Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-23 PDF

Description

Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-23 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-23 – PDF DOWNLOAD

Language : English
Pages :1574
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-23 – PDF DOWNLOAD

SERIAL NUMBERS 2001 and up

1. General precautions 

TABLE OF CONTENTS:

Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-23 – PDF DOWNLOAD

SERIAL NUMBERS 2001 and up

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword and general information 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of electric equipment and hydraulic component 27
Handling of connectors newly used for engines 36
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 Specification 59
Specification and technical data 59
Specification drawings 60
Specifications 61
Weight table 64
Fuel, coolant and lubricants 65
10 Structure, function and maintenance standard 69
Engine and cooling system 69
Radiator, oil cooler, aftercooler 70
Output shaft 71
Power train, Part 1 75
Power train skeleton 76
Torque converter and transmission hydraulic piping 80
Brake cooling oil control valve (BCV) 82
Power train pump 83
Torque converter 86
Transmission 92
Transmission control valve 120
ECMV 121
Main relief, torque converter relief valve 128
Power train, Part 2 131
Drive shaft 132
Axle 140
Differential 144
Limited slip differential 156
Final drive 160
Steering system 165
Steering column 166
Brake system 169
Brake piping 170
Brake valve 172
Accumulator charge valve 175
Accumulator 179
Slack adjuster 180
Brake 182
Proportional reducing valve 187
Brake system tank 188
Parking brake 190
Parking brake solenoid valve 194
Undercarriage and frame 197
Suspension 198
Suspension cylinder 203
Oscillation hitch 205
Hydraulic system 209
Steering, hoist oil pressure piping diagram 210
Dump body control 211
Hydraulic tank and filter 212
Flow amp valve 213
Steering valve 216
Steering cylinder 220
Hoist valve 222
Dump control valve (EPC valve) 228
Pilot check valve 232
Hoist cylinder 233
Hydraulic pump 234
Cab and its attachments 239
ROPS cab 240
Cab tilt 241
Air conditioner 244
Rear view monitor 252
Controller related 255
Electrical system, Part 1 257
Machine monitor system 258
Electrical system, Part 2 279
Automatic shift control system 280
Transmission controller 283
Retarder control system 312
Auto emergency steering system 324
Battery disconnect switch 326
Emergency engine stop switch 331
Dump control lever 333
Electrical system, Part 3 339
Payload meter (Card type) 340
Electrical system, Part 4 373
Sensors, switches 374
KOMTRAX terminal system (if equipped) 383
20 Standard value table 387
Standard service value table 387
Standard value table for engine 388
Standard value table for chassis 389
30 Testing and adjusting 395
Testing and adjusting, Part 1 395
Tools for testing, adjusting, and troubleshooting 396
Measuring engine speed 401
Testing intake air pressure (boost pressure) 402
Testing exhaust temperature 403
Testing exhaust gas color 405
Adjusting valve clearance 406
Testing compression pressure 407
Testing blow-by pressure 409
Testing engine oil pressure 410
Testing EGR valve and bypass valve drive oil pressure 411
Handling of fuel system devices 412
Releasing residual pressure from fuel system 412
Testing fuel pressure 413
Testing fuel return and leakage amount 414
Bleeding air from fuel circuit 417
Testing the fuel circuit for leakage 419
Testing and adjusting fan belt tension 420
Testing and adjusting alternator belt tension 421
Testing and adjusting air conditioner compressor belt tension 422
Adjustment of body mount shims 423
Testing and adjusting, Part 2 425
Testing torque converter stall speed 426
Testing power train oil pressure 427
Testing and adjusting of differential lock oil pressure (differential lock spec) 435
Adjusting transmission speed sensor 440
Testing and adjusting brake oil pressure 442
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 446
Testing brake performance 454
Releasing remaining pressure in brake circuit 455
Bleeding air from brake circuit 456
Testing wear of wheel brake disc 457
Testing the parking brake pad wear 458
Emergency release of the parking brake 460
Testing and adjusting steering circuit oil pressure 461
Testing and adjusting suspension cylinder 463
Method of tilting cab up 467
Testing and adjusting dump circuit oil pressure 469
Adjusting body positioner sensor 471
Adjusting length of spring in body heating spherical joint 472
Adjustment of tilt lock lever of steering wheel 473
Handling of voltage circuit of engine controller 474
Adjusting transmission controller 474
Method for emergency escape at electrical system failure 475
Testing and adjusting, Part 3 481
Setting and adjusting various equipments 482
Special function of machine monitor 491
How to start operation of KOMTRAX terminal 536
Lamp display of KOMTRAX terminal 541
Pm Clinic check sheet 544
Initial setting of payload meter 547
40 Troubleshooting 549
General information on troubleshooting 549
Points to remember when performing troubleshooting 550
How to proceed in troubleshooting 552
