 ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX)...................................................................... 760 (BK-25) FAILURE CODE [DK51L5]................................................................................................... 762 TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)......................................................................... 762 (BK-26) FAILURE CODE [DK52KX]................................................................................................... 764 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)................................................................................... 764 (BK-27) FAILURE CODE [DK53L8]................................................................................................... 766 DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)................................................................................... 766 (BK-28) FAILURE CODE [DK54KX]................................................................................................... 768 BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)............................................................................... 768 (BK-29) FAILURE CODE [DLF4KA]................................................................................................... 770 TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA)................................................................ 770 (BK-30) FAILURE CODE [DLT3KA]................................................................................................... 771 TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA)................................................................ 771 (BK-31) FAILURE CODE [DW71KZ]................................................................................................... 773 EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)................................................................................. 773 (BK-32) FAILURE CODE [DK72KX]................................................................................................... 774 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)................................................................................... 774 (BK-33) FAILURE CODE [DW73KZ]................................................................................................... 776 DUMP SELECTOR VALVE OPEN OR SHORTED (KZ).................................................................................... 776 (BK-34) FAILURE CODE [DX11KA]................................................................................................... 778 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA).................................................................. 778 (BK-35) FAILURE CODE [DX11KB]................................................................................................... 779 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB).................................................................. 779 (BK-36) FAILURE CODE [DX11KY]................................................................................................... 780 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY).................................................................. 780 (BK-37) FAILURE CODE [DX12KA]................................................................................................... 781 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)................................................................. 781 (BK-38) FAILURE CODE [DX12KB]................................................................................................... 782 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)................................................................. 782 (BK-39) FAILURE CODE [DX13KA]................................................................................................... 783 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)................................................................................ 783 (BK-40) FAILURE CODE [DX13KB]................................................................................................... 785 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)................................................................................ 785 (BK-41) FAILURE CODE [DX13KY]................................................................................................... 787 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)................................................................................ 787 (BK-42) FAILURE CODE [DX14KZ]................................................................................................... 789 REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)........................................................................ 789 (BK-43) FAILURE CODE [DX15KZ]................................................................................................... 790 FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)....................................................................... 790 (BK-44) NO FAILURE CODE DISPLAYED............................................................................................... 792 PARKING BRAKE SYSTEM FAILURE................................................................................................ 792 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 797 MON CONTROL SYSTEM CIRCUIT DIAGRAM.............................................................................................. 803 CONTENT OF CODE DISPLAY (1)..................................................................................................... 808 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 810 (MON-1) FAILURE CODE [B@C6NS]................................................................................................... 812 FRONT BRAKE OIL OVERHEAT CONDITION (NS)..................................................................................... 812 (MON-3) FAILURE CODE [B@C8NS]................................................................................................... 813 CENTER BRAKE OIL OVERHEAT CONDITION (NS).................................................................................... 813 (MON-4) FAILURE CODE [B@CENS]................................................................................................... 814 TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS).......................................................................... 814 (MON-5) FAILURE CODE [DAF0KM]................................................................................................... 815 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)......................................................................... 815 (MON-6) FAILURE CODE [DAF9KM]................................................................................................... 817 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)......................................................................... 817 (MON-7) FAILURE CODE [DAFSKQ]................................................................................................... 818 MODEL SELECTION DOES NOT MATCH (KQ)......................................................................................... 818 (MON-8) FAILURE CODE [AQSKR].................................................................................................... 819 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 819 (MON-9) FAILURE CODE [DA1SKR]................................................................................................... 821 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 821 (MON-10) FAILURE CODE [DA2SKR].................................................................................................. 823 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 823 (MON-11) FAILURE CODE [DV00KB].................................................................................................. 825 DEFECTIVE ALARM BUZZER (KB)................................................................................................. 825 (MON-12) NO FAILURE CODE DISPLAYED.............................................................................................. 827 WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL................................................................. 827 (MON-13) NO FAILURE CODE DISPLAYED.............................................................................................. 829 WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL................................................................ 829 (MON-14) NO FAILURE CODE DISPLAYED.............................................................................................. 831 ALARM BUZZER DOES NOT SOUND................................................................................................. 831 (MON-15) NO FAILURE CODE DISPLAYED.............................................................................................. 833 INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL................................................................... 833 (MON-16) NO FAILURE CODE DISPLAYED.............................................................................................. 