Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-26 PDF

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Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-26 – PDF DOWNLOAD

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Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-26 – PDF DOWNLOAD

Language : English
Pages :1558
Downloadable : Yes
File Type : PDF

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Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-26 – PDF DOWNLOAD

SERIAL NUMBERS 2001 and up

1. General precautions 
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu Articulated Dump Truck HM400-2 Shop Manual SEN00239-26 – 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 24
Explanation of terms for maintenance standard 26
Handling of electric equipment and hydraulic component 28
Handling of connectors newly used for engines 37
How to read electric wire code 40
Precautions when carrying out operation 43
Method of disassembling and connecting push-pull type coupler 46
Standard tightening torque table 49
Conversion table 53
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
Precautions before work 397
Tools for testing, adjusting, and troubleshooting 398
Measuring engine speed 403
Testing intake air pressure (boost pressure) 404
Testing exhaust temperature 405
Testing exhaust gas color 407
Adjusting valve clearance 408
Testing compression pressure 409
Testing blow-by pressure 411
Testing engine oil pressure 412
Testing EGR valve and bypass valve drive oil pressure 413
Handling of fuel system devices 414
Releasing residual pressure from fuel system 414
Testing fuel pressure 415
Testing fuel return and leakage amount 416
Bleeding air from fuel circuit 419
Testing the fuel circuit for leakage 421
Testing and adjusting fan belt tension 422
Testing and adjusting alternator belt tension 423
Testing and adjusting air conditioner compressor belt tension 424
Adjustment of body mount shims 425
Testing and adjusting, Part 2 427
Testing torque converter stall speed 428
Testing power train oil pressure 429
Testing and adjusting of differential lock oil pressure (differential lock spec) 437
Adjusting transmission speed sensor 442
Testing and adjusting brake oil pressure 444
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 448
Testing brake performance 456
Releasing remaining pressure in brake circuit 457
Bleeding air from brake circuit 458
Testing wear of wheel brake disc 459
Testing the parking brake pad wear 460
Emergency release of the parking brake 462
Testing and adjusting steering circuit oil pressure 463
Testing and adjusting suspension cylinder 465
Method of tilting cab up 469
Testing and adjusting dump circuit oil pressure 471
Adjusting body positioner sensor 473
Adjusting length of spring in body heating spherical joint 474
Adjustment of tilt lock lever of steering wheel 475
Handling of voltage circuit of engine controller 476
Adjusting transmission controller 476
Method for emergency escape at electrical system failure 477
Testing and adjusting, Part 3 483
Setting and adjusting various equipments 484
Special function of machine monitor 493
How to start operation of KOMTRAX terminal 538
Lamp display of KOMTRAX terminal 543
Pm Clinic check sheet 546
Initial setting of payload meter 549
40 Troubleshooting 551
General information on troubleshooting 551
Precautions before work 552
Points to remember when performing troubleshooting 553
How to proceed in troubleshooting 555
Check before troubleshooting 557
Classification and procedures of troubleshooting 558
Information in troubleshooting table 562
Troubleshooting method for disconnecting wiring harness of pressure sensor system 564
Phenomena looking like troubles and troubleshooting Nos 566
Connection table for connector pin numbers 568
T- branch box and T- branch adapter table 604
Troubleshooting by failure code, General 609
Failure codes table 610
Before troubleshooting by failure code 618
Information in troubleshooting table 626
Troubleshooting by failure code, Part 1 629
Failure code [1500L0] Detecting dual engagement 631
Failure code [15B0NX] Transmission oil filter: Clogging 632
Failure code [15F0KM] R → F gear shift abuse 1 634
Failure code [15F0MB] R → F gear shift abuse 2 634
Failure code [15F7KM] Transmission forward clutch abuse 635
Failure code [15G0MW] Reverse clutch system failure (Slip is detected) 636
Failure code [15G7KM] Transmission reverse clutch abuse 638
Failure code [15H0MW] Hi clutch system failure (Slip is detected) 640
Failure code [15J0MW] Lo clutch system failure (Slip is detected) 642
Failure code [15K0MW] 1st clutch system failure (Slip is detected) 644
Failure code [15L0MW] 2nd clutch system failure (Slip is detected) 646
Failure code [15M0MW] 3rd clutch system failure (Slip is detected) 648
Failure code [15SBL1] Reverse clutch pressure control valve failure I 650