Check before troubleshooting 554
Classification and procedures of troubleshooting 555
Information in troubleshooting table 559
Troubleshooting method for disconnecting wiring harness of pressure sensor system 561
Phenomena looking like troubles and troubleshooting Nos 563
Connection table for connector pin numbers 565
T- branch box and T- branch adapter table 601
Troubleshooting by failure code, General 605
Failure codes table 606
Before troubleshooting by failure code 614
Information in troubleshooting table 622
Troubleshooting by failure code, Part 1 625
Failure code [1500L0] Detecting dual engagement 627
Failure code [15B0NX] Transmission oil filter: Clogging 628
Failure code [15F0KM] R → F gear shift abuse 1 630
Failure code [15F0MB] R → F gear shift abuse 2 630
Failure code [15F7KM] Transmission forward clutch abuse 631
Failure code [15G0MW] Reverse clutch system failure (Slip is detected) 632
Failure code [15G7KM] Transmission reverse clutch abuse 634
Failure code [15H0MW] Hi clutch system failure (Slip is detected) 636
Failure code [15J0MW] Lo clutch system failure (Slip is detected) 638
Failure code [15K0MW] 1st clutch system failure (Slip is detected) 640
Failure code [15L0MW] 2nd clutch system failure (Slip is detected) 642
Failure code [15M0MW] 3rd clutch system failure (Slip is detected) 644
Failure code [15SBL1] Reverse clutch pressure control valve failure I 646
Failure code [15SBMA] Reverse clutch pressure control valve failure II 650
Failure code [15SCL1] Hi clutch pressure control valve failure I 652
Failure code [15SCMA] Hi clutch pressure control valve failure II 656
Failure code [15SDL1] Lo clutch pressure control valve failure I 658
Failure code [15SDMA] Lo clutch pressure control valve failure II 660
Troubleshooting by failure code, Part 2 665
Failure code [15SEL1] Trouble in 1st clutch pressure control valve I 667
Failure code [15SEMA] Trouble in 1st clutch pressure control valve II 670
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I 672
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II 676
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I 678
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II 682
Failure code [15SJMA] Trouble in lockup clutch pressure control valve II 684
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II 686
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 688
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1 690
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 692
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 694
Failure code [2C4MNX] Clogging of retarder cooling oil filter 696
Failure code [2F00KM] Dragging of parking brake 698
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 700
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 700
Failure code [989A00] Operation of engine overrun prevention system 701
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 701
Failure code [A570NX] Clogging of engine oil filter 702
Failure code [AA10NX] Clogging of air cleaner 704
Failure code [AB00MA] Trouble in battery charge circuit 706
Failure code [B@BAZG] Lowering of engine oil pressure 707
Failure code [B@BAZK] Lowering of engine oil level 708
Failure code [B@BCNS] Overheating of engine 709
Failure code [B@BCZK] Lowering of coolant level 710
Failure code [B@BFZK] Lowering of fuel level 712
Failure code [B@C6NS] Overheating of brake cooling oil (front) 713
Failure code [B@C7NS] Overheating of brake cooling oil (rear) 713
Failure code [B@C8NS] Overheating of brake cooling oil (center) 714
Failure code [B@CENS] Overheating of torque converter oil 714
Failure code [B@JANS] Overheating of steering oil 715
Troubleshooting by failure code, Part 3 717
Failure code [CA111] Abnormality in engine controller 720
Failure code [CA115] Engine Ne or Bkup speed sensor error 722
Failure code [CA122] Charge (boost) pressure sensor high error 724
Failure code [CA123] Charge (boost) pressure sensor low error 726
Failure code [CA131] Throttle sensor high error 728
Failure code [CA132] Throttle sensor low error 731
Failure code [CA135] Engine oil pressure sensor high error 734
Failure code [CA141] Engine oil pressure sensor low error 736
Failure code [CA144] Coolant temperature sensor high error 738
Failure code [CA145] Coolant temperature sensor low error 740
Failure code [CA153] Charge (boost) temperature sensor high error 742
Failure code [CA154] Charge (boost) temperature sensor low error 744
Failure code [CA187] Sensor power supply 2 low error 746
Failure code [CA221] Atmospheric pressure sensor high error 750
Failure code [CA222] Atmospheric pressure sensor low error 752
Failure code [CA227] Sensor power supply 2 high error 754
Failure code [CA234] Engine overspeed 755
Failure code [CA238] Ne speed sensor power supply error 756
Failure code [CA263] Fuel Temperature Sensor High Error 758
Failure code [CA265] Fuel Temperature Sensor Low Error 760
Failure code [CA271] PCV1 Short circuit 762
Failure code [CA272] PCV1 Disconnection 763
Failure code [CA273] PCV2 Short circuit 764
Failure code [CA274] PCV2 Disconnection 765
Failure code [CA322] Injector #1 open/short error 766
