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Komatsu HM400-1 Shop Manual 1001 and up – PDF DOWNLOAD
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Komatsu HM400-1 Shop Manual
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HM400-1 1001 and up
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Description
Komatsu HM400-1 Shop Manual
FILE DETAILS:
Komatsu HM400-1 Shop Manual
Brands: Komatsu
Manuals Type: Shop Manual
Machine Model: HM400-1
Serial Number: 1001 and up
Book Code: SEBM023017
Language: English
Pages: 1112
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM400-1 Shop Manual
FOREWORD:
General :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu- rate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service work- shop. For ease of understanding. the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
Structure and function:
This section explains the structure and function of each component It serves not only to give an under- standing of the structure, but also serves as reference material for troubleshooting. in addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
Testing and adjusting:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems‘ with “Causes‘ are also included in this section.
Disassembly and assembly:
This section explains the procedures for removing, installing, disassembling and assembling each compo- nent, as well as precautions for them.
Maintenance standard:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in “Structure and function.
Others:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. in addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu HM400-1 Shop Manual
COVER ........................................................................................................................................................... 1 CONTENTS......................................................................................................................................................... 2 01 GENERAL....................................................................................................................................................... 29 SPECIFICATION DRAWINGS....................................................................................................................................... 30 SPECIFICATIONS............................................................................................................................................... 31 WEIGHT TABLE................................................................................................................................................. 34 FUEL,COOLANT AND LUBRICANTS.................................................................................................................................. 35 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD................................................................................................................... 37 RADIATOR,OIL COOLER,AFTERCOOLER.............................................................................................................................. 38 POWER TRAIN SKELETON......................................................................................................................................... 39 OUTPUT SHAFT................................................................................................................................................. 43 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING........................................................................................................... 45 TORQUE CONVERTER............................................................................................................................................. 47 TRANSMISSION................................................................................................................................................. 53 TRANSMISSION VALVE........................................................................................................................................... 71 ECMV (ELECTRONIC CONTROL MODULATION VALVE)................................................................................................................... 72 MAIN RELIEF,TORQUE CONVERTER RELIEF VALVE.................................................................................................................... 79 DRIVE SHAFT.................................................................................................................................................. 81 AXLE......................................................................................................................................................... 82 DIFFERENTIAL................................................................................................................................................. 85 LIMITED SLIP DIFFERENTIAL.................................................................................................................................... 98 FINAL DRIVE.................................................................................................................................................. 102 STEERING COLUMN.............................................................................................................................................. 106 BRAKE PIPING................................................................................................................................................. 107 BRAKE VALVE.................................................................................................................................................. 109 ACCUMULATOR CHARGE VALVE..................................................................................................................................... 112 ACCUMULATOR.................................................................................................................................................. 116 SLACK ADJUSTER............................................................................................................................................... 117 BRAKE........................................................................................................................................................ 119 PROPORTIONAL REDUCING VALVE.................................................................................................................................. 124 BRAKE SYSTEM TANK............................................................................................................................................ 125 PARKING BRAKE................................................................................................................................................ 126 PARKING BRAKE CALIPER........................................................................................................................................ 128 SPRING CYLINDER.............................................................................................................................................. 129 PARKING BRAKE SOLENOID....................................................................................................................................... 130 SUSPENSION................................................................................................................................................... 131 SUSPENSION CYLINDER.......................................................................................................................................... 136 OSCILLATION HITCH............................................................................................................................................ 138 STEERING, HOIST OIL PRESSURE PIPING DIAGRAM.................................................................................................................. 141 DUMP BODY CONTROL............................................................................................................................................ 142 HYDRAULIC TANK AND FILTER.................................................................................................................................... 143 FLOW AMP VALVE............................................................................................................................................... 144 STEERING VALVE............................................................................................................................................... 147 STEERING CYLINDER............................................................................................................................................ 151 HOIST VALVE.................................................................................................................................................. 152 EPC VALVE.................................................................................................................................................... 158 PILOT CHECK VALVE............................................................................................................................................ 159 HOIST CYLINDER............................................................................................................................................... 160 HYDRAULIC PUMP............................................................................................................................................... 161 CAB TILT..................................................................................................................................................... 167 AIR CONDITIONER.............................................................................................................................................. 168 MACHINE MONITOR SYSTEM....................................................................................................................................... 173 AUTOMATIC SHIFT CONTROL SYSTEM............................................................................................................................... 187 TRANSMISSION CONTROLLER...................................................................................................................................... 189 AUTO EMERGENCY STEERING SYSTEM............................................................................................................................... 195 SENSORS,SWITCHES............................................................................................................................................. 196 RETARDER CONTROL SYSTEM...................................................................................................................................... 204 BRAKE CONTROL SYSTEM (E-SPEC)................................................................................................................................ 214 DUMP CONTROL LEVER........................................................................................................................................... 