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KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10001 & UP) – PDF DOWNLOAD
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- KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
- Serial Number:A10001 & UP
- SERIAL NUMBERS:HM400-1L A10001 and up
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Description
KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10001 & UP)
KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10001 & UP) – PDF DOWNLOAD:
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KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10001 & UP)
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 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” 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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU HM400-1L ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:A10001 & UP)
MAIN MENU........................................................................................................................... 0 COVER............................................................................................................................... 1 CONTENTS............................................................................................................................ 2 FOREWORD............................................................................................................................ 15 SAFETY.......................................................................................................................... 15 SAFETY NOTICE............................................................................................................... 15 IMPORTANT SAFETY NOTICE................................................................................................. 15 GENERAL PRECAUTIONS..................................................................................................... 15 PREPARATIONS FOR WORK................................................................................................... 15 PRECAUTIONS DURING WORK................................................................................................. 15 GENERAL......................................................................................................................... 17 HOW TO READ THE SHOP MANUAL..................................................................................................... 18 VOLUMES..................................................................................................................... 18 DISTRIBUTION AND UPDATING................................................................................................... 18 FILING METHOD............................................................................................................... 18 REVISED EDITION MARK........................................................................................................ 18 REVISIONS................................................................................................................... 18 SYMBOLS..................................................................................................................... 18 HOISTING INSTRUCTIONS........................................................................................................... 19 HOISTING.................................................................................................................... 19 WIRE ROPES.................................................................................................................. 19 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................. 20 COATING MATERIALS............................................................................................................... 22 STANDARD TIGHTENING TORQUE...................................................................................................... 24 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................................ 24 TIGHTENING TORQUE OF HOSE NUTS.............................................................................................. 25 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS..................................................................................... 25 TIGHTENING TORQUE FOR FLARED NUTS........................................................................................... 25 TIGHTENING TORQUE FOR 102 ENGINE SERIES..................................................................................... 26 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...................................................... 26 ELECTRIC WIRE CODE.............................................................................................................. 28 CLASSIFICATION BY THICKNESS................................................................................................. 28 CLASSIFICATION BY COLOR AND CODE............................................................................................ 28 CONVERSION TABLES............................................................................................................... 29 METHOD OF USING THE CONVERSION TABLE........................................................................................ 29 01 GENERAL.......................................................................................................................... 35 SPECIFICATION DRAWING........................................................................................................... 36 SPECIFICATIONS.................................................................................................................. 37 WEIGHT TABLE.................................................................................................................... 40 FUEL, COOLANT AND LUBRICANTS.................................................................................................... 41 ENGINE OIL SPECIFICATIONS................................................................................................... 42 NORMAL OPERATION........................................................................................................ 42 ARCTIC OPERATION........................................................................................................ 42 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.... 43 FINAL DRIVE OIL SPECIFICATIONS.......................................................................................... 43 DRIVE AXLE OIL SPECIFICATIONS........................................................................................... 43 DIESEL FUEL SPECIFICATIONS.................................................................................................. 43 COOLANT SPECIFICATIONS...................................................................................................... 44 GENERAL................................................................................................................. 44 WATER................................................................................................................... 44 ANTIFREEZE.............................................................................................................. 44 SUPPLEMENTAL COOLANT ADDITIVES.......................................................................................... 46 COOLING SYSTEM TEST KIT................................................................................................. 50 10 STRUCTURE AND FUNCTION........................................................................................................... 51 RADIATOR, OIL COOLER, AFTERCOOLER............................................................................................... 56 SPECIFICATIONS.............................................................................................................. 56 POWER TRAIN SKELETON............................................................................................................ 57 LOCKING DIFFERENTIAL........................................................................................................ 57 OUTPUT SHAFT.................................................................................................................... 59 FUNCTION.................................................................................................................... 59 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING.............................................................................. 61 TORQUE CONVERTER................................................................................................................ 63 SPECIFICATIONS.............................................................................................................. 63 TRANSMISSION POWER PATH................................................................................................. 67 OIL FLOW................................................................................................................ 68 TRANSMISSION.................................................................................................................... 69 OUTLINE..................................................................................................................... 73 FL - R CLUTCH............................................................................................................... 74 FH - 1ST CLUTCH............................................................................................................. 75 2ND - 3RD CLUTCH............................................................................................................ 76 DIFFERENTIAL LOCK........................................................................................................... 77 CLUTCH OPERATIONS....................................................................................................... 79 FORWARD 1ST................................................................................................................. 80 OPERATION............................................................................................................... 80 FORWARD 2ND................................................................................................................. 81 OPERATION............................................................................................................... 81 FORWARD 3RD................................................................................................................. 82 OPERATION............................................................................................................... 82 FORWARD 4TH................................................................................................................. 83 OPERATION............................................................................................................... 83 FORWARD 5TH................................................................................................................. 84 OPERATION............................................................................................................... 84 FORWARD 6TH................................................................................................................. 85 OPERATION............................................................................................................... 85 REVERSE 1ST................................................................................................................. 86 OPERATION............................................................................................................... 86 TRANSMISSION VALVE.............................................................................................................. 87 ECMV (ELECTRONIC CONTROL MODULATION VALVE)...................................................................................... 89 ECMV FOR LOCK-UP CLUTCH..................................................................................................... 90 OUTLINE................................................................................................................. 90 OPERATION............................................................................................................... 90 DURING DIRECT TRAVEL........................................................................................................ 91 FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL........................................................................... 91 ECMV SPEED CLUTCH........................................................................................................... 92 ECMV OUTLINE............................................................................................................ 92 ECMV AND PROPORTIONAL SOLENOID.......................................................................................... 92 ECMV AND FILL SWITCH.................................................................................................... 92 ECMV OPERATION.......................................................................................................... 93 ECMV FOR DIFFERENTIAL LOCK.............................................................................................. 95 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...................................................................................... 96 OUTLINE..................................................................................................................... 97 TORQUE CONVERTER RELIEF VALVE........................................................................................... 97 MAIN RELIEF VALVE....................................................................................................... 97 OPERATION............................................................................................................... 97 DRIVE SHAFT..................................................................................................................... 99 OUTLINE..................................................................................................................... 99 AXLE............................................................................................................................ 100 FRONT....................................................................................................................... 100 CENTER...................................................................................................................... 101 REAR........................................................................................................................ 102 LOCKING DIFFERENTIAL............................................................................................................ 103 FRONT....................................................................................................................... 103 CENTER...................................................................................................................... 105 REAR........................................................................................................................ 107 OPERATION............................................................................................................... 108 TRAVELING IN A STRAIGHT LINE............................................................................................ 108 TURNING................................................................................................................. 