Failure code [15SBMA] Reverse clutch pressure control valve failure II 653
Failure code [15SCL1] Hi clutch pressure control valve failure I 654
Failure code [15SCMA] Hi clutch pressure control valve failure II 657
Failure code [15SDL1] Lo clutch pressure control valve failure I 658
Failure code [15SDMA] Lo clutch pressure control valve failure II 661
Troubleshooting by failure code, Part 2 663
Failure code [15SEL1] 1st clutch pressure control valve failure I 666
Failure code [15SEMA] 1st clutch pressure control valve failure II 669
Failure code [15SFL1] 2nd clutch pressure control valve failure I 670
Failure code [15SFMA] 2nd clutch pressure control valve failure II 673
Failure code [15SGL1] 3rd clutch pressure control valve failure I 674
Failure code [15SGMA] 3rd clutch pressure control valve failure II 677
Failure code [15SJMA] Lockup clutch pressure control valve failure II 678
Failure code [15SKMA] Interaxle differential lock clutch pressure control valve failure II 680
Failure code [2A62L1] Front wheel differential lock pressure control valve failure II 682
Failure code [2A62LH] Front wheel differential lock pressure control valve failure I 684
Failure code [2B62L1] Rear wheel differential lock pressure control valve failure II 686
Failure code [2B62LH] Rear wheel differential lock pressure control valve failure I 688
Failure code [2C4MNX] Retarder cooling oil filter clogging 690
Failure code [2F00KM] Dragging of parking brake 692
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 694
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 694
Failure code [989A00] Engine overrun prevention activated 695
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) 695
Failure code [A570NX] Engine oil filter clogging 696
Failure code [AA10NX] Air cleaner clogging 698
Failure code [AB00MA] Battery charge circuit failure 700
Failure code [B@BAZG] Lowering of engine oil pressure 701
Failure code [B@BAZK] Lowering of engine oil level 702
Failure code [B@BCNS] Engine overheat 703
Failure code [B@BCZK] Lowering of coolant level 704
Failure code [B@C6NS] Overheat of brake cooling oil temperature (front) 706
Failure code [B@C8NS] Overheat of brake cooling oil temperature (center) 706
Failure code [B@CENS] Overheat of torque converter oil temperature 707
Failure code [B@JANS] Overheat of steering oil temperature 707
Troubleshooting by failure code, Part 3 709
Failure code [CA111] Abnormality in engine controller 712
Failure code [CA115] Engine Ne or Bkup speed sensor error 714
Failure code [CA122] Charge (boost) pressure sensor high error 716
Failure code [CA123] Charge (boost) pressure sensor low error 718
Failure code [CA131] Throttle sensor high error 720
Failure code [CA132] Throttle sensor low error 723
Failure code [CA135] Engine oil pressure sensor high error 726
Failure code [CA141] Engine oil pressure sensor low error 728
Failure code [CA144] Coolant temperature sensor high error 730
Failure code [CA145] Coolant temperature sensor low error 732
Failure code [CA153] Charge (boost) temperature sensor high error 734
Failure code [CA154] Charge (boost) temperature sensor low error 736
Failure code [CA187] Sensor power supply 2 low error 738
Failure code [CA221] Atmospheric pressure sensor high error 742
Failure code [CA222] Atmospheric pressure sensor low error 744
Failure code [CA227] Sensor power supply 2 high error 746
Failure code [CA234] Engine overspeed 747
Failure code [CA238] Ne speed sensor power supply error 748
Failure code [CA263] Fuel Temperature Sensor High Error 750
Failure code [CA265] Fuel Temperature Sensor Low Error 752
Failure code [CA271] PCV1 Short circuit 754
Failure code [CA272] PCV1 Disconnection 755
Failure code [CA273] PCV2 Short circuit 756
Failure code [CA274] PCV2 Disconnection 757
Failure code [CA322] Injector #1 open/short error 758
Failure code [CA323] Injector #5 open/short error 760
Failure code [CA324] Injector #3 open/short error 762
Failure code [CA325] Injector #6 open/short error 764
Failure code [CA331] Injector #2 open/short error 766
Failure code [CA332] Injector #4 open/short error 768
Failure code [CA342] Calibration code inconsistency 770
Failure code [CA351] Injectors drive circuit error 771
Failure code [CA352] Sens Supply 1 Volt Low Error 772
Failure code [CA386] Sensor power supply 1 high error 774
Troubleshooting by failure code, Part 4 777
Failure code [CA431] Idle validation switch error 780
Failure code [CA432] Idle validation action error 783
Failure code [CA441] Battery voltage low error 786
Failure code [CA442] Battery voltage high error 787
Failure code [CA449] Common rail pressure high error 2 788
Failure code [CA451] Common rail pressure sensor high error 790
Failure code [CA452] Common rail pressure sensor low error 792
Failure code [CA553] Common rail pressure high error 1 794
Failure code [CA554] Common rail pressure sensor in range error 795
Failure code [CA559] Supply pump pressure very low error 1 796