224 PLM-HM....................................................................................................................................................... 229 20 TESTING AND ADJUSTING......................................................................................................................................... 265 STANDARD VALUE TABLE FOR ENGINE.............................................................................................................................. 266 STANDARD VALUE TABLE FOR CHASSIS............................................................................................................................. 267 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................... 271 TESTING AND ADJUSTING........................................................................................................................................ 285 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................................ 286 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)........................................................................................................... 288 MEASURING EXHAUST TEMPERATURE............................................................................................................................ 289 MEASURING EXHAUST COLOR.................................................................................................................................. 291 MEASURING COMPRESSION PRESSURE........................................................................................................................... 292 ADJUSTING VALVE CLEARANCE................................................................................................................................ 293 MEASURING BLOW-BY PRESSURE............................................................................................................................... 294 MEASURING ENGINE OIL PRESSURE............................................................................................................................ 295 HANDING EQUIPMENT IN FUEL CIRCUIT........................................................................................................................ 296 RELEASING REMAINING PRESSURE IN FUEL SYSTEM.............................................................................................................. 296 MEASURING FUEL PRESSURE.................................................................................................................................. 297 BLEEDING AIR FROM FUEL CIRCUIT........................................................................................................................... 298 REDUCED CYLINDER MODE OPERATION.......................................................................................................................... 299 CHECKING FOR LEAKAGE IN FUEL CIRCUIT..................................................................................................................... 300 ADJUSTING ENGINE SPEED SENSOR............................................................................................................................ 301 TESTING AND ADJUSTING FAN BELT TENSION................................................................................................................... 302 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................................ 303 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION............................................................................................ 303 ADJUSTING THE BODY MOUNT................................................................................................................................. 304 TESTING TORQUE CONVERTER STALL SPEED..................................................................................................................... 306 MEASURING POWER TRAIN OIL PRESSURE....................................................................................................................... 307 TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE...................................................................................... 315 ADJUSTING TRANSMISSION SPEED SENSOR...................................................................................................................... 320 TESTING AND ADJUSTING BRAKE OIL PRESSURE................................................................................................................. 322 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS.................................................... 327 TESTING BRAKE PERFORMANCE................................................................................................................................ 331 BLEEDING AIR FROM BRAKE CIRCUIT.......................................................................................................................... 333 TESTING WEAR OF WHEEL BRAKE DISC......................................................................................................................... 335 TESTING WEAR OF PARKING BRAKE PAD........................................................................................................................ 336 METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE............................................................................................................ 338 TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE.......................................................................................................... 339 TESTING AND ADJUSTING SUSPENSION CYLINDER................................................................................................................ 341 METHOD OF TILTING CAB UP................................................................................................................................. 345 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE.............................................................................................................. 347 ADJUSTING BODY POSITIONER SENSOR......................................................................................................................... 350 PROCEDURE FOR ADUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT.................................................................................. 351 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT.......................................................................................................... 351 ADJUSTING TRANSMISSION CONTROLLER........................................................................................................................ 352 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM................................................................................... 353 ADJUSTING MACHINE MONITOR................................................................................................................................ 357 SPECIAL FUNCTIONS OF MACHINE MONITOR..................................................................................................................... 361 PM-CLINIC INSPECTION SHEET............................................................................................................................... 397 TROUBLESHOOTING.............................................................................................................................................. 400 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................................................................. 401 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................... 402 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................................... 403 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................ 411 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................... 412 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................... 426 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................... 453 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)................................................................................................... 457 ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................... 459 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 462 ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1)).................................................................................................... 474 ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))........................................................................................ 475 ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))........................................................................................ 476 ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA)).................................................................................. 476 ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))................................................................................... 477 ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))............................................................................. 479 ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))................................................................................ 479 ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA)).................................................................. 480 ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB)).................................................................. 481 ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))................................................................. 482 ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))................................................................. 483 ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 484 ENG-13 FAILURE CODE [ADZKKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).................................................................. 485 ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 489 ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 490 ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 491 ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).................................................................. 492 ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 496 ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...................................................................... 497 ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))................................................................................. 498 ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))........................................................................................ 499 ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))......................................................................................... 500 ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))......................................................... 501 ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................................ 503 ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))......................................................... 