108 WHEN DIFFERENTIAL LOCK IS ACTUATED...................................................................................... 109 FINAL DRIVE..................................................................................................................... 110 FRONT....................................................................................................................... 110 CENTER, REAR................................................................................................................ 112 FUNCTION................................................................................................................ 113 OPERATION............................................................................................................... 113 STEERING COLUMN................................................................................................................. 114 BRAKE PIPING.................................................................................................................... 115 BRAKE VALVE..................................................................................................................... 117 OPERATION................................................................................................................... 118 UPPER PORTION........................................................................................................... 118 LOWER PORTION........................................................................................................... 118 APPLYING BRAKE WHEN UPPER VALVE FAILS................................................................................... 118 APPLYING BRAKE WHEN LOWER VALVE FAILS................................................................................... 118 WHEN ACTUATION IS BALANCED.............................................................................................. 118 BRAKE RELEASED.......................................................................................................... 120 ACCUMULATOR CHARGE VALVE........................................................................................................ 121 FUNCTION.................................................................................................................... 121 OPERATION................................................................................................................... 123 ACCUMULATOR..................................................................................................................... 125 FUNCTION.................................................................................................................... 125 SPECIFICATIONS.............................................................................................................. 125 SLACK ADJUSTER.................................................................................................................. 126 FUNCTION.................................................................................................................... 127 OPERATION................................................................................................................... 127 BRAKE........................................................................................................................... 129 FRONT....................................................................................................................... 129 CENTER, REAR................................................................................................................ 130 FUNCTION................................................................................................................ 133 OPERATIONS.............................................................................................................. 133 PROPORTIONAL REDUCING VALVE..................................................................................................... 134 FUNCTION.................................................................................................................... 134 BRAKE SYSTEM TANK............................................................................................................... 135 PARKING BRAKE................................................................................................................... 136 FUNCTION.................................................................................................................... 136 PARKING BRAKE CALIPER........................................................................................................... 138 OUTLINE..................................................................................................................... 138 SPRING CYLINDER................................................................................................................. 139 OUTLINE..................................................................................................................... 139 PARKING BRAKE SOLENOID.......................................................................................................... 140 FUNCTION.................................................................................................................... 140 SUSPENSION...................................................................................................................... 141 FRONT....................................................................................................................... 141 REAR........................................................................................................................ 143 OUTLINE................................................................................................................. 145 FUNCTION................................................................................................................ 145 SUSPENSION CYLINDER............................................................................................................. 147 STRUCTURE AND OPERATION..................................................................................................... 148 OSCILLATION HITCH............................................................................................................... 149 OUTLINE..................................................................................................................... 151 STEERING, HOIST OIL PRESSURE PIPING DIAGRAM..................................................................................... 152 DUMP BODY CONTROL............................................................................................................... 153 FUNCTION.................................................................................................................... 153 HYDRAULIC TANK AND FILTER....................................................................................................... 154 FLOW AMP VALVE.................................................................................................................. 155 OUTLINE..................................................................................................................... 155 OPERATION................................................................................................................... 156 STEERING VALVE.................................................................................................................. 158 OUTLINE..................................................................................................................... 159 STRUCTURE................................................................................................................... 159 CONNECTION BETWEEN HAND PUMP AND SLEEVE..................................................................................... 160 FUNCTION OF CENTER SPRING................................................................................................... 162 STEERING CYLINDER............................................................................................................... 163 HOIST VALVE..................................................................................................................... 164 OPERATION................................................................................................................... 166 HOIST VALVE AT HOLD POSITION............................................................................................ 166 HOIST VALVE AT RAISE POSITION........................................................................................... 167 HOIST VALVE AT FLOAT POSITION........................................................................................... 168 HOIST VALVE AT LOWER POSITION........................................................................................... 169 EPC VALVE....................................................................................................................... 170 FUNCTION.................................................................................................................... 170 PILOT CHECK VALVE............................................................................................................... 171 HOIST CYLINDER.................................................................................................................. 172 HYDRAULIC PUMP.................................................................................................................. 173 STEERING, HOIST + PILOT PUMP................................................................................................ 173 TRANSMISSION + DIFFERENTIAL LOCK PUMP....................................................................................... 174 BRAKE COOLING + BRAKE PUMP.................................................................................................. 175 AUXILIARY STEERING PUMP..................................................................................................... 176 DIFFERENTIAL LOCK PUMP...................................................................................................... 177 CAB TILT........................................................................................................................ 178 AIR CONDITIONER................................................................................................................. 179 FUNCTION.................................................................................................................... 179 AIR CONDITIONER UNIT........................................................................................................ 180 RECEIVER DRYER.............................................................................................................. 181 CONDENSER................................................................................................................... 182 COMPRESSOR.................................................................................................................. 183 MACHINE MONITOR SYSTEM.......................................................................................................... 184 NETWORK DATA................................................................................................................ 184 OUTLINE..................................................................................................................... 185 MACHINE MONITOR............................................................................................................. 187 OPTION SETTING CONNECTOR DIAGRAM............................................................................................ 189 ADJUSTING MACHINE MONITOR................................................................................................... 189 MACHINE MONITOR NORMAL DISPLAY FUNCTIONS.................................................................................... 190 SELF-DIAGNOSTIC FUNCTION WHEN OPERATING STARTING SWITCH................................................................. 193 CHECK FUNCTION OF CENTRAL WARNING LAMP, ALARM BUZZER, MONITOR LAMPS AND METERS.......................................... 194 SERVICE METER DISPLAY................................................................................................... 194 ODOMETER................................................................................................................ 194 OUTLINE OF SERVICE MODE..................................................................................................... 194 OUTLINE................................................................................................................. 194 OPERATION METHOD............................................................................................................ 198 AUTOMATIC SHIFT CONTROL SYSTEM.................................................................................................. 199 OUTLINE..................................................................................................................... 200 TRANSMISSION CONTROLLER......................................................................................................... 201 OUTLINE..................................................................................................................... 201 GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE................................................................... 204 GEARSHIFTING CHARACTERISTICS............................................................................................ 204 AUTOMATIC GEARSHIFTING GRAPH................................................................................................ 205 GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD........................................................................... 206 SHIFT HOLD FUNCTION..................................................................................................... 207 GEARSHIFTING TIME DELAY................................................................................................. 207 SAFETY FUNCTIONS........................................................................................................ 207 SELF-DIAGNOSTIC FUNCTION................................................................................................ 208 AUTO AUXILIARY STEERING SYSTEM.................................................................................................. 209 OUTLINE..................................................................................................................... 209 SENSORS, SWITCHES............................................................................................................... 210 ENGINE SPEED SENSOR......................................................................................................... 210 FUNCTION.................................................................................................................... 210 ACCELERATOR SENSOR.............................................................................................................. 211 OUTLINE..................................................................................................................... 211 ACCELERATOR SIGNAL...................................................................................................... 211 IDLE VALIDATION SIGNAL.................................................................................................. 211 ENGINE COOLANT TEMPERATURE SENSOR........................................................................................... 