Failure code [CA689] Engine Ne speed sensor error 800
Failure code [CA731] Engine Bkup speed sensor phase error 802
Failure code [CA757] All continuous data lost error 803
Failure code [CA778] Engine Bkup speed sensor error 804
Failure code [CA1228] EGR valve servo error 1 806
Failure code [CA1625] EGR valve servo error 2 807
Failure code [CA1626] Bypass valve solenoid current high error 808
Failure code [CA1627] Bypass valve solenoid current low error 810
Failure code [CA1628] Bypass Valve Servo Error 1 812
Failure code [CA1629] Bypass Valve Servo Error 2 813
Failure code [CA1631] Bypass valve lift sensor high error 814
Failure code [CA1632] Bypass valve lift sensor low error 816
Failure code [CA1633] KOMNET datalink timeout error 818
Failure code [CA1642] EGR inlet pressure sensor low error 820
Failure code [CA1653] EGR inlet pressure sensor high error 822
Failure code [CA2185] Throttle sensor supply voltage high error 824
Failure code [CA2186] Throttle sensor power supply low error 826
Failure code [CA2249] Supply pump pressure very low error 2 828
Failure code [CA2271] EGR valve lift sensor high error 830
Failure code [CA2272] EGR valve lift sensor low error 832
Failure code [CA2351] EGR valve solenoid operation short circuit 834
Failure code [CA2352] EGR valve solenoid operation disconnect 836
Failure code [CA2555] Intake air heater relay open circuit error 838
Failure code [CA2556] Intake air heater relay short circuit error 840
Troubleshooting by failure code, Part 5 843
Failure code [DAF9KM] Wrong connection of connector 846
Failure code [DAFRKR] Abnormal CAN communication (machine monitor): Abnormal communication 847
Failure code [DAQ0KK] Lowering of source voltage 848
Failure code [DAQ0KT] Trouble in non-volatile memory 850
Failure code [DAQ2KK] Trouble in solenoid power supply system 852
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) 854
Failure code [DAQRKR] Abnormal CAN communication (Transmission): Abnormal communication 856
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) 861
Failure code [DB10KT] Trouble in non-volatile memory 861
Failure code [DB12KK] Trouble in solenoid power supply system 862
Failure code [DB13KK] Lowering of battery direct voltage 864
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) 866
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) 867
Failure code [DB1RKR] CAN communication (retarder controller): Communication disabled 868
Failure code [DB2RKR] CAN communication (engine controller): Communication disabled 872
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal 878
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 880
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 881
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 882
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 883
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 884
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 885
Failure code [DF10KA] Input of no lever signals 886
Failure code [DF10KB] Input of multiple lever signals 890
Failure code [DGF1KX] Transmission oil temperature out of range 894
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) 896
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) 898
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) 900
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) 902
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) 904
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) 906
Failure code [DGR6KX] Steering oil temperature out of range 908
Troubleshooting by failure code, Part 6 911
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system 914
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system 916
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 918
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system 920
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system 922
Failure code [DJF1KA] Disconnection in fuel level sensor system 924
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS 926
Failure code [DK52KX] Trouble in dump lever potentiometer 1 928
Failure code [DK53L8] Trouble in dump lever potentiometer 2 930
Failure code [DK54KX] Trouble in dump positioner sensor 932
Failure code [DKH0KX] Pitch angle sensor signal out of range 934
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system 936
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor 937
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system 938
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system 939
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system 940
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system 941
Failure code [DV00KB] Short circuit in buzzer output circuit 942
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system 944
Failure code [DW73KZ] Trouble in dump selector valve output system 946
Failure code [DW78KZ] Trouble in rear wheel BCV command output system 948