504 ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))...................................................... 506 ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))................................................................. 507 ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE,INPUT (KK)).................................... 508 ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))..................................... 510 ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA)).................................... 511 ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))................................................................................... 512 ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))............................................................................... 513 ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))........................................................................ 515 ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))............................... 517 ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))............................................. 518 ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).............................................................. 519 ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 520 ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).......................................................... 522 ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 524 ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))............................................................................ 526 ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))............................................................................. 527 ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)............................................................................ 528 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE).............................................................................................. 531 TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM........................................................................................................... 534 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 540 TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))........................................................................................... 566 TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))................................................................................. 567 TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))................................................................................... 568 TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))................................................................................................. 569 TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))................................................................................................ 570 TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))................................................................................................ 571 TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))............................................................................................... 572 TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))............................................................................................... 573 TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))............................................................................................... 574 TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1)) ................................................................................. 575 TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))............................................................................ 576 TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))................................................................................. 577 TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))........................................................................... 578 TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))................................................................................. 579 TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))........................................................................... 580 TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))................................................................................ 581 TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 582 TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))................................................................................ 583 TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 584 TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))................................................................................ 585 TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA)).......................................................................... 586 TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))............................................................................ 587 TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))...................................................................... 588 TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))....................................................... 589 TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................. 590 TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))..................................................................... 591 TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) ........................................................... 592 TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX)).................................................................................... 594 TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))................................................................ 595 TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)).......................................... 596 TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00)).................................................................................... 597 TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))....................................................................................... 599 TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))................................................................................... 600 TM-34 FAILURE CODE [B@BCZK] (RADIATOR WATER: DROP IN LEVEL (ZK))..................................................................................... 601 TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))................................................................................. 602 TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))............................................................................................ 603 TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................................ 604 TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))........................................... 606 TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 607 TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))....................................................................... 608 TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)).................................................................... 610 TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...................................................... 611 TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............................... 612 TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............................... 613 TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))..................... 614 TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))............................................. 615 TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP)).................................... 616 TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))....................................... 617 TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))........................................ 618 TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))...................................................................... 618 TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))................................................ 619 TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))..................................................................... 620 TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA)).......................................................................... 621 TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA)).......................................................................... 622 TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))......................................................................... 623 TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))......................................................................... 624 TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))......................................................................... 625 TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))........................................................................... 626 TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA)).................................................................................... 627 TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB)).................................................................................... 629 TM-61 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))............................................. 631 TM-62 FAILURE CODE [DGR2L8] (BRAKE OIL TEMPERATURE SENSOR (REAR): *SEE CONTENTS (L8))................................................................ 632 TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8)).............................................................. 633 TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))............................................................... 634 TM-65 FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))............................................... 635 TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).................................................. 636 TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))............................................................... 638 TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6)).................................................................................. 639 TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................. 640 TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))................................................................................ 642 TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))................................................................................ 643 TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA)).............................................................. 