212 BRAKE COOLING OIL TEMPERATURE SENSOR........................................................................................ 212 FUNCTION................................................................................................................ 212 STEERING OIL TEMPERATURE SENSOR............................................................................................. 212 FUNCTION................................................................................................................ 212 FUEL LEVEL SENSOR........................................................................................................... 213 FUNCTION................................................................................................................ 213 TILT SENSOR................................................................................................................. 214 FUNCTION................................................................................................................ 214 AIR CLEANER CLOGGING SENSOR................................................................................................. 215 FUNCTION................................................................................................................ 215 HYDRAULIC OIL LEVEL SENSOR.................................................................................................. 216 FUNCTION................................................................................................................ 216 BODY POSITIONER SENSOR...................................................................................................... 217 FUNCTION.................................................................................................................... 217 RETARDER CONTROL SYSTEM......................................................................................................... 218 RETARDER CONTROLLER......................................................................................................... 219 OUTLINE..................................................................................................................... 219 RETARDER CONTROL FUNCTION................................................................................................... 223 RETARDER CONTROL SYSTEM DIAGRAM......................................................................................... 223 HOIST CONTROL FUNCTION...................................................................................................... 225 HOIST CONTROL SYSTEM DIAGRAM............................................................................................ 225 DIFFERENTIAL LOCK CONTROL FUNCTION.......................................................................................... 227 DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM................................................................................ 227 BRAKE CONTROL SYSTEM (E-SPEC)................................................................................................... 229 BRAKE CONTROLLER (E-SPEC)................................................................................................... 230 OUTLINE................................................................................................................. 230 BRAKE CONTROL FUNCTION...................................................................................................... 234 BRAKE CONTROL SYSTEM DIAGRAM............................................................................................ 234 HOIST CONTROL FUNCTION...................................................................................................... 235 HOIST CONTROL SYSTEM DIAGRAM............................................................................................ 235 DIFFERENTIAL LOCK CONTROL FUNCTION.......................................................................................... 237 DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM................................................................................ 237 DUMP CONTROL LEVER.............................................................................................................. 238 FUNCTION.................................................................................................................... 240 OPERATION................................................................................................................... 240 DUMP CONTROL LEVER OPERATED TO FLOAT.................................................................................... 240 DUMP CONTROL LEVER FLOAT CANCELED....................................................................................... 240 DUMP CONTROL LEVER OPERATED TO LOWER.................................................................................... 241 DUMP CONTROL LEVER OPERATED TO RAISE.................................................................................... 241 DUMP CONTROL LEVER RAISE CANCELED....................................................................................... 241 PLM-HM.......................................................................................................................... 242 SYSTEM STRUCTURE............................................................................................................ 242 PRINCIPLE OF CALCULATION.................................................................................................... 243 ACCURATE CALCULATION........................................................................................................ 244 GENERAL LOCATIONS OF LOAD METER............................................................................................. 245 LEFT FACE................................................................................................................... 246 BASIC FUNCTIONS............................................................................................................. 247 KEY OPERATION............................................................................................................... 255 SERVICE CHECK MODE.......................................................................................................... 257 SENSORS..................................................................................................................... 262 ERROR CODE TABLE............................................................................................................ 264 LOCAL INSTALLATION.......................................................................................................... 267 20 TESTING, ADJUSTING AND TROUBLESHOOTIN............................................................................................ 275 STANDARD VALUE TABLE............................................................................................................ 277 FOR ENGINE.................................................................................................................. 277 FOR CHASSIS................................................................................................................. 278 FOR ELECTRICAL COMPONANTS................................................................................................... 282 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 296 ENGINE COMPONENTS............................................................................................................... 298 MEASURING EXHAUST SMOKE..................................................................................................... 298 MEASURING EXHAUST TEMPERATURE............................................................................................... 298 ADJUSTING VALVE CLEARANCE................................................................................................... 298 MEASURING COMPRESSION PRESSURE.............................................................................................. 298 MEASURING CRANCASE PRESSURE................................................................................................. 298 MEASURING ENGINE OIL PRESSURE............................................................................................... 298 MEASURING BOOST PRESSURE.................................................................................................... 298 MEASURING FUEL PRESSURE..................................................................................................... 298 BLEEDING AIR FROM FUEL SYSTEM............................................................................................... 298 ADJUSTING ENGINE SPEED SENSOR............................................................................................... 299 ADJUSTING “V” BELT TENSION.................................................................................................. 300 ADJUSTING ALTERNATOR BELT................................................................................................... 301 ADJUSTING REFRIGERANT COMPRESSOR BELT....................................................................................... 302 TESTING TORQUE CONVERTER STALL SPEED............................................................................................ 303 MEASURING POWER TRAIN OIL PRESSURES............................................................................................. 304 MEASURING POWER TRAIN MAIN RELIEF PRESSURE.................................................................................. 305 MEASURING TORQUE CONVERTER “INLET” OIL PRESSURE............................................................................. 305 MEASURING TORQUE CONVERTER “OUTLET” OIL PRESSURE............................................................................ 305 MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE........................................................................ 306 MEASURING TRANSMISSION “LO” CLUTCH PRESSURE................................................................................. 307 MEASURING TRANSMISSION “HI” CLUTCH PRESSURE................................................................................. 307 MEASURING TRANSMISSION “1ST” CLUTCH PRESSURE................................................................................ 307 MEASURING TRANSMISSION “2ND” CLUTCH PRESSURE................................................................................ 308 MEASURING TRANSMISSION “3RD” CLUTCH PRESSURE................................................................................ 308 MEASURING TRANSMISSION “R” CLUTCH PRESSURE.................................................................................. 309 MEASURING INTER-AXLE “DIFFERENTIAL LOCK” CLUTCH PRESSURE.................................................................... 309 “L” AND “R” DIFFERENTIAL LOCK PRESSURE.......................................................................................... 310 TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE........................................................................... 310 TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE.......................................................................... 311 TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE............................................................................ 311 ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE......................................................................... 312 ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE........................................................................ 313 ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE.......................................................................... 313 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................. 314 TESTING AND ADJUSTING BRAKE OIL PRESSURE........................................................................................ 316 MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 316 MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP........................................................................... 316 MEASURING ACTUATION PRESSURE ON PARKING BRAKE............................................................................... 317 MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID...................................................................... 318 ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 319 TESTING BRAKE PERFORMANCE....................................................................................................... 320 TESTING BRAKING PERFORMANCE OF FOOT BRAKE................................................................................... 320 TESTING BRAKING PERFORMANCE OF RETARDER BRAKE............................................................................... 320 TESTING PARKING BRAKE BRAKING PERFORMANCE................................................................................... 321 TESTING OVERRUN PROTECTION BRAKING PERFORMANCE.............................................................................. 321 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................................. 322 BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE..................................................................... 322 BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT................................................................. 323 BLEEDING AIR FROM PARKING BRAKE CIRCUIT..................................................................................... 323 CHECKING WEAR LIMIT ON WHEEL BRAKE DISC......................................................................................... 324 CHECKING BRAKE DISC......................................................................................................... 324 CHECKING BRAKE PAD.......................................................................................................... 325 ADJUSTING PAD CLEARANCE..................................................................................................... 326 RELEASING EMERGENCY PARKING BRAKE............................................................................................... 327 STEERING CIRCUIT PRESSURE....................................................................................................... 328 MEASURING STEERING RELIEF OIL PRESSURE...................................................................................... 328 ADJUSTING STEERING RELIEF OIL PRESSURE...................................................................................... 329 TESTING AND ADJUSTING SUSPENSION CYLINDER....................................................................................... 330 CHECKING CYLINDER LENGTH.................................................................................................... 330 RELEASING NITROGEN GAS...................................................................................................... 330 ADJUSTING OIL LEVEL......................................................................................................... 331 CHARGING WITH NITROGEN GAS.................................................................................................. 332 ADJUSTING CYLINDER LENGTH................................................................................................... 333 TILTING THE CAB UP.............................................................................................................. 334 PREPARATORY WORK............................................................................................................ 334 TILTING CAB UP.............................................................................................................. 334 USING EXTERNAL CRANE........................................................................................................ 