Failure code [CA323] Injector #5 open/short error 768
Failure code [CA324] Injector #3 open/short error 770
Failure code [CA325] Injector #6 open/short error 772
Failure code [CA331] Injector #2 open/short error 774
Failure code [CA332] Injector #4 open/short error 776
Failure code [CA342] Calibration code inconsistency 778
Failure code [CA351] Injectors drive circuit error 779
Failure code [CA352] Sens Supply 1 Volt Low Error 780
Failure code [CA386] Sensor power supply 1 high error 782
Troubleshooting by failure code, Part 4 785
Failure code [CA431] Idle validation switch error 788
Failure code [CA432] Idle validation action error 791
Failure code [CA441] Battery voltage low error 794
Failure code [CA442] Battery voltage high error 795
Failure code [CA449] Common rail pressure high error 2 796
Failure code [CA451] Common rail pressure sensor high error 798
Failure code [CA452] Common rail pressure sensor low error 800
Failure code [CA553] Common rail pressure high error 1 802
Failure code [CA554] Common rail pressure sensor in range error 803
Failure code [CA559] Supply pump pressure very low error 1 804
Failure code [CA689] Engine Ne speed sensor error 808
Failure code [CA731] Engine Bkup speed sensor phase error 810
Failure code [CA757] All continuous data lost error 811
Failure code [CA778] Engine Bkup speed sensor error 812
Failure code [CA1228] EGR valve servo error 1 814
Failure code [CA1625] EGR valve servo error 2 815
Failure code [CA1626] Bypass valve solenoid current high error 816
Failure code [CA1627] Bypass valve solenoid current low error 818
Failure code [CA1628] Bypass Valve Servo Error 1 820
Failure code [CA1629] Bypass Valve Servo Error 2 821
Failure code [CA1631] Bypass valve lift sensor high error 822
Failure code [CA1632] Bypass valve lift sensor low error 824
Failure code [CA1633] KOMNET datalink timeout error 826
Failure code [CA1642] EGR inlet pressure sensor low error 828
Failure code [CA1653] EGR inlet pressure sensor high error 830
Failure code [CA2185] Throttle sensor supply voltage high error 832
Failure code [CA2186] Throttle sensor power supply low error 834
Failure code [CA2249] Supply pump pressure very low error 2 836
Failure code [CA2271] EGR valve lift sensor high error 838
Failure code [CA2272] EGR valve lift sensor low error 840
Failure code [CA2351] EGR valve solenoid operation short circuit 842
Failure code [CA2352] EGR valve solenoid operation disconnect 844
Failure code [CA2555] Intake air heater relay open circuit error 846
Failure code [CA2556] Intake air heater relay short circuit error 848
Troubleshooting by failure code, Part 5 851
Failure code [DAF9KM] Wrong connection of connector 854
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 855
Failure code [DAQ0KK] Lowering of source voltage 856
Failure code [DAQ0KT] Trouble in non-volatile memory 858
Failure code [DAQ2KK] Trouble in solenoid power supply system 860
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 862
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 864
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 869
Failure code [DB10KT] Trouble in non-volatile memory 869
Failure code [DB12KK] Trouble in solenoid power supply system 870
Failure code [DB13KK] Lowering of battery direct voltage 872
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 874
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) 875
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 876
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 880
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 886
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 888
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 889
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 890
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 891
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 892
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 893
Failure code [DF10KA] Input of no lever signals 894
Failure code [DF10KB] Input of multiple lever signals 898
Failure code [DGF1KX] Transmission oil temperature out of range 902
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) 904
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) 906
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) 908
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 910
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) 912
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 914
Failure code [DGR6KX] Steering oil temperature out of range 916
Troubleshooting by failure code, Part 6 919
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 922
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 924
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 926
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system 928
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system 930
Failure code [DJF1KA] Disconnection in fuel level sensor system 932
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS 934
Failure code [DK52KX] Trouble in dump lever potentiometer 1 936
Failure code [DK53L8] Trouble in dump lever potentiometer 2 938
Failure code [DK54KX] Trouble in dump positioner sensor 940
