Komatsu HM350-1 Dump Truck Service Repair Shop Manual (1001 and up) - SEBM030300

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Articulated Dump Truck HM350-1 (SN: 1001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu Dump Truck HM350-1
(-40°C Specification)
Serial Numbers : 1001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 TESTING AND ADJUSTMENT
30 DISASSEMBLY AND ASSEMBLY
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM030300
Total Pages : 986


This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
CONTENTS
01 GENERAL
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL,COOLANT AND LUBRICANTS

10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD
RADIATOR,OIL COOLER, AFTERCOOLER
POWER TRAIN SKELETON
OUTPUT SHAFT
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION VALVE
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
DRIVE SHAFT
AXLE
DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
FINAL DRIVE
STEERING COLUMN
BRAKE PIPING
BRAKE VALVE
ACCUMULATOR CHARGE VALVE
ACCUMULATOR
SLACK ADJUSTER
BRAKE
PROPORTIONAL REDUCING VALVE
BRAKE SYSTEM TANK
PRAKING BRAKE
PARKING BRAKE CALIPER
SPRING CYLINDER
PARKING BRAKE SOLENOID
SUSPENSION
SUSPENSION CYLINDER
OSCILLATION HITCH
STEERING,HOIST OIL PRESSURE PIPING DIAGRAM
DUMP BODY CONTROL
HYDRAULIC TANK AND FILTER
FLOW AMP VALVE
STEERING VALVE
STEERING CYLINDER
HOIST VALVE
EPC VALVE
PILOT CHECK VALVE
HOIST CYLINDER
HYDRAULIC PUMP
CAB TILT
AIR CONDITIONER
MACHINE MONITOR SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
AUTO EMERGENCY STEERING SYSTEM
SENSORS,SWITCHES
RETARDER CONTROL SYSTEM
BRAKE CONTROL SYSTEM (E-SPEC)
DUMP CONTROL LEVER