335 HOLDING CAB IN POSITION..................................................................................................... 335 LOWERING CAB DOWN........................................................................................................... 335 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE..................................................................................... 336 TESTING DUMP MAIN RELIEF OIL PRESSURE....................................................................................... 336 ADJUSTING DUMP MAIN RELIEF OIL PRESSURE..................................................................................... 336 MEASURING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 337 ADJUSTING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 337 ADJUSTING BODY POSITIONER SENSOR................................................................................................ 338 CHECKING SENSOR OUTPUT/INPUT VOLTAGE........................................................................................ 338 ADJUSTING LINK LENGTH....................................................................................................... 338 CALIBRATING SYSTEM.......................................................................................................... 339 ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT.......................................................................................... 340 ADJUSTING TRANSMISSION CONTROLLER............................................................................................... 341 SETTING ROTARY SWITCH....................................................................................................... 341 ADJUSTING TRANSMISSION...................................................................................................... 341 ESCAPE METHOD FOR ELECTRICAL SYSTEM............................................................................................. 342 ADJUSTING MACHINE MONITOR....................................................................................................... 346 FUNCTIONS OF MACHINE MONITOR.................................................................................................... 350 NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR......................................................................... 350 FLOW OF MODES AND FUNCTIONs................................................................................................. 351 OPERATION AND DISPLAYS FOR OPERATOR MODE.................................................................................... 353 SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY.............................................................................. 361 TROUBLESHOOTING (GENERAL)....................................................................................................... 381 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................... 382 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................... 384 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................... 385 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.......................................................................... 385 HANDLING ELECTRONIC CONTROL UNIT........................................................................................ 390 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS............................................................. 391 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.................................................................... 392 CHECKS BEFORE TROUBLESHOOTING............................................................................................... 394 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................... 395 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.......................................................................... 396 TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS........................................................................... 398 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................................... 400 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................. 408 T-ADAPTER TABLE............................................................................................................. 432 CONNECTOR LAYOUT DRAWING.................................................................................................... 435 TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)............................................................................. 441 CONNECTOR ARRANGEMENT AND LOCATIONS......................................................................................... 443 ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM....................................................................................... 449 CONTENT OF CODE DISPLAY..................................................................................................... 452 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................. 464 (ENG-1) FAILURE CODE [A000N1]............................................................................................... 466 ENGINE OVERSPEEDS (N1).................................................................................................. 466 (ENG-2) FAILURE CODE [A570NX]............................................................................................... 467 ENGINE OIL FILTER CLOG SENSOR SYSTEM.................................................................................... 467 (ENG-3) FAILURE CODE [AD00L2]............................................................................................... 468 COMMON RAIL HIGHER THAN SET VALUE....................................................................................... 468 (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3].............................................................................. 469 COMMON RAIL PRESSURE HIGH OR LOW........................................................................................ 469 (ENG-6) FAILURE CODE [AD10MA]........................................................................................... 471 (ENG-7) FAILURE CODE [AD10MB]........................................................................................... 471 (ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB].............................................................................. 472 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM........................................................................... 472 (ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB]............................................................................ 474 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM........................................................................... 474 (ENG-12) FAILURE CODE [ADA1KA].............................................................................................. 475 OPEN IN NO. 1 INJECTOR SOLENOID VALVE................................................................................... 475 (ENG-13) FAILURE CODE [ADZKKB].............................................................................................. 477 SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE.................................................................... 477 (ENG-14) FAILURE CODE [ADB1KA].............................................................................................. 480 OPEN IN NO. 2 INJECTOR SOLENOID VALVE................................................................................... 480 (ENG-15) FAILURE CODE [ADC1KA].............................................................................................. 482 OPEN IN NO. 3 INJECTOR SOLENOID VALVE................................................................................... 482 (ENG-16) FAILURE CODE [ADD1KA].............................................................................................. 484 OPEN IN NO. 4 INJECTOR SOLENOID VALVE................................................................................... 484 (ENG-17) FAILURE CODE [ADDZKB].............................................................................................. 486 SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE.................................................................... 486 (ENG-18) FAILURE CODE [ADE1KA].............................................................................................. 489 OPEN IN NO. 5 INJECTOR SOLENOID VALVE................................................................................... 489 (ENG-19) FAILURE CODE [ADF1KA].............................................................................................. 491 OPEN IN NO. 6 INJECTOR SOLENOID VALVE................................................................................... 491 (ENG-20) FAILURE CODE [B@BAZG].............................................................................................. 493 ENGINE OIL PRESSURE DROP (ZG)........................................................................................... 493 (ENG-21) FAILURE CODE [B@BAZK].............................................................................................. 495 ENGINE OIL LEVEL DROP (ZK).............................................................................................. 495 (ENG-22) FAILURE CODE [B@BCNS].............................................................................................. 496 COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)................................................................... 496 (ENG-23) FAILURE CODE [D181KZ].............................................................................................. 498 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ).................................................................... 498 (ENG-24) FAILURE CODE [D182KZ].............................................................................................. 500 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ).................................................................... 500 (ENG-25) FAILURE CODE [D1D0KB].............................................................................................. 502 SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)......................................................................... 502 (ENG-26) FAILURE CODE [D5ZAKX].............................................................................................. 504 ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX).......................................................................... 504 (ENG-27) FAILURE CODE [DB20KT].............................................................................................. 506 CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW............................................................................. 506 (ENG-28) FAILURE CODE [DB22KK].............................................................................................. 507 DROP IN VOLTAGE LOAD POWER SUPPLY (KK).................................................................................. 507 (ENG-29) FAILURE CODE [DB29KQ].............................................................................................. 509 NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ)...................................... 509 (ENG-30) FAILURE CODE [DB2AMA].............................................................................................. 511 “Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA).............................................................. 511 (ENG-31) FAILURE CODE [KK11KB].............................................................................................. 512 TROUBLE IN INPUT OF ignition switch C (KB).............................................................................. 512 (ENG-32) FAILURE CODE [DDA1L5].............................................................................................. 513 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)................................................................... 513 (ENG-33) FAILURE CODE [DDE2L6].............................................................................................. 515 ENGINE OIL PRESSURE DROP (L6)........................................................................................... 515 (ENG-34) FAILURE CODE [DGE2KX].............................................................................................. 517 COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)..................................................................... 517 (ENG-35) FAILURE CODE [DGE3LC].............................................................................................. 518 COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6)...................................................................... 518 (ENG-36) FAILURE CODE [DGE4KX].............................................................................................. 519 TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX).......................................................................... 519 (ENG-37) FAILURE CODE [DH30KX].............................................................................................. 520 TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)............................................................................ 520 (ENG-38) FAILURE CODE [DH40KX].............................................................................................. 522 TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)................................................................. 522 (ENG-39) FAILURE CODE [DK10KX].............................................................................................. 524 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)................................................................... 524 (ENG-40) FAILURE CODE [DLE3LC].............................................................................................. 526 TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM................................................................................ 526 (ENG-41) FAILURE CODE [DLE1LC].............................................................................................. 527 TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)............................................................................ 527 (ENG-42) NO FAILURE CODE DISPLAYED.......................................................................................... 528 ENGINE DOES NOT CRANK................................................................................................... 528 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)..................................................................... 531 CONNECTOR ARRANGEMENT AND LOCATIONS......................................................................................... 535 TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM...................................................................................... 541 CONTENT OF CODE DISPLAY..................................................................................................... 548 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................. 574 (TM-1) FAILURE CODE [1380MW]................................................................................................ 