644 TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC)).............................................................. 645 TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))....................................................... 646 TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))....................................................... 647 TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))............................................................. 648 TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))............................................................. 649 TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA)).......................................................... 650 TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB)).......................................................... 651 TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))........................................................................ 652 TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))........................................................................ 653 TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))............................................................................. 654 TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))............................................................................. 655 TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))............................................................................. 656 TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))............................................................................. 657 TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))............................................................................ 658 TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))............................................................................ 659 TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))............................................................................ 660 TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))............................................................................ 661 TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))............................................................................ 662 TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))............................................................................ 663 TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA)).............................................................................. 664 TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB)).............................................................................. 665 TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY................................................................................................ 666 TROUBLESHOOTING OF RETARDER CONTROLLER (※1) SYSTEM (BK MODE)............................................................................................. 669 BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM........................................................................................................... 671 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE......................................................................... 677 BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................. 691 BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)................. 692 BK-3 FAILURE CODE [2B62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL).................. 693 BK-4 FAILURE CODE [2B62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL).................. 694 BK-5 FAILURE CODE [2C4MNX] (RETARDER COOLING FILTER: CLOGGED (NX))................................................................................... 695 BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA)).......................................................................................... 696 BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))........................................................................................... 697 BK-8 FAILURE CODE [2D03CA] (CENTER BRAKE (RIGHT): WEAR (CA))......................................................................................... 698 BK-9 FAILURE CODE [2D04CA] (CENTER BRAKE (LEFT): WEAR (CA)).......................................................................................... 699 BK-10 FAILURE CODE [2D05CA] (REAR BRAKE (RIGHT): WEAR (CA)).......................................................................................... 700 BK-11 FAILURE CODE [2D06CA] (REAR BRAKE (LEFT): WEAR (CA))........................................................................................... 701 BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))......................................................................... 702 BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)).......................................................................... 702 BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))................................................................... 703 BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................................. 704 BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................................. 705 BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)........................................................... 706 BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).................................... 707 BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).................................... 708 BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).......................... 709 BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))........................................ 710 BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))................................................... 711 BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))............................................... 712 BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))................................................ 714 BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))................................................................. 716 BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))............................................................ 719 BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))......................................................................... 721 BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................................ 722 BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))........................................................... 724 BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))........................................................... 725 BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)............................... 726 BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 727 BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...................................................... 728 BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))........................................................ 729 BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))........................................................ 730 BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))................................... 731 BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))....................................................... 732 BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))....................................................... 733 BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)).................................. 734 BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))............................................................................ 735 BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))............................................................................ 736 BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))....................................................... 737 BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)..... 738 BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL).... 739 BK-45 PARKING BRAKE DOES NOT WORK PROPERLY........................................................................................................... 740 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)..................................................................................................... 743 MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................... 744 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ........................................................................ 748 MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))......................................................................................... 750 MON-2 FAILURE CODE [B@C7NS] (REAR BRAKE OIL: OVERHEAT (NS)).......................................................................................... 750 MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))........................................................................................ 751 MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))........................................................................................ 751 MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))............................................................. 752 MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))............................................................. 753 MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))................................................................ 754 MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))............. 755 MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))................. 757 MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).................. 759 MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))...................................................................................... 761 MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY........................................................................... 762 MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED............................................................................... 763 MON-14 ALARM BUZZER DOES NOT SOUND................................................................................................................... 764 MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY....................................................... 765 MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY............................................................................... 767 MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY................................................................................................. 768 MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY........................................................................................... 771 MON-19 AISS FUNCTION DOES NOT WORK PROPERLY.......................................................................................................... 