834 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED...................................................................... 834 (MON-17) NO FAILURE CODE DISPLAYED.............................................................................................. 835 MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE..................................................................... 835 (MON-18) NO FAILURE CODE DISPLAYED.............................................................................................. 837 POWER MODE SWITCH DOES NOT WORK PROPERLY.................................................................................... 837 (MON-19) NO FAILURE CODE DISPLAYED.............................................................................................. 838 AISS FUNCTION DOES NOT WORK PROPERLY........................................................................................ 838 (MON-20) NO FAILURE CODE DISPLAYED.............................................................................................. 839 RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROPERLY.............................................................. 839 (MON-20) NO FAILURE CODE DISPLAYED.............................................................................................. 841 LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK PROPERLY........................................................ 841 (MON-21) NO FAILURE CODE DISPLAYED.............................................................................................. 843 INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY.................................................................. 843 (MON-22) NO FAILURE CODE DISPLAYED.............................................................................................. 844 EXHAUST BRAKE DOES NOT WORK PROPERLY........................................................................................ 844 (MON-23) NO FAILURE CODE DISPLAYED.............................................................................................. 846 SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY............................................................................... 846 (MON-24) NO FAILURE CODE DISPLAYED.............................................................................................. 847 SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY................................................................................. 847 (MON-25) NO FAILURE CODE DISPLAYED.............................................................................................. 850 HEAD AND TAIL LAMPS DO NOT WORK PROPERLY.................................................................................... 850 (H-1)........................................................................................................................... 856 THE MACHINE DOES NOT MOVE................................................................................................... 856 (H-2) AND (H-3)................................................................................................................. 857 MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY)........................................................................ 857 LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING).................................................................. 857 (H-4) AND (H-5)................................................................................................................. 858 EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS..................................................................... 858 TRANSMISSION WILL NOT UP SHIFT GEAR RANGE................................................................................... 858 (H-6)........................................................................................................................... 859 MACHINE LACKS POWER OR SPEED WHEN TRAVELING................................................................................. 859 (H-6)........................................................................................................................... 860 ABNORMAL OPERATION AT SOME SPEED RANGES..................................................................................... 860 (H-6)........................................................................................................................... 861 TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.................................................................................... 861 (H-7)........................................................................................................................... 862 TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES................................................................... 862 (H-8)........................................................................................................................... 863 TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)..................................................................... 863 (H-9)........................................................................................................................... 864 TORQUE CONVERTER OIL PRESSURE LOW........................................................................................... 864 (H-10).......................................................................................................................... 865 FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY.................................................................. 865 (H-11).......................................................................................................................... 866 CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE............................................................... 866 (H-12).......................................................................................................................... 867 STEERING EFFORT SEeMS HEAVY................................................................................................. 867 (H-13).......................................................................................................................... 868 STEERING SYSTEM DOES NOT OPERATE............................................................................................ 868 (H-14).......................................................................................................................... 869 STEERING WHEEL VIBRATES..................................................................................................... 869 (H-15).......................................................................................................................... 870 DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER.............................................................................. 870 (H-16).......................................................................................................................... 871 DUMP OPERATIONS DO NOT WORK................................................................................................. 871 (H-17).......................................................................................................................... 872 EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY...................................................................................... 872 30 DISASSEMBLY AND ASSEMBLY......................................................................................................... 873 HOW TO USE MANUAL............................................................................................................... 876 PRECAUTIONS WHEN CARRYING OUT REPAIR............................................................................................ 877 SPECIAL TOOL LIST............................................................................................................... 880 SKETCHES OF SPECIAL TOOLS....................................................................................................... 885 CONNECTOR REPAIR PROCEDURES..................................................................................................... 897 CONTACT TERMINAL REMOVAL (HD30 TYPE)........................................................................................ 897 STRIPING INSULATION......................................................................................................... 898 CRIMPING CONTACT TERMINAL (HD30 TYPE)....................................................................................... 899 INSERTION OF CONTACT TERMINAL (HD30 TYPE)................................................................................... 900 CONTACT TERMINAL REMOVAL (DT TYPE).......................................................................................... 901 STRIPING INSULATION......................................................................................................... 902 CRIMPING CONTACT TERMINAL (DT TYPE)......................................................................................... 903 INSERTION OF CONTACT TERMINAL (DT TYPE)..................................................................................... 