576 LOCK-UP CLUTCH SLIPPING (MW)............................................................................................ 576 (TM-2) FAILURE CODE [1500LO]................................................................................................ 578 TRANSMISSION CLUTCH (LO)................................................................................................ 578 (TM-3) FAILURE CODE [15BONX]................................................................................................ 579 TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)............................................................. 579 (TM-4) FAILURE CODE [15GOMW]................................................................................................ 581 “R” CLUTCH SLIPPING (MW)................................................................................................ 581 (TM-5) FAILURE CODE [15HOMW]................................................................................................ 583 “HI” CLUTCH SLIPPING (MW)............................................................................................... 583 (TM-6) FAILURE CODE [15JOMW]................................................................................................ 585 “LO” CLUTCH SLIPPING (MW)............................................................................................... 585 (TM-7) FAILURE CODE [15KOMW]................................................................................................ 587 1ST CLUTCH SLIPPING (MW)................................................................................................ 587 (TM-8) FAILURE CODE [15LOMW]................................................................................................ 589 2ND CLUTCH SLIPPING (MW)................................................................................................ 589 (TM-9) FAILURE CODE [15MOMW]................................................................................................ 591 3RD CLUTCH SLIPPING (MW)................................................................................................ 591 (TM-10) FAILURE CODE [15SBL1]............................................................................................... 593 ECMV FOR “R” CLUTCH NOT DISENGAGING (L1)................................................................................ 593 (TM-11) FAILURE CODE [15SBMA]............................................................................................... 595 ECMV FOR “R” CLUTCH NOT ENGAGING (MA)................................................................................... 595 (TM-12) FAILURE CODE [15SCL1]............................................................................................... 597 ECMV “HI” CLUTCH NOT DISENGAGING (L1)................................................................................... 597 (TM-13) FAILURE CODE [15SCMA]............................................................................................... 599 ECMV “HI” CLUTCH NOT DISENGAGING (MA)................................................................................... 599 (TM-14) FAILURE CODE [15SDL1]............................................................................................... 601 ECMV “LO” CLUTCH NOT DISENGAGING (L1)................................................................................... 601 (TM-15) FAILURE CODE [15SDMA]............................................................................................... 603 ECMV “LO” CLUTCH NOT ENGAGING (MA)...................................................................................... 603 (TM-16) FAILURE CODE [15SEL1]............................................................................................... 605 ECMV “1st” CLUTCH NOT DISENGAGING (L1).................................................................................. 605 (TM-17) FAILURE CODE [15SEMA]............................................................................................... 607 ECMV “1ST” CLUTCH NOT ENGAGING (MA)..................................................................................... 607 (TM-18) FAILURE CODE [15SFL1]............................................................................................... 609 ECMV “2ND” CLUTCH NOT DISENGAGING (L1).................................................................................. 609 (TM-19) FAILURE CODE [15SFMA]............................................................................................... 611 ECMV “2ND” CLUTCH NOT ENGAGING (MA)..................................................................................... 611 (TM-20) FAILURE CODE [15SGL1]............................................................................................... 613 ECMV “3RD” CLUTCH NOT DISENGAGING (L1).................................................................................. 613 (TM-21) FAILURE CODE [15SGMA]............................................................................................... 615 ECMV “3RD” CLUTCH NOT ENGAGING (MA)..................................................................................... 615 (TM-22) FAILURE CODE [15SJL1]............................................................................................... 617 ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1).............................................................................. 617 (TM-23) FAILURE CODE [15SJMA]............................................................................................... 619 ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA)................................................................................. 619 (TM-24) FAILURE CODE [15SKL1]............................................................................................... 621 ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1)........................................................................... 621 (TM-25) FAILURE CODE [15SKMA]............................................................................................... 623 ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA).............................................................................. 623 (TM-26) FAILURE CODE [2B61MW]............................................................................................... 625 ECMV “INTER-AXLE” CLUTCH SLIPPING (MW).................................................................................. 625 (TM-27) FAILURE CODE [2F00KM]............................................................................................... 627 PARKING BRAKE SYSTEM INDICATING FAILURE (KM)............................................................................ 627 (TM-28) FAILURE CODE [6014NX]............................................................................................... 629 HYDRAULUC TANK FILTER CLOGGED (NX)...................................................................................... 629 (TM-29) FAILURE CODE [989A00]............................................................................................... 631 POSSIBLE ENGINE OVER SPEED CONDITION (00)............................................................................... 631 (TM-30) FAILURE CODE [989AKZ]............................................................................................... 632 OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ).................................................................. 632 (TM-31)FAILURE CODE [989D00]................................................................................................ 634 REAR OVERTURN SIGNAL OUT OF RANGE (00).................................................................................. 634 (TM-32)FAILURE CODE [AA10NX]................................................................................................ 636 AIR CLEANER CLOGG INDICATION (NX)....................................................................................... 636 (TM-33) FAILURE CODE [AB00MA]............................................................................................... 638 ALTERNATOR NOT CHARGING PROPERLY (MA)................................................................................... 638 (TM-34) FAILURE CODE [B@BCZK]............................................................................................... 639 COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)..................................................................... 639 (TM-35) FAILURE CODE [B@HAZK]............................................................................................... 641 LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)............................................................................. 641 (TM-36) FAILURE CODE [B@JANS]............................................................................................... 642 STEERING OIL OVERHEAT CONDITION INDICATED (ZK).......................................................................... 642 (TM-37) FAILURE CODE [D1B0KZ]............................................................................................... 643 POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)............................................................ 643 (TM-38) FAILURE CODE [D5ZBKX]............................................................................................... 645 DEFFERENTIAL LOCK CIRCUIT SIGNIAL INCORRECT (KX)........................................................................ 645 (TM-39) FAILURE CODE [D5ZCKZ]............................................................................................... 647 OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ)...................................................................... 647 (TM-40) FAILURE CODE [DF10KA]............................................................................................... 649 FORCED NEUTRAL DEMAND SIGNAL (L4)....................................................................................... 649 (TM-41) FAILURE CODE [D5ZEKX]............................................................................................... 651 ENGINE LOAD SIGNIAL OUT OF RANGE (KX)................................................................................... 651 (TM-42) FAILURE CODE [DAQ0KK]............................................................................................... 653 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)....................................................................... 653 (TM-43) FAILURE CODE [DAQ1KK]............................................................................................... 655 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)....................................................................... 655 (TM-44) FAILURE CODE [DAQ2KK]............................................................................................... 657 POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK).............................................................. 657 (TM-45) FAILURE CODE [DAQ3KK]............................................................................................... 659 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)....................................................................... 659 (TM-46) FAILURE CODE [DAQ5KP]............................................................................................... 661 TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)........................................................................ 661 (TM-47) FAILURE CODE [DAQ9KM]............................................................................................... 663 MISTAKEN OPERATION SETTING (KP)......................................................................................... 663 (TM-48) FAILURE CODE [DAQ9KM]............................................................................................... 664 NO MATCH IN MODEL SELECTION SIGNAL (KP)................................................................................. 664 (TM-49) FAILURE CODE [DAQAKQ]............................................................................................... 665 TRANSMISSION CONTROLLER ROTARY SWITCH................................................................................... 665 (TM-50) FAILURE CODE [DAQSMA]............................................................................................... 665 TRANSMISSION FUNCTION INNOPERABLE....................................................................................... 665 (TM-51) FAILURE CODE [DDTFKA]............................................................................................... 666 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)................................................................ 666 (TM-52) FAILURE CODE [DDTFKA]............................................................................................... 668 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)................................................................ 668 (TM-53) FAILURE CODE [DDTHKA]............................................................................................... 670 “HI” CLUTCH SYSTEM OPEN OR SHORTED (KA)................................................................................. 670 (TM-54) FAILURE CODE [DDTJKA]............................................................................................... 672 “LO” CLUTCH SYSTEM OPEN OR SHORTED (KA)................................................................................. 672 (TM-55) FAILURE CODE [DDTKKA]............................................................................................... 674 1st CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 674 (TM-56) FAILURE CODE [DDTLKA]............................................................................................... 676 2ND CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 676 (TM-57) FAILURE CODE [DDTMKA]............................................................................................... 678 3RD CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 678 (TM-58) FAILURE CODE [DDTNKA]............................................................................................... 680 “R” CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 680 (TM-59) FAILURE CODE [DF10KA]............................................................................................... 682 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA).................................................................. 682 (TM-60) FAILURE CODE [DF10KB]............................................................................................... 684 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA).................................................................. 684 (TM-61) FAILURE CODE [DGF1KX]............................................................................................... 686 TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)................................................................... 686 (TM-62) FAILURE CODE [DGR2L8]............................................................................................... 687 REAR BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)..................................................................... 687 (TM-63) FAILURE CODE [DGR3L8]............................................................................................... 689 CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)................................................................... 