Failure code [DW79KZ] Trouble in front wheel BCV command output system 950
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 952
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve 954
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve 956
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve 958
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 960
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 962
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve 964
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve 966
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve 968
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 970
Troubleshooting by failure code, Part 7 973
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve 976
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve 978
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 980
Failure code [DX14KZ] Rear wheel differential lock command output system failure 982
Failure code [DX15KZ] Front wheel differential lock command output system failure 984
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid 986
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid 988
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid 990
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid 992
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid 994
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid 996
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch ECMV solenoid 998
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid1000
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid1002
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch ECMV solenoid1004
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid1006
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid1008
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch ECMV solenoid1010
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid1012
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid1014
Troubleshooting by failure code, Part 81017
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch ECMV solenoid1018
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid1020
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid1022
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch ECMV solenoid1024
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid1026
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid1028
Failure code [DXH7KA] Disconnection in output circuit of Reverse clutch ECMV solenoid1030
Failure code [DXH7KB] Ground fault in output circuit of Reverse clutch ECMV solenoid1032
Failure code [DXH7KY] Hot short in output circuit of Reverse clutch ECMV solenoid1034
Troubleshooting of electrical system (E-mode)1037
Before troubleshooting for electrical system1038
Information in troubleshooting table1044
E-1 Engine does not start (Starting motor does not turn)1045
E-2 Auto preheater does not operate1051
E-3 When starting switch is turned ON, machine monitor displays nothing1054
E-4 When starting switch is turned OFF, machine monitor cannot be operated1058
E-5 Alarm buzzer does not stop sounding1062
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section1063
E- 7 Display of character display section cannot be changed1064
E- 8 Power mode selection function does not operate normally1067
E- 9 AISS function does not operate normally1069
E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) 1071
E-11 Interaxle differential lock-up function does not operate normally1075
E-12 Display of seat belt caution lamp is abnormal1077
E-13 Turn signal lamps and pilot lamps do not operate normally1079
E-14 Night lighting is abnormal1084
E-15 Backup lamp and backup buzzer operate abnormally1091
E-16 Emergency steering system does not operate1096
E-17 Air conditioner does not operate normally1100
Troubleshooting of hydraulic and mechanical system (H-mode)1105
Troubleshooting of hydraulic and mechanical system (H-mode)1107
Information in troubleshooting table1107
H-1 Machine does not start1108
H-2 Travel is not smooth (Machine hunts)1110
H-3 Lockup is not reset1110
H-4 Start shock and gear shift shock are abnormally large1111
H-5 Gear is not shifted up1112
H-6 Travel speed or power is low1114
H-7 Start and gearshift time lag is large1118
H-8 Torque converter oil temperature is high1120
H-9 Torque converter oil temperature is low1121
H-10 Front brake does not work fully1122
H-11 Center brake does not work fully1123
H-12 Rear brake does not work fully1124
H-13 Steering wheel is heavy1125
H-14 Steering wheel does not move1126
H-15 Steering wheel waggle1127
H-16 Dump body raising speed is low1128
H-17 Dump body does not move1129
H-18 Hydraulic drift of dump body is large1130
Troubleshooting of engine (S-mode)1133
Method of using troubleshooting chart1136
S-1 Starting performance of engine is poor1140
S-2 Engine does not start1142