904 ENGINE REMOVAL AND INSTALLATION PROCEDURES...................................................................................... 905 REMOVAL..................................................................................................................... 905 INSTALLATION................................................................................................................ 908 RADIATOR REMOVAL AND INSTALLATION PROCEDURES.................................................................................... 910 REMOVAL..................................................................................................................... 910 INSTALLATION................................................................................................................ 912 OUTPUT SHAFT SYSTEM............................................................................................................. 913 REMOVAL..................................................................................................................... 913 INSTALLATION................................................................................................................ 915 OUTPUT SHAFT DIAGRAM........................................................................................................ 917 OUTPUT SHAFT ASSEMBLY PROCEDURES............................................................................................ 918 TRANSMISSION AND FRONT DIFFERENTIAL............................................................................................. 921 REMOVAL..................................................................................................................... 921 INSTALLATION................................................................................................................ 928 SPLITTING DIFFERENTIAL AND TRANSMISSION ASSEMBLY................................................................................ 930 SEPARATING.................................................................................................................. 930 REATTACHING................................................................................................................. 931 TORQUE CONVERTER OVERHAUL PROCEDURES............................................................................................ 932 DISASSEMBLY................................................................................................................. 932 ASSEMBLY.................................................................................................................... 937 TRANSMISSION OVERHAUL PROCEDURES................................................................................................ 942 DISASSEMBLY................................................................................................................. 942 ASSEMBLY.................................................................................................................... 960 FRONT DIFFERENTIAL OVERHAUL PROCEDURES.......................................................................................... 991 DISASSEMBLY................................................................................................................. 991 ASSEMBLY....................................................................................................................1000 CENTER DIFFERENTIAL.............................................................................................................1014 REMOVAL.....................................................................................................................1014 REMOVING DIFFERENTIAL COUPLING FLANGE...................................................................................1016 INSTALLATION................................................................................................................1017 OVERHAUL PROCEDURES.........................................................................................................1019 DISASSEMBLY.............................................................................................................1019 ASSEMBLY................................................................................................................1026 REAR DIFFERENTIAL...............................................................................................................1038 REMOVAL.....................................................................................................................1038 INSTALLATION................................................................................................................1039 OVERHAUL PROCEDURES.........................................................................................................1040 DISASSEMBLY.............................................................................................................1040 ASSEMBLY................................................................................................................1044 FRONT FINAL DRIVE AND BRAKE.....................................................................................................1053 REMOVAL.....................................................................................................................1053 INSTALLATION................................................................................................................1055 OVERHAUL PROCEDURES.........................................................................................................1056 DISASSEMBLY.............................................................................................................1056 ASSEMBLY................................................................................................................1063 CENTER FINAL DRIVE AND BRAKE....................................................................................................1073 REMOVAL.....................................................................................................................1073 INSTALLATION................................................................................................................1074 OVERHAUL PROCEDURES.........................................................................................................1075 DISASSEMBLY.............................................................................................................1075 ASSEMBLY................................................................................................................1081 REAR FINAL DRIVE................................................................................................................1090 REMOVAL.....................................................................................................................1090 INSTALLATION................................................................................................................1091 OVERHAUL PROCEDURES.........................................................................................................1092 DISASSEMBLY.............................................................................................................1092 ASSEMBLY................................................................................................................1094 AXLE REMOVAL AND INSTALLATION PROCEDURES........................................................................................1100 CENTER AXLE REMOVAL.........................................................................................................1100 CENTER AXLE INSTALLATION....................................................................................................1103 REAR AXLE REMOVAL...........................................................................................................1104 REAR AXLE INSTALLATION......................................................................................................1106 PARKING BRAKE SYSTEM............................................................................................................1107 REMOVAL.....................................................................................................................1107 INSTALLATION................................................................................................................1108 CALIPER OVERHAUL PROCEDURES.................................................................................................1109 DISASSEMBLY.............................................................................................................1109 ASSEMBLY................................................................................................................1109 BRAKE PAD REPLACEMENT.......................................................................................................1111 REMOVAL.................................................................................................................1111 INSTALLATION............................................................................................................1111 SUSPENSION SYSTEM...............................................................................................................1112 FRONT CYLINDER