Failure code [DKH0KX] Pitch angle sensor signal out of range 942
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 944
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor 945
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system 946
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system 947
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 948
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 949
Failure code [DV00KB] Short circuit in buzzer output circuit 950
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system 952
Failure code [DW73KZ] Trouble in dump selector valve output system 954
Failure code [DW78KZ] Trouble in rear wheel BCV command output system 956
Failure code [DW79KZ] Trouble in front wheel BCV command output system 958
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 960
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve 962
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve 964
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve 966
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 968
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 970
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 972
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve 974
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve 976
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 978
Troubleshooting by failure code, Part 7 981
Troubleshooting by failure code, Part 7 984
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve 984
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve 986
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 988
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system 990
Failure code [DX15KZ] Trouble in front wheel differential lock command output system 992
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid 994
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid 996
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid 998
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 999
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid1000
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid1002
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid1004
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve1006
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve1008
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid1012
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve1014
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve1016
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid1020
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve1022
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve1024
Troubleshooting by failure code, Part 81029
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid1030
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid1032
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid1034
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid1038
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid1040
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid1042
Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid1046
Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid1048
Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid1050
Troubleshooting of electrical system (E-mode)1055
Before troubleshooting for electrical system1056
Information in troubleshooting table1062
E-1 Engine does not start (Starting motor does not turn)1063
E-2 Auto preheater does not operate1069
E-3 When starting switch is turned ON, machine monitor displays nothing1072
E-4 When starting switch is turned OFF, machine monitor cannot be operated1076
E-5 Alarm buzzer does not stop sounding1080
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section1081
E- 7 Display of character display section cannot be changed1082
E- 8 Power mode selection function does not operate normally1085
E- 9 AISS function does not operate normally1087
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) 1089
E-11 Interaxle differential lock-up function does not operate normally1093
E-12 Display of seat belt caution lamp is abnormal1095
E-13 Turn signal lamps and pilot lamps do not operate normally1097
E-14 Night lighting is abnormal1102
E-15 Backup lamp and backup buzzer operate abnormally1109
E-16 Emergency steering system does not operate1114
E-17 Air conditioner does not operate normally1118
Troubleshooting of hydraulic and mechanical system (H-mode)1123
Troubleshooting of hydraulic and mechanical system (H-mode)1125
Information in troubleshooting table1125
H-1 Machine does not start1126
H-2 Travel is not smooth (Machine hunts)1128
H-3 Lockup is not reset1128
H-4 Start shock and gear shift shock are abnormally large1129
H-5 Gear is not shifted up1130
H-6 Travel speed or power is low1132
H-7 Start and gearshift time lag is large1136
H-8 Torque converter oil temperature is high1138
H-9 Torque converter oil temperature is low1139
H-10 Front brake does not work fully1140
H-11 Center brake does not work fully1141
H-12 Rear brake does not work fully1142
H-13 Steering wheel is heavy1143
H-14 Steering wheel does not move1144
H-15 Steering wheel waggle1145