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
MEASURING COMPRESSION PRESSURE
ADJUSTING VALVE CLEARANCE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING EQUIPMENT IN FUEL CIRCUIT
RELEASING REMAINING PRESSURE IN FUEL SYSTEM
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL CIRCUIT
REDUCED CYLINDER MODE OPERATION
CHECKING FOR LEAKAGE IN FUEL CIRCUIT
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING TORQUE CONVERTER STALL SPEED
MEASURING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING LEFT AND RIGHT DIFFERENTIAL LOCK OIL PRESSURE (MACHINE WITH DIFFERENTIAL LOCK DIFFERENTIAL)
ADJUSTING TRANSMISSION SPEED SENSOR
TESTING AND ADJUSTING BRAKE OIL PRESSURE
TESTING BRAKE PERFORMANCE
BLEEDING AIR FORM BRAKE CIRCUIT
TESTING WEAR OF WHEEL BRAKE DISC
TESTING WEAR OF PARKING BRAKE PAD
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
TESTING AND ADJUSTING SUSPENSION CYLINDER
METHOD OF TILTING CAB UP
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
ADJUSTING BODY POSITIONER SENSOR
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
ADJUSTING TRANSMISSION CONTROLLER
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM
ADJUSTING MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE
ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))
ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX)
ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))
ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))
ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))
ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))
ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))
ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))
ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))
ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))
ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))
ENG-12 FAILURE CODE [ADA1KA] (NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))
ENG-13 FAILURE CODE [ADZKKB] (NO. 1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))
ENG-14 FAILURE CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))
ENG-15 FAILURE CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))
ENG-16 FAILURE CODE [ADD1KA] (NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))
ENG-17 FAILURE CODE [ADDZKB] (NO. 4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))
ENG-18 FAILURE CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)
ENG-19 FAILURE CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))
ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))
ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))
ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))
ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))
ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))
ENG-25 FAILURE CODE [D1DDKB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))
ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))
ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE,INPUT (KK))
ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))
ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))
ENG-31 FAILURE CODE [KK11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))
ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))
ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))
ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-35 FAILURE CODE [DGE3LC] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))
ENG-36 FAILURE CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-37 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-38 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-39 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
ENG-40 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))
ENG-41 FAILURE CODE [DLE1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))
ENG-42 FAILURE CODE (ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE
TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))
TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE CONTENTS (LO))
TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))
TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))
TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))
TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))
TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))
TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))
TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))
TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE CONTENTS (L1))
TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE CONTENTS (L1))
TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE CONTENTS (L1))
TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE CONTENTS (L1))
TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE CONTENTS (L1))
TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE CONTENTS (L1))
TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE CONTENTS (L1))
TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE CONTENTS (L1))
TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))
TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))
TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
TM-28 FAILURE CODE [6014NX] (HYDRAULIC TANK FILTER: CLOGGED (NX))
TM-29 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))
TM-30 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))
TM-31 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))
TM-32 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))
TM-33 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))
TM-34 FAILURE CODE [B@BCZK] (RADIATOR WATER: DROP IN LEVEL (ZK))
TM-35 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))
TM-36 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (ZK))
TM-37 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))
TM-38 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-39 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))
TM-40 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE CONTENTS (L4))
TM-41 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-42 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
TM-43 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
TM-44 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
TM-45 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))
TM-46 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))
TM-47 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KP))
TM-48 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KP))
TM-49 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KP))
TM-50 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))
TM-51 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))
TM-52 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))
TM-53 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))
TM-54 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))
TM-55 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))
TM-56 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))
TM-57 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))
TM-58 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))
TM-59 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))
TM-60 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))
TM-61 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-63 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE CONTENTS (L8))
TM-64 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE CONTENTS (L8))
TM-65 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-66 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-67 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE CONTENTS (L6))
TM-68 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (L6))
TM-69 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
TM-70 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))
TM-71 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE CONTENTS (LC))
TM-72 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))
TM-73 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))
TM-74 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA))
TM-75 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: *SEE CONTENTS (LC))
TM-76 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))
TM-77 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE CONTENTS (LC))
TM-78 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))
TM-79 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))
TM-80 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))
TM-81 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))
TM-82 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))
TM-83 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))
TM-84 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))
TM-85 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))