772 MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY....................................................................................... 773 MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY........................................................................................... 776 MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)................................................................... 777 MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY.......................................................................................... 779 MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY............................................................................................ 780 MON-25 NIGHT LIGHTING IS NOT NORMAL.................................................................................................................. 785 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)................................................................................................. 791 H-1 MACHINE DOES NOT START........................................................................................................................... 792 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)................................................................................................. 793 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS).............................................................................................. 793 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING........................................................................................................ 794 H-5 TRANSMISSION DOES NOT SHIFT UP................................................................................................................... 794 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING...................................................................................................... 795 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR............................................................................................. 798 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH......................................................................................................... 799 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW............................................................................................................. 800 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE....................................................................................... 801 H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE...................................................................................... 802 H-12 REAR BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE........................................................................................ 803 H-13 STEERING WHEEL IS HEAVY......................................................................................................................... 804 H-14 STEERING WHEEL DOES NOT WORK.................................................................................................................... 805 H-15 STEEIRNG WHEEL VIBRATES......................................................................................................................... 806 H-16 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER................................................................................................. 807 H-17 DUMP DOES NOT WORK.............................................................................................................................. 808 H-18 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.......................................................................................................... 809 TROUBLESHOOTING OF THE ENGINE BODY (S MODE).............................................................................................................. 810 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................. 811 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................... 812 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................................ 815 S-2 ENGINE DOES NOT START............................................................................................................................ 816 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................................................................................. 819 S-4 ENGINE STOPS DURING OPERATIONS................................................................................................................... 820 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................................ 821 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)............................................................................................................. 822 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)................................................................................................... 823 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).......................................................................................... 824 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................................................................................. 825 S-10 FUEL CONSUMPTION IS EXCESSIVE................................................................................................................... 826 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN)........................................................................ 827 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...................................................................................... 828 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)............................................................................................................ 829 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................................ 830 S-15 ABNORMAL NOISE IS MADE.......................................................................................................................... 831 S-16 VIBRATION IS EXCESSIVE.......................................................................................................................... 832 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................... 833 HOW TO READ THIS MANUAL...................................................................................................................................... 835 REMOVAL AND INSTALLATION OF ASSEMBLIES................................................................................................................... 835 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES................................................................................................................... 836 PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................................... 837 SPECIAL TOOL LIST............................................................................................................................................ 839 SKETCHES OF SPECIAL TOOLS.................................................................................................................................... 844 REMOVAL OF FUEL SUPPLY PUMP.................................................................................................................................. 857 INSTALLATION OF FUEL SUPPLY PUMP............................................................................................................................. 858 REMOVAL OF ENGINE ASSEMBLY................................................................................................................................... 859 INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................. 864 REMOVAL OF CYLINDER HEAD ASSEMBLY............................................................................................................................ 865 INSTALLATION OF CYLINDER HEAD................................................................................................................................ 869 REMOVAL AND INSTALLATION OF NOZZLE TIP....................................................................................................................... 874 REMOVAL.................................................................................................................................................. 874 INSTALLATION............................................................................................................................................. 875 REMOVAL OF RADIATOR ASSEMBLY................................................................................................................................. 876 INSTALLATION OF RADIATOR ASSEMBLY............................................................................................................................ 878 REMOVAL OF OUTPUT SHAFT ASSEMBLY............................................................................................................................. 879 INSTALLATION OF OUTPUT SHAFT ASSEMBLY........................................................................................................................ 882 DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY......................................................................................................................... 883 ASSEMBLY OF OUTPUT SHAFT ASSEMBLY............................................................................................................................ 884 REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...................................................................................................... 886 INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY................................................................................................. 892 DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION......................................................................................................... 894 COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION.............................................................................................................. 894 DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY..................................................................................................................... 895 ASSEMBLY OF TORQUE CONVERTER ASSEMBLY........................................................................................................................ 899 DISASSEMBLY OF TRANSMISSION ASSEMBLY......................................................................................................................... 903 ASSEMBLY OF TRANSMISSION ASSEMBLY............................................................................................................................ 