Komatsu HM400-1L Dump Truck Shop Manual CEBM015302 PDF

Description

Komatsu HM400-1L Dump Truck Shop Manual CEBM015302 – PDF DOWNLOAD

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Komatsu HM400-1L Dump Truck Shop Manual CEBM015302 – PDF DOWNLOAD 

Language : English
Pages : 1340
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HM400-1L Dump Truck Shop Manual CEBM015302 – PDF DOWNLOAD 

SERIAL NUMBERS HM400-1L A10001 and up
ENGINE 6D140E-3

GENERAL 

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.

GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.

TABLE OF CONTENTS:

Komatsu HM400-1L Dump Truck Shop Manual CEBM015302 – PDF DOWNLOAD 

SERIAL NUMBERS HM400-1L A10001 and up
ENGINE 6D140E-3

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

S.V 15/12/24