689 (TM-64) FAILURE CODE [DGR4L8]............................................................................................... 691 FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8).................................................................... 691 (TM-65) FAILURE CODE [DGT1LX]............................................................................................... 693 TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)................................................................... 693 (TM-66) FAILURE CODE [DHT5KX]............................................................................................... 694 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX).................................................................. 694 (TM-67) FAILURE CODE [DHT5L6]............................................................................................... 696 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6).................................................................. 696 (TM-68) FAILURE CODE [DJF1KA]............................................................................................... 698 FUEL LEVEL SENSOR OUT OF RANGE (L6)..................................................................................... 698 (TM-69) FAILURE CODE [DK11KX]............................................................................................... 700 THROTTLE ANGLE SENDOR OUT OF RANGE (KX)................................................................................. 700 (TM-70) FAILURE CODE [DLE2KA]............................................................................................... 702 ENGINE SPEED SENSOR OPEN OR SHORTED (KA)................................................................................ 702 (TM-71) FAILURE CODE [DLE2LC]............................................................................................... 703 ENGINE SPEED SENSOR OPEN OR SHORTED (LC)................................................................................ 703 (TM-72) FAILURE CODE [DLF1KA]............................................................................................... 704 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA).............................................................. 704 (TM-73) FAILURE CODE [DLF1LC]............................................................................................... 705 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC).............................................................. 705 (TM-74) FAILURE CODE [DLF2KA]............................................................................................... 706 TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA)........................................................ 706 (TM-75) FAILURE CODE [DLF2LC]............................................................................................... 707 TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC)........................................................ 707 (TM-76) FAILURE CODE [DLT3KA]............................................................................................... 708 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)............................................................. 708 (TM-77) FAILURE CODE [DLT3LC]............................................................................................... 710 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)............................................................. 710 (TM-78) FAILURE CODE [DXH0KA]............................................................................................... 712 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA)................................................................ 712 (TM-79) FAILURE CODE [DXH0KB]............................................................................................... 714 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB)................................................................ 714 (TM-80) FAILURE CODE [DXH1KA]............................................................................................... 716 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA).............................................................................. 716 (TM-81) FAILURE CODE [DXH1KB]............................................................................................... 718 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB).............................................................................. 718 (TM-82) FAILURE CODE [DXH2KA]............................................................................................... 720 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)................................................................................. 720 (TM-83) FAILURE CODE [DXH2KB]............................................................................................... 722 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)................................................................................. 722 (TM-84) FAILURE CODE [DXH3KA]............................................................................................... 724 LOW CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 724 (TM-85) FAILURE CODE [DXH3KB]............................................................................................... 726 LOW CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 726 (TM-86) FAILURE CODE [DXH4KA]............................................................................................... 728 1st CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 728 (TM-87) FAILURE CODE [DXH4KB]............................................................................................... 730 1st CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 730 (TM-88) FAILURE CODE [DXH5KA]............................................................................................... 732 2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)................................................................................. 732 (TM-89) FAILURE CODE [DXH5KB]............................................................................................... 734 2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB)................................................................................. 734 (TM-90) FAILURE CODE [DXH6KA]............................................................................................... 736 3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)................................................................................. 736 (TM-91) FAILURE CODE [DXH6KB]............................................................................................... 738 3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)................................................................................. 738 (TM-92) FAILURE CODE [DXH7KA]............................................................................................... 740 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA).............................................................................. 740 (TM-93) FAILURE CODE [DXH7KB]............................................................................................... 742 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB).............................................................................. 742 (TM-94) NO FAILURE CODE DISPLAYED........................................................................................... 744 BACK-UP LIGHTS AND ALARM DO NOT OPERATE................................................................................. 744 TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM (BK MODE)......................................................................... 747 CONNECTOR ARRANGEMENT AND LOCATIONS......................................................................................... 749 BK CONTROL SYSTEM CIRCUIT DIAGRAM........................................................................................... 755 CONTENT OF CODE DISPLAY..................................................................................................... 762 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................. 776 (BK-1) FAILURE CODE [2A62L1]................................................................................................ 778 FRONT DIFFERENTIAL CONTROL VALVE (L1)................................................................................... 778 (BK-2) FAILURE CODE [2A62LH]................................................................................................ 780 FRONT DIFFERENTIAL CONTROL VALVE (LH)................................................................................... 780 (BK-3) FAILURE CODE [2B62L1]................................................................................................ 782 REAR DIFFERENTIAL LOCK CONTROL VALVE (L1)............................................................................... 782 (BK-4) FAILURE CODE [2B62LH]................................................................................................ 784 REAR DIFFERENTIAL LOCK CONTROL VALVE (LH)............................................................................... 784 (BK-5) FAILURE CODE [2C4MNX]................................................................................................ 786 BRAKE COOLING FILTER CLOG INDICATED (NX)................................................................................ 786 (BK-6) FAILURE CODE [2D02CA]................................................................................................ 788 LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)..................................................................... 788 (BK-7) FAILURE CODE [2D01CA]................................................................................................ 789 RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA).................................................................... 789 (BK-8) FAILURE CODE [2D03CA]................................................................................................ 790 CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)............................................................. 790 (BK-9) FAILURE CODE [2D04CA]................................................................................................ 791 CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA).................................................................... 791 (BK-10) FAILURE CODE [2D05CA]............................................................................................... 792 RIGHT REAR BRAKE WEAR INDICATOR SWITCH WARNING (CA)..................................................................... 792 (BK-11) FAILURE CODE [2D06CA]............................................................................................... 793 LEFT FEAR BRAKE WEAR INDICATOR SWITCH WARNING (CA)...................................................................... 793 (BK-12) FAILURE CODE [2G42ZG]............................................................................................... 794 ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG).......................................................................... 794 (BK-13) FAILURE CODE [2G43ZG]............................................................................................... 795 ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)........................................................................... 795 (BK-14) FAILURE CODE [D1C0KZ]............................................................................................... 796 OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)............................................................................... 796 (BK-15) FAILURE CODE [D5ZFKZ]............................................................................................... 798 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)..................................................................................... 798 (BK-16) FAILURE CODE [D5ZGKZ]............................................................................................... 800 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)..................................................................................... 800 (BK-17) FAILURE CODE [DB10KK]............................................................................................... 802 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)................................................................................ 802 (BK-18) FAILURE CODE [DB11KK]............................................................................................... 804 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)................................................................................ 804 (BK-19) FAILURE CODE [DB12KK]............................................................................................... 806 VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)............................................................................ 806 (BK-20) FAILURE CODE [DB13KK]............................................................................................... 808 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)................................................................................ 808 (BK-21) FAILURE CODE [DB19KM]............................................................................................... 810 MISTAKEN OPERATION OF RETARDER CONTROLLER (KM).......................................................................... 810 (BK-22) FAILURE CODE [DB1SKQ]............................................................................................... 811 RETARDER CONTROL S-NET LINE MISMATCHED (KQ)............................................................................. 811 (BK-23) FAILURE CODE [DHU2KX]............................................................................................... 812 ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)................................................................. 812 (BK-24) FAILURE CODE [DHU3KX]............................................................................................... 814 ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX).................................................................. 814 (BK-25) FAILURE CODE [DK51L5]............................................................................................... 816 TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)..................................................................... 816 (BK-26) FAILURE CODE [DK52KX]............................................................................................... 818 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)............................................................................... 818 (BK-27) FAILURE CODE [DK53L8]............................................................................................... 820 DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)............................................................................... 820 (BK-28) FAILURE CODE [DK54KX]............................................................................................... 822 BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)........................................................................... 822 (BK-29) FAILURE CODE [DLF4KA]............................................................................................... 824 TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA)............................................................ 