TM-86 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))
TM-87 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))
TM-88 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))
TM-89 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))
TM-90 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))
TM-91 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))
TM-92 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))
TM-93 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))
TM-94 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY
TROUBLESHOOTING OF RETARDER CONTROLLER(※1) SYSTEM (BK MODE)
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE
BK-1 FAILURE CODE [2A62L1] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1))
BK-2 FAILURE CODE [2A62LH] (FRONT DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH))
BK-3 FAILURE CODE [2B62L1] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (L1))
BK-4 FAILURE CODE [2B62LH] (REAR DIFFERENTIAL LOCK CONTROL VALVE: *SEE CONTENTS (LH))
BK-5 FAILURE CODE [2C4MNX] (BRAKE COOLING FILTER: CLOGGED (NX))
BK-6 FAILURE CODE [2D01CA] (FRONT BRAKE (RIGHT): WEAR (CA))
BK-7 FAILURE CODE [2D02CA] (FRONT BRAKE (LEFT): WEAR (CA))
BK-8 FAILURE CODE [2D03CA] (CENTER BRAKE (RIGHT): WEAR (CA))
BK-9 FAILURE CODE [2D04CA] (CENTER BRAKE (LEFT): WEAR (CA))
BK-12 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))
BK-13 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))
BK-14 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-15 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-16 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-17 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)
BK-18 FAILURE CODE [DB11KK] (RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
BK-19 FAILURE CODE [DB12KK] (RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
BK-20 FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))
BK-21 FAILURE CODE [DB19KM] (RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
BK-22 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))
BK-23 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))
BK-24 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))
BK-25 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (BK))
BK-26 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))
BK-27 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE CONTENTS (L8))
BK-28 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))
BK-29 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))
BK-30 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))
BK-31 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-32 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-33 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-34 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))
BK-35 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))
BK-36 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))
BK-37 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))
BK-38 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))
BK-39 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))
BK-40 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))
BK-41 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))
BK-42 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))
BK-43 FAILURE CODE [DX14KZ] (REAR DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-44 FAILURE CODE [DX15KZ] (FRONT DIFFERENTIAL LOCK SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))
BK-45 PARKING BRAKE DOES NOT WORK PROPERLY
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE
MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))
MON-3 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))
MON-4 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))
MON-5 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
MON-6 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))
MON-7 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))
MON-8 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))
MON-9 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))
MON-10 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))
MON-11 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))
MON-12 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY
MON-13 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED
MON-14 ALARM BUZZER DOES NOT SOUND
MON-15 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY
MON-16 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY
MON-17 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY
MON-18 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY
MON-19 AISS FUNCTION DOES NOT WORK PROPERLY
MON-20 LEFT AND RIGHT DIFFERENTIAL LOCK DOES NOT WORK PROPERLY
MON-21 INTER-AXLE DIFFERENTIAL LOCK DOES NOT WORK PROPERLY
MON-22 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)
MON-23 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY
MON-24 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY
MON-25 NIGHT LIGHTING IS NOT NORMAL
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
H-1 MACHINE DOES NOT START
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING
H-5 TRANSMISSION DOES NOT SHIFT UP
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE
H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE
H-12 STEERING WHEEL IS HEAVY
H-13 STEERING WHEEL DOES NOT WORK
H-14 STEEIRNG WHEEL VIBRATES
H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER
H-16 DUMP DOES NOT WORK
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
REMOVAL OF ENGINE ASSEMBLY
INSTALLATION OF ENGINE ASSEMBLY
REMOVAL OF CYLINDER HEAD ASSEMBLY
INSTALLATION OF CYLINDER HEAD
REMOVAL OF RADIATOR ASSEMBLY
INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL OF OUTPUT SHAFT ASSEMBLY
INSTALLATION OF OUTPUT SHAFT ASSEMBLY
DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY
ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
REMOVAL OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY
INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY
DISCONNECTION OF FRONT FINAL DRIVE AND TRANSMISSION
COUPLING OF FRONT FINAL DRIVE AND TRANSMISSION
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
DISASSEMBLY OF TRANSMISSION ASSEMBLY
ASSEMBLY OF TRANSMISSION ASSEMBLY
DISASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY
ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY
REMOVAL OF CENTER DIFFERENTIAL ASSEMBLY
INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY
ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY
ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY
REMOVAL OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY
INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY
DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY
ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY
REMOVAL OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY
INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY
DISASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY
ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY
REMOVAL OF REAR FINAL DRIVE ASSEMBLY
INSTALLATION OF REAR FINAL DRIVE ASSEMBLY
DISASSEMBLY OF REAR FINAL DRIVE ASSEMBLY
ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY
REMOVAL OF CENTER AXLE ASSEMBLY
INSTALLATION OF CENTER AXLE ASSEMBLY
REMOVAL OF REAR AXLE ASSEMBLY
INSTALLATION OF REAR AXLE ASSEMBLY
REMOVAL OF FRONT SUSPENSION CYLINDER ASSEMBLY
INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY
REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY
INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY
REMOVAL OF EQUALIZER BAR ASSEMBLY
INSTALLATION OF EQUALIZER BAR ASSEMBLY
REMOVAL OF FRONT WHEEL ASSEMBLY
INSTALLATION OF FRONT WHEEL ASSEMBLY
REMOVAL OF CENTER WHEEL ASSEMBLY
INSTALLATION OF CENTER WHEEL ASSEMBLY
REMOVAL OF REAR WHEEL ASSEMBLY
INSTALLATION OF REAR WHEEL ASSEMBLY
REMOVAL OF HITCH FRAME ASSEMBLY
INSTALLATION OF HITCH FRAME ASSEMBLY
DISASSEMBLY OF HITCH FRAME
ASSEMBLY OF HITCH FRAME ASSEMBLY
STANDARD INTEGRAL ORBIT-TOLL
DISASSEMBLY OF STEERING VALVE
ASSEMBLY OF STEERING VALVE
REMOVAL OF FLOW AMPLIFIER VALVE ASSEMBLY
INSTALLATION OF FLOW AMPLIFIER VALVE ASSEMBLY
REMOVAL OF HOIST VALVE ASSEMBLY
INSTALLATION OF HOIST VALVE ASSEMBLY
DISASSEMBLY OF HOIST VALVE ASSEMBLY
ASSEMBLY OF HOIST VALVE ASSEMBLY
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY
ASSEMBLY OF STEERING CYLINDER ASSEMBLY
DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
ASSEMBLY OF HOIST CYLINDER ASSEMBLY
REMOVAL OF BODY ASSEMBLY
INSTALLATION OF BODY ASSEMBLY

90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
BRAKE HYDRAULIC CIRCUIT DIAGRAM
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/2)
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/2)
EXTERNAL POWER SUPPLY HEATER

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