Day: June 8, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck GALEO HM350-1L, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Articulated Dump Truck GALEO HM350-1L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM015400 – Articulated Dump Truck GALEO HM350-1L Shop Manual.pdf
CEAM015501 – Articulated Dump Truck HM350-1L Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,481 pages
File Format: PDF
Language: English

MAIN SECTIONS
COVER…1
FOREWORD…2
CONTENTS…2
SAFETY…3
SAFETY NOTICE…3
IMPORTANT SAFETY NOTICE…3
GENERAL PRECAUTIONS…3
PREPARATIONS FOR WORK…3
PRECAUTIONS DURING WORK…3
GENERAL…5
HOW TO READ THE SHOP MANUAL…6
VOLUMES…6
DISTRIBUTION AND UPDATING…6
FILING METHOD…6
REVISED EDITION MARK…6
REVISIONS…6
SYMBOLS…6
HOISTING INSTRUCTIONS…7
HOISTING…7
WIRE ROPES…7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…8
Disconnection…8
Connection…8
COATING MATERIALS…10
STANDARD TIGHTENING TORQUE…12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…12
TIGHTENING TORQUE OF HOSE NUTS…13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…13
TIGHTENING TORQUE FOR FLARED NUTS…13
TIGHTENING TORQUE FOR 102 ENGINE SERIES…14
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…14
ELECTRIC WIRE CODE…16
CLASSIFICATION BY THICKNESS…16
CLASSIFICATION BY COLOR AND CODE…16
CONVERSION TABLES…17
METHOD OF USING THE CONVERSION TABLE…17
TEMPERATURE…22
01 GENERAL…23
SPECIFICATION DRAWING…24
SPECIFICATIONS…25
WEIGHT TABLE…28
FUEL, COOLANT AND LUBRICANTS…29
ENGINE OIL SPECIFICATIONS…30
NORMAL OPERATION…30
ARCTIC OPERATION…30
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS…31
FINAL DRIVE OIL SPECIFICATIONS…31
DRIVE AXLE OIL SPECIFICATIONS…31
DIESEL FUEL SPECIFICATIONS…31
COOLANT SPECIFICATIONS…32
GENERAL…32
WATER…32
ANTIFREEZE…32
SUPPLEMENTAL COOLANT ADDITIVES…34
COOLING SYSTEM TEST KIT…38
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…39
COOLING SYSTEMS…43
SPECIFICATIONS…43
POWER TRAIN…44
LOCKING DIFFERENTIAL…44
TORQUE DAMPER…46
FUNCTION…46
TORQUE CONVERTER AND TRANSMISSION…48
HYDRAULIC PIPING…48
TORQUE CONVERTER…49
SPECIFICATIONS…49
TRANSMISSION POWER FLOW…53
OIL FLOW…54
TRANSMISSION…55
OUTLINE…59
FL – R CLUTCH…60
FH – 1ST CLUTCH…61
2ND – 3RD CLUTCH…62
DIFFERENTIAL LOCK…63
CLUTCH AND TRANSMISSION OPERATIONS…65
FORWARD 1ST…66
OPERATION…66
FORWARD 2ND…67
OPERATION…67
FORWARD 3RD…68
OPERATION…68
FORWARD 4TH…69
OPERATION…69
FORWARD 5TH…70
OPERATION…70
FORWARD 6TH…71
OPERATION…71
REVERSE 1ST…72
OPERATION…72
TRANSMISSION VALVE OPERATIONS…73
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…74
ECMV LOCK-UP CLUTCH…75
OUTLINE…75
OPERATION…75
DURING DIRECT TRAVEL…76
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL…76
ECMV SPEED CLUTCH…77
ECMV OUTLINE…77
ECMV AND PROPORTIONAL SOLENOID…77
ECMV AND FILL SWITCH…77
ECMV OPERATION…78
ECMV FOR DIFFERENTIAL LOCK…80
OPERATION…80
MAIN AND TORQUE CONVERTER RELIEF VALVE…81
VALVE OUTLINE AND OPERATIONS…82
TORQUE CONVERTER RELIEF VALVE…82
MAIN RELIEF VALVE…82
OPERATION…82
DRIVE SHAFT…83
OUTLINE…83
DRIVE AXLES…84
FRONT…84
CENTER…85
REAR…86
LOCKING DIFFERENTIAL…87
FRONT…87
CENTER…89
REAR…91
OPERATION…93
TRAVELING IN A STRAIGHT LINE…93
TURNING…93
WHEN DIFFERENTIAL LOCK IS ACTUATED…93
FINAL DRIVE SYSTEM…94
FRONT…94
CENTER…96
REAR…98
FUNCTION…99
OPERATION…99
STEERING COLUMN…100
WHEEL BRAKING SYSTEM…101
PIPING LAY-OUT…101
BRAKE VALVE…102
VALVE OPERATION…103
ACCUMULATOR CHARGE VALVE…105
FUNCTION…105
VALVE OPERATION…107
ACCUMULATOR…109
FUNCTION…109
SPECIFICATIONS…109
SLACK ADJUSTER…110
FUNCTION…111
OPERATION…111
FRONT BRAKE…112
CENTER, REAR BRAKE…114
FUNCTION…116
OPERATIONS…116
PROPORTIONAL REDUCING VALVE…117
FUNCTION…117
BRAKE SYSTEM TANK…118
PARKING BRAKE…119
FUNCTION…119
PARKING BRAKE CALIPER…121
OUTLINE…121
SPRING CYLINDER…122
OUTLINE…122
PARKING BRAKE SOLENOID…123
FUNCTION…123
SUSPENSION SYSTEM…124
FRONT…124