824 (BK-30) FAILURE CODE [DLT3KA]............................................................................................... 825 TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA)............................................................ 825 (BK-31) FAILURE CODE [DW71KZ]............................................................................................... 827 EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)............................................................................. 827 (BK-32) FAILURE CODE [DK72KX]............................................................................................... 828 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)............................................................................... 828 (BK-33) FAILURE CODE [DW73KZ]............................................................................................... 830 DUMP SELECTOR VALVE OPEN OR SHORTED (KZ)................................................................................ 830 (BK-34) FAILURE CODE [DX11KA]............................................................................................... 832 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA).............................................................. 832 (BK-35) FAILURE CODE [DX11KB]............................................................................................... 833 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB).............................................................. 833 (BK-36) FAILURE CODE [DX11KY]............................................................................................... 834 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY).............................................................. 834 (BK-37) FAILURE CODE [DX12KA]............................................................................................... 835 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)............................................................. 835 (BK-38) FAILURE CODE [DX12KB]............................................................................................... 836 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)............................................................. 836 (BK-39) FAILURE CODE [DX13KA]............................................................................................... 837 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)............................................................................ 837 (BK-40) FAILURE CODE [DX13KB]............................................................................................... 839 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)............................................................................ 839 (BK-41) FAILURE CODE [DX13KY]............................................................................................... 841 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)............................................................................ 841 (BK-42) FAILURE CODE [DX14KZ]............................................................................................... 843 REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ).................................................................... 843 (BK-43) FAILURE CODE [DX15KZ]............................................................................................... 844 FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)................................................................... 844 (BK-44) NO FAILURE CODE DISPLAYED........................................................................................... 846 PARKING BRAKE SYSTEM FAILURE............................................................................................ 846 TROUBLESHOOTING MACHINE MONITOR PANEL SYSTEM (MON MODE)......................................................................... 849 CONNECTOR ARRANGEMENT AND LOCATIONS......................................................................................... 851 MON CONTROL SYSTEM CIRCUIT DIAGRAM.......................................................................................... 857 CONTENT OF CODE DISPLAY..................................................................................................... 864 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................................. 866 (MON-1) FAILURE CODE [B@C6NS]............................................................................................... 868 FRONT BRAKE OIL OVERHEAT CONDITION (NS)................................................................................. 868 (MON-2) FAILURE CODE [B@C7NS]............................................................................................... 868 REAR BRAKE OIL OVERHEAT CONDITION (NS).................................................................................. 868 (MON-3) FAILURE CODE [B@C8NS]............................................................................................... 869 CENTER BRAKE OIL OVERHEAT CONDITION (NS)................................................................................ 869 (MON-4) FAILURE CODE [B@CENS]............................................................................................... 869 TORQUE CONVERTER OIL IS IN OVERHEAT CONDITION (NS)...................................................................... 869 (MON-5) FAILURE CODE [DAF0KM]............................................................................................... 870 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)..................................................................... 870 (MON-6) FAILURE CODE [DAF9KM]............................................................................................... 872 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)..................................................................... 872 (MON-7) FAILURE CODE [DAFSKQ]............................................................................................... 873 MODEL SELECTION DOES NOT MATCH (KQ)..................................................................................... 873 (MON-8) FAILURE CODE [DAQSKR]............................................................................................... 874 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR).................................................................... 874 (MON-9) FAILURE CODE [DA1SKR]............................................................................................... 876 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR).................................................................... 876 (MON-10) FAILURE CODE [DA2SKR].............................................................................................. 878 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR).................................................................... 878 (MON-11) FAILURE CODE [DV00KB].............................................................................................. 880 DEFECTIVE ALARM BUZZER (KB)............................................................................................. 880 (MON-12) NO FAILURE CODE DISPLAYED.......................................................................................... 882 WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL............................................................. 882 (MON-13) NO FAILURE CODE DISPLAYED.......................................................................................... 884 WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL............................................................ 884 (MON-14) NO FAILURE CODE DISPLAYED.......................................................................................... 886 ALARM BUZZER DOES NOT SOUND............................................................................................. 886 (MON-15) NO FAILURE CODE DISPLAYED.......................................................................................... 888 INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL............................................................... 888 (MON-16) NO FAILURE CODE DISPLAYED.......................................................................................... 889 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED.................................................................. 889 (MON-17) NO FAILURE CODE DISPLAYED.......................................................................................... 891 MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE................................................................. 891 (MON-18) NO FAILURE CODE DISPLAYED.......................................................................................... 893 POWER MODE SWITCH DOES NOT WORK PROPERLY................................................................................ 893 (MON-19) NO FAILURE CODE DISPLAYED.......................................................................................... 895 AISS FUNCTION DOES NOT WORK PROPERLY.................................................................................... 895 (MON-20) NO FAILURE CODE DISPLAYED.......................................................................................... 897 RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROPERLY.......................................................... 897 (MON-20) NO FAILURE CODE DISPLAYED.......................................................................................... 899 LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK PROPERLY.................................................... 899 (MON-21) NO FAILURE CODE DISPLAYED.......................................................................................... 901 INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY.............................................................. 901 (MON-22) NO FAILURE CODE DISPLAYED.......................................................................................... 903 EXHAUST BRAKE DOES NOT WORK PROPERLY.................................................................................... 903 (MON-23) NO FAILURE CODE DISPLAYED.......................................................................................... 905 SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY........................................................................... 905 (MON-24) NO FAILURE CODE DISPLAYED.......................................................................................... 907 SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY............................................................................. 907 (MON-25) NO FAILURE CODE DISPLAYED.......................................................................................... 910 HEAD AND TAIL LAMPS DO NOT WORK PROPERLY................................................................................ 910 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM (H MODE).................................................................... 913 (H-1)....................................................................................................................... 914 THE MACHINE DOES NOT MOVE............................................................................................... 914 (H-2) AND (H-3)............................................................................................................. 915 MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKEY)................................................................... 915 LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING).............................................................. 915 (H-4) AND (H-5)............................................................................................................. 916 EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS................................................................. 916 TRANSMISSION WILL NOT UP SHIFT GEAR RANGE............................................................................... 916 (H-6)....................................................................................................................... 917 MACHINE LACKS POWER OR SPEED WHEN TRAVELING............................................................................. 917 (H-6)....................................................................................................................... 918 ABNORMAL OPERATION AT SOME SPEED RANGES................................................................................. 918 (H-6)....................................................................................................................... 919 TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE................................................................................ 919 (H-7)....................................................................................................................... 920 TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES............................................................... 920 (H-8)....................................................................................................................... 921 TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)................................................................. 921 (H-9)....................................................................................................................... 922 TORQUE CONVERTER OIL PRESSURE LOW....................................................................................... 922 (H-10)...................................................................................................................... 923 FRONT BRAKE IS INEFFECTIVE OR INNEFECTIVE ON ONE SIDE ONLY.............................................................. 923 (H-11)...................................................................................................................... 924 CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE........................................................... 924 (H-12)...................................................................................................................... 925 REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE ONLY................................................................. 925 (H-13)...................................................................................................................... 926 STEERING EFFERT SEAMS HEAVY............................................................................................. 926 (H-14)...................................................................................................................... 927 STEERING SYSTEM DOES NOT OPERATE........................................................................................ 927 (H-15)...................................................................................................................... 928 STEERING WHEEL VIBRATES................................................................................................. 928 (H-16)...................................................................................................................... 929 DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER.......................................................................... 929 (H-17)...................................................................................................................... 