S-3 Engine does not pick up smoothly1146
S-4 Engine stops during operation1147
S-5 Engine does not rotate smoothly1148
S-6 Engine lack output (or lacks power)1149
S-7 Exhaust gas is black (incomplete combustion)1150
S-8 Oil consumption is excessive (or exhaust gas is blue)1152
S-9 Oil becomes dirty quickly1153
S-10 Fuel consumption is excessive1154
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1155
S-12 Oil pressure drops1156
S-13 Oil level rises (Entry of coolant or fuel)1158
S-14 Coolant temperature becomes too high (Overheating)1160
S-15 Abnormal noise is made1161
S-16 Vibration is excessive1162
50 Disassembly and assembly1165
General information on disassembly and assembly1165
Precautions before work1166
How to read this manual1167
Coating materials list1169
Special tool list1172
Sketches of special tools1177
Engine and cooling system1193
Removal and installation of fuel supply pump1194
Removal and installation of engine assembly1197
Removal and installation of cylinder head assembly1205
Removal and installation of fuel injector assembly1218
Removal and installation of radiator assembly1224
Removal and installation of cooling assembly1228
Removal and installation of aftercooler1232
Removal and installation of engine front seal1235
Removal and installation of engine rear seal1237
Replacement procedure of exhaust pipe fire prevention cover1241
Power train, Part 11251
Removal and installation of output shaft assembly1252
Disassembly and assembly of output shaft assembly1256
Removal and installation of transmission and front differential assembly1259
Disconnection and coupling of front differential and transmission1267
Disassembly and assembly of torque converter assembly1268
Disassembly and assembly of transmission assembly1276
Power train, Part 21321
Disassembly and assembly of front differential assembly1322
Removal and installation of center differential assembly1339
Disassembly and assembly of center differential assembly1342
Removal and installation of rear differential assembly1357
Disassembly and assembly of rear differential assembly1359
Power train, Part 31373
Removal and installation of front final drive and brake assembly1374
Disassembly and assembly of front final drive and brake assembly1377
Removal and installation of center final drive and brake assembly1393
Disassembly and assembly of center final drive and brake assembly1395
Removal and installation of rear final drive and brake assembly1407
Disassembly and assembly of rear final drive and brake assembly1409
Removal and installation of center axle assembly1421
Removal and installation of rear axle assembly1424
Undercarriage and frame1429
Removal and installation of front suspension cylinder assembly1430
Removal and installation of rear suspension cylinder assembly1432
Disassembly and assembly of front and rear suspension cylinder assembly1433
Removal and installation of equalizer bar assembly1435
Removal and installation of front wheel assembly1437
Removal and installation of rear front wheel assembly1438
Removal and installation of rear rear wheel assembly1438
Removal and installation of hitch frame assembly1439
Disassembly and assembly of hitch frame1447
Removal and installation of body assembly1452
Hydraulic system1455
Disassembly and assembly of steering valve1456
Removal and installation of flow amplifier valve assembly1466
Removal and installation of hoist valve assembly1468
Disassembly and assembly of hoist valve assembly1470
Disassembly and assembly of steering cylinder assembly1472
Disassembly and assembly of hoist cylinder assembly1478
Cab and its attachments1487
Removal and installation of operator’s cab1488
Removal and installation of operator’s cab glass (Stuck glass)1493
Disassembly and assembly of operator’s seat assembly1500
Removal and installation of air conditioner unit assembly1510
Electrical system1517
Removal and installation of retarder controller assembly1518
Removal and installation of transmission controller assembly1520
Removal and installation of engine controller assembly1522
90 Diagrams and drawings1525
Hydraulic diagrams and drawings1525
Power train hydraulic circuit diagram1527
Steering and hoist hydraulic circuit diagram1529
Brake hydraulic circuit diagram1531
Brake cooling hydraulic circuit diagram1532
Differential lock hydraulic circuit diagram1533
Electrical diagrams and drawings1535
Electrical circuit diagram for inside cab (1/4)1537
Electrical circuit diagram for inside cab (2/4)1539
Electrical circuit diagram for inside cab (3/4)1541
Electrical circuit diagram for inside cab (4/4)1543
Electrical circuit diagram for outside cab (1/4)1545
Electrical circuit diagram for outside cab (2/4)1547
Electrical circuit diagram for outside cab (3/4)1549
Electrical circuit diagram for outside cab (4/4)1551
Electrical circuit diagram for payload meter1553
Connectors table and arrangement drawing 1555

S.M 29/12/24