922 DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY................................................................................................................... 948 ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY...................................................................................................................... 955 REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY...................................................................................................................... 966 INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY................................................................................................................. 968 DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY.................................................................................................................. 969 ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY..................................................................................................................... 975 REMOVAL OF REAR DIFFERENTIAL ASSEMBLY........................................................................................................................ 985 INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY................................................................................................................... 986 DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY.................................................................................................................... 987 ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY....................................................................................................................... 991 REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ............................................................................................................. 999 INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ........................................................................................................1000 DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY .........................................................................................................1001 ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ............................................................................................................1007 REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY ............................................................................................................1014 INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY........................................................................................................1015 DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE ASSEMBLY ........................................................................................................1016 ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY............................................................................................................1020 REMOVAL OF REAR FINAL DRIVE AND BRAKE ASSEMBLY ..............................................................................................................1026 INSTALLATION OF REAR FINAL DRIVE AND BRAKE ASSEMBLY..........................................................................................................1027 DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE ASSEMBLY ..........................................................................................................1027 ASSEMBLY OF REAR FINAL DRIVE AND BRAKE ASSEMBLY..............................................................................................................1032 REMOVAL OF CENTER AXLE ASSEMBLY .............................................................................................................................1037 INSTALLATION OF CENTER AXLE ASSEMBLY ........................................................................................................................1039 REMOVAL OF REAR AXLE ASSEMBLY ...............................................................................................................................1040 INSTALLATION OF REAR AXLE ASSEMBLY ..........................................................................................................................1042 REMOVAL OF FRONT SUSPENSION CYLINDER ASSEMBLY ...............................................................................................................1043 INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY ..........................................................................................................1044 REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY ................................................................................................................1044 INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY............................................................................................................1045 DISSEMBLY AND ASSEMBLYOF FRONT AND REAR SUSPENSIONCYLINDER ASSEMBLY..........................................................................................1046 REMOVAL OF EQUALIZER BAR ASSEMBLY ...........................................................................................................................1048 INSTALLATION OF EQUALIZER BAR ASSEMBLY.......................................................................................................................1049 REMOVAL OF FRONT WHEEL ASSEMBLY .............................................................................................................................1050 INSTALLATION OF FRONT WHEEL ASSEMBLY ........................................................................................................................1050 REMOVAL, INSTALLATION OF REAR WHEEL ASSEMBLY ................................................................................................................1051 REMOVAL OF HITCH FRAME ASSEMBLY .............................................................................................................................1052 INSTALLATION OF HITCH FRAME ASSEMBLY ........................................................................................................................1056 DISASSEMBLY OF HITCH FRAME...................................................................................................................................1060 ASSEMBLY OF HITCH FRAME ASSEMBLY ............................................................................................................................1061 STANDARD INTEGRAL ORBIT-ROLL.................................................................................................................................1063 DISASSEMBLY OF STEERING VALVE................................................................................................................................1065 ASSEMBLY OF STEERING VALVE...................................................................................................................................1067 REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY.....................................................................................................................1072 INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY................................................................................................................1073 REMOVAL OF HOIST VALVE ASSEMBLY..............................................................................................................................1074 INSTALLATION OF HOIST VALVE ASSEMBLY.........................................................................................................................1075 DISASSEMBLY OF HOIST VALVE ASSEMBLY..........................................................................................................................1076 ASSEMBLY OF HOIST VALVE ASSEMBLY.............................................................................................................................1077 DISASSEMBLY OF STEERING CYLINDER ASSEMBLY....................................................................................................................1078 ASSEMBLY OF STEERING CYLINDER ASSEMBLY.......................................................................................................................1079 DISASSEMBLY OF HOIST CYLINDER ASSEMBLY.......................................................................................................................1081 ASSEMBLY OF HOIST CYLINDER ASSEMBLY..........................................................................................................................1083 REMOVAL OF BODY ASSEMBLY.....................................................................................................................................1086 INSTALLATION OF BODY ASSEMBLY................................................................................................................................1087 DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY.........................................................................................................1088 90 OTHERS........................................................................................................................................................1098 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................1099 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................1100 DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................1101 BRAKE HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................................1102 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................1103 DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER...............................................................................................................1104 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)..............................................................................................................1105 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)..............................................................................................................1106 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)..............................................................................................................1107 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)..............................................................................................................1108 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3).............................................................................................................1109 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/3).............................................................................................................1110 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (3/3).............................................................................................................1111 PAYLOAD METER ELECTRICAL CIRCUIT.............................................................................................................................1112
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