930 DUMP OPERATIONS DO NOT WORK............................................................................................. 930 (H-18)...................................................................................................................... 931 EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY.................................................................................. 931 30 DISASSEMBLY AND ASSEMBLY......................................................................................................... 933 HOW TO USE MANUAL............................................................................................................... 935 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................... 936 SPECIAL TOOL LIST............................................................................................................... 938 SKETCHES OF SPECIAL TOOLS....................................................................................................... 943 FUEL SUPPLY PUMP REMOVAL........................................................................................................ 956 FUEL SUPPLY PUMP INSTALLATION................................................................................................... 957 ENGINE ASSEMBLY REMOVAL......................................................................................................... 958 ENGINE ASSEMBLY INSTALLATION.................................................................................................... 963 CYLINDER HEAD ASSEMBLY REMOVAL.................................................................................................. 965 CYLINDER HEAD INSTALLATION...................................................................................................... 971 REMOVAL AND INSTALLATION OF NOZZLE TIP.......................................................................................... 978 RADIATOR ASSEMBLY REMOVAL....................................................................................................... 981 RADIATOR ASSEMBLY INSTALLATION.................................................................................................. 984 OUTPUT SHAFT REMOVAL............................................................................................................ 985 OUTPUT SHAFT INSTALLATION....................................................................................................... 988 OUTPUT SHAFT DISASSEMBLY DIAGRAM................................................................................................ 989 ASSEMBLY OF OUTPUT SHAFT........................................................................................................ 990 TRANSMISSION AND FRONT DIFFERENTIAL REMOVAL..................................................................................... 993 TRANSMISSION AND FRONT DIFFERENTIAL INSTALLATION................................................................................1002 DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION............................................................................1004 COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION.................................................................................1005 DISASSEMBLY OF TORQUE CONVERTER.................................................................................................1006 ASSEMBLY OF TORQUE CONVERTER....................................................................................................1011 DISASSEMBLY OF TRANSMISSION.....................................................................................................1017 ASSEMBLY OF TRANSMISSION........................................................................................................1046 DISASSEMBLY OF FRONT DIFFERENTIAL...............................................................................................1082 ASSEMBLY OF FRONT DIFFERENTIAL..................................................................................................1093 REMOVAL OF CENTER DIFFERENTIAL..................................................................................................1107 INSTALLATION OF CENTER DIFFERENTIAL.............................................................................................1109 DISASSEMBLY OF CENTER DIFFERENTIAL..............................................................................................1111 ASSEMBLY OF CENTER DIFFERENTIAL.................................................................................................1119 REAR DIFFERENTIAL REMOVAL.......................................................................................................1132 REAR DIFFERENTIAL INSTALLATION..................................................................................................1133 DISASSEMBLY OF REAR DIFFERENTIAL................................................................................................1134 ASSEMBLY OF REAR DIFFERENTIAL...................................................................................................1140 REMOVAL OF FRONT FINAL DRIVE AND BRAKE..........................................................................................1149 INSTALLATION OF FRONT FINAL DRIVE AND BRAKE.....................................................................................1151 DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE......................................................................................1152 ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE.........................................................................................1160 REMOVAL OF CENTER FINAL DRIVE AND BRAKE.........................................................................................1170 INSTALLATION OF CENTER FINAL DRIVE AND BRAKE....................................................................................1172 DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE.....................................................................................1173 ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE........................................................................................1180 REMOVAL OF REAR FINAL DRIVE AND BRAKE...........................................................................................1188 INSTALLATION OF REAR FINAL DRIVE AND BRAKE......................................................................................1189 DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE.......................................................................................1190 ASSEMBLY OF REAR FINAL DRIVE AND BRAKE..........................................................................................1197 REMOVAL OF CENTER AXLE..........................................................................................................1204 INSTALLATION OF CENTER AXLE.....................................................................................................1207 REMOVAL OF REAR AXLE............................................................................................................1209 INSTALLATION OF REAR AXLE.......................................................................................................1212 INSTALLATION OF FRONT SUSPENSION CYLINDER.......................................................................................1214 REMOVAL OF FRONT SUSPENSION CYLINDER............................................................................................1213 REMOVAL OF REAR SUSPENSION CYLINDER.............................................................................................1215 REMOVAL OF EQUALIZER BAR........................................................................................................1217 INSTALLATION OF EQUALIZER BAR...................................................................................................1219 REMOVAL OF FRONT WHEEL..........................................................................................................1220 INSTALLATION OF FRONT WHEEL.....................................................................................................1220 REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY.................................................................................1221 REMOVAL OF HITCH FRAME..........................................................................................................1222 INSTALLATION OF HITCH FRAME.....................................................................................................1228 DISASSEMBLY OF HITCH FRAME......................................................................................................1230 ASSEMBLY OF HITCH FRAME.........................................................................................................1232 STANDARD INTEGRAL ORBIT-ROLL....................................................................................................1235 DISASSEMBLY OF STEERING VALVE...................................................................................................1237 ASSEMBLY OF STEERING VALVE......................................................................................................1241 REMOVAL OF FLOW AMPLIFIER VALVE.................................................................................................1247 INSTALLATION OF FLOW AMPLIFIER VALVE............................................................................................1248 REMOVAL OF HOIST VALVE..........................................................................................................1249 INSTALLATION OF HOIST VALVE.....................................................................................................1250 DISASSEMBLY OF HOIST VALVE......................................................................................................1251 ASSEMBLY OF HOIST VALVE.........................................................................................................1252 DISASSEMBLY OF STEERING CYLINDER................................................................................................1254 ASSEMBLY OF STEERING CYLINDER ASSEMBLY..........................................................................................1256 DISASSEMBLY OF HOIST CYLINDER ASSEMBLY..........................................................................................1259 ASSEMBLY OF HOIST CYLINDER......................................................................................................1261 REMOVAL OF BODY ASSEMBLY........................................................................................................1265 INSTALLATION OF BODY ASSEMBLY...................................................................................................1267 DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT.....................................................................................1268 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...........................................................................................1282 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM....................................................................................1283 DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM.....................................................................................1284 90 OTHERS...........................................................................................................................1281 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...........................................................................................1282 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM....................................................................................1283 DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM.....................................................................................1284 BRAKE HYDRAULIC CIRCUIT DIAGRAM.................................................................................................1285 AIR CONDITIONER.................................................................................................................1287 TO ENGINE CONTROLLER (1/2)......................................................................................................1289 TO ENGINE CONTROLLER (2/2)......................................................................................................1291 TO MAIN HARNESS INSIDE OF CAB (1/10)............................................................................................1293 TO MAIN HARNESS INSIDE OF CAB (2/10)............................................................................................1295 TO MAIN HARNESS INSIDE OF CAB (3/10)............................................................................................1297 TO MAIN HARNESS INSIDE OF CAB (4/10)............................................................................................1299 TO MAIN HARNESS INSIDE OF CAB (5/10)............................................................................................1301 TO MAIN HARNESS INSIDE OF CAB (6/10)............................................................................................1303 TO MAIN HARNESS INSIDE OF CAB (7/10)............................................................................................1305 TO MAIN HARNESS INSIDE OF CAB (8/10)............................................................................................1307 TO MAIN HARNESS INSIDE OF CAB (9/10)............................................................................................1309 TO MAIN HARNESS INSIDE OF CAB (10/10)...........................................................................................1311 SWITCH PANEL (1/3)..............................................................................................................1313 SWITCH PANEL (2/3)..............................................................................................................1315 SWITCH PANEL (3/3)..............................................................................................................1317 DISPLAY PANEL (1/2).............................................................................................................1319 DISPLAY PANEL (2/2).............................................................................................................1321 RETARD CONTROLLER (1/2).........................................................................................................1323 RETARD CONTROLLER (2/2).........................................................................................................1325 TO TRANSMISSION CONTROLLER (1/2)................................................................................................1327 TO TRANSMISSION CONTROLLER (2/2)................................................................................................1329 TO HARNESS OUTSIDE OF CAB (1/2).................................................................................................1331 TO HARNESS OUTSIDE OF CAB (2/2).................................................................................................1333 FUSE BLOCK......................................................................................................................1335 LOAD METER (1/2)................................................................................................................1337 LOAD METER (2/2)................................................................................................................1339
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