H-16 Dump body raising speed is low1146
H-17 Dump body does not move1147
H-18 Hydraulic drift of dump body is large1148
Troubleshooting of engine (S-mode)1151
Method of using troubleshooting chart1154
S-1 Starting performance of engine is poor1158
S-2 Engine does not start1160
S-3 Engine does not pick up smoothly1164
S-4 Engine stops during operation1165
S-5 Engine does not rotate smoothly1166
S-6 Engine lack output (or lacks power)1167
S-7 Exhaust gas is black (incomplete combustion)1168
S-8 Oil consumption is excessive (or exhaust gas is blue)1170
S-9 Oil becomes dirty quickly1171
S-10 Fuel consumption is excessive1172
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1173
S-12 Oil pressure drops1174
S-13 Oil level rises (Entry of coolant or fuel)1176
S-14 Coolant temperature becomes too high (Overheating)1178
S-15 Abnormal noise is made1179
S-16 Vibration is excessive1180
50 Disassembly and assembly1183
General information on disassembly and assembly1183
How to read this manual1184
Coating materials list1186
Special tool list1189
Sketches of special tools1194
Engine and cooling system1209
Removal and installation of fuel supply pump1210
Removal and installation of engine assembly1213
Removal and installation of cylinder head assembly1221
Removal and installation of fuel injector assembly1234
Removal and installation of radiator assembly1240
Removal and installation of cooling assembly1244
Removal and installation of aftercooler1248
Removal and installation of engine front seal1251
Removal and installation of engine rear seal1253
Replacement procedure of exhaust pipe fire prevention cover1257
Power train, Part 11267
Removal and installation of output shaft assembly1268
Disassembly and assembly of output shaft assembly1272
Removal and installation of transmission and front differential assembly1275
Disconnection and coupling of front differential and transmission1283
Disassembly and assembly of torque converter assembly1284
Disassembly and assembly of transmission assembly1292
Power train, Part 21337
Disassembly and assembly of front differential assembly1338
Removal and installation of center differential assembly1355
Disassembly and assembly of center differential assembly1358
Removal and installation of rear differential assembly1373
Disassembly and assembly of rear differential assembly1375
Power train, Part 31389
Removal and installation of front final drive and brake assembly1390
Disassembly and assembly of front final drive and brake assembly1393
Removal and installation of center final drive and brake assembly1409
Disassembly and assembly of center final drive and plate assembly1411
Removal and installation of rear final drive and brake assembly1423
Disassembly and assembly of rear final drive and brake assembly1425
Removal and installation of center axle assembly1437
Removal and installation of rear axle assembly1440
Undercarriage and frame1445
Removal and installation of front suspension cylinder assembly1446
Removal and installation of rear suspension cylinder assembly1448
Disassembly and assembly of front and rear suspension cylinder assembly1449
Removal and installation of equalizer bar assembly1451
Removal and installation of front wheel assembly1453
Removal and installation of rear front wheel assembly1454
Removal and installation of rear rear wheel assembly1454
Removal and installation of hitch frame assembly1455
Disassembly and assembly of hitch frame1463
Removal and installation of body assembly1468
Hydraulic system1471
Disassembly and assembly of steering valve1472
Removal and installation of flow amplifier valve assembly1482
Removal and installation of hoist valve assembly1484
Disassembly and assembly of hoist valve assembly1486
Disassembly and assembly of steering cylinder assembly1488
Disassembly and assembly of hoist cylinder assembly1494
Cab and its attachments1503
Removal and installation of operator’s cab1504
Removal and installation of operator’s cab glass (Stuck glass)1509
Disassembly and assembly of operator’s seat assembly1516
Removal and installation of air conditioner unit assembly1526
Electrical system1533
Removal and installation of retarder controller assembly1534
Removal and installation of transmission controller assembly1536
Removal and installation of engine controller assembly1538
90 Diagrams and drawings1541
Hydraulic diagrams and drawings1541
Power train hydraulic circuit diagram1543
Steering and hoist hydraulic circuit diagram1545
Brake hydraulic circuit diagram1547
Brake cooling hydraulic circuit diagram1548
Differential lock hydraulic circuit diagram1549
Electrical diagrams and drawings1551
Electrical circuit diagram for inside cab (1/4)1553
Electrical circuit diagram for inside cab (2/4)1555
Electrical circuit diagram for inside cab (3/4)1557
Electrical circuit diagram for inside cab (4/4)1559
Electrical circuit diagram for outside cab (1/4)1561
Electrical circuit diagram for outside cab (2/4)1563
Electrical circuit diagram for outside cab (3/4)1565
Electrical circuit diagram for outside cab (4/4)1567
Electrical circuit diagram for payload meter1569
Connectors table and arrangement drawing 1571

S.M 29/12/24