REMOVAL......................................................................................................1112 FRONT CYLINDER INSTALLATION.................................................................................................1113 REAR CYLINDER REMOVAL.......................................................................................................1113 REAR CYLINDER INSTALLATION..................................................................................................1114 EQUALIZER BAR REMOVAL.......................................................................................................1114 EQUALIZER BAR INSTALLATION..................................................................................................1116 TRUCK WHEELS....................................................................................................................1117 FRONT WHEEL REMOVAL.........................................................................................................1117 INSTALLATION OF FRONT WHEEL.................................................................................................1117 REAR TANDEM WHEELS..........................................................................................................1118 CENTER WHEEL REMOVAL....................................................................................................1118 CENTER WHEEL INSTALLATION...............................................................................................1118 REAR WHEEL REMOVAL......................................................................................................1118 REAR WHEEL INSTALLATION.................................................................................................1118 ARTICULATED HITCH SYSTEM........................................................................................................1119 REMOVAL.....................................................................................................................1119 INSTALLATION................................................................................................................1124 OVERHAUL PROCEDURES.........................................................................................................1126 DISASSEMBLY.............................................................................................................1126 ASSEMBLY................................................................................................................1127 ORBITAL STEERING UNIT...........................................................................................................1130 UNIT BREAKDOWN VIEW.........................................................................................................1130 OVERHAUL PROCEDURES.........................................................................................................1132 DISASSEMBLY.............................................................................................................1132 ASSEMBLY................................................................................................................1135 FLOW AMPLIFIER VALVE............................................................................................................1141 REMOVAL.....................................................................................................................1141 INSTALLATION................................................................................................................1141 HOIST VALVE UNIT................................................................................................................1142 REMOVAL.....................................................................................................................1142 INSTALLATION................................................................................................................1142 OVERHAUL PROCEDURES.........................................................................................................1143 DISASSEMBLY.............................................................................................................1143 ASSEMBLY................................................................................................................1144 HYDRAULIC CYLINDER OVERHAUL PROCEDURES..........................................................................................1145 STEERING CYLINDER DISASSEMBLY...............................................................................................1145 STEERING CYLINDER ASSEMBLY..................................................................................................1146 HOIST CYLINDER DISASSEMBLY..................................................................................................1149 HOIST CYLINDER ASSEMBLY.....................................................................................................1151 TRUCK BODY ASSEMBLY.............................................................................................................1155 REMOVAL.....................................................................................................................1155 INSTALLATION................................................................................................................1156 OPERATOR’S SEAT.................................................................................................................1157 DISASSEMBLY.................................................................................................................1157 ASSEMBLY....................................................................................................................1164 90 OTHERS...........................................................................................................................1171 CAB.............................................................................................................................1173 CLIMATE CONTROL SYSTEM......................................................................................................1173 CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER.............................................................................1175 CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER.........................................................................1177 LIGHTING WIPER AND RELAY BANK...............................................................................................1179 RELAY AND SWITCH CIRCUITS...................................................................................................1181 MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS......................................................................1183 DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS................................................................................1185 DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT............................................................1187 RETARDER SYSTEM.............................................................................................................1189 RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING..............................................................1191 TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL..............................................................1193 TRANSMISSION CONTROLLER.....................................................................................................1195 TO HARNESS OUTSIDE OF CAB...................................................................................................1197 TO HARNESS OUTSIDE OF CAB AND TO ENGINE.....................................................................................1199 CHASSIS.........................................................................................................................1201 SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OF CAB..................................................................1201 TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS...............................................................................1203 TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS.........................................................................1205 CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS.............................................................................1207 CHASSIS SENSOR SYSTEMS......................................................................................................1209 CONNECTORS OUTSIDE OF CAB...................................................................................................1211 ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS...........................................1213 DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM....................................................1215 BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR..........................................................................1217 TRANSMISSION SELECTOR SYSTEM................................................................................................1219
KOMATSU HM350-1L DUMP TRUCK SERVICE MANUAL CEBM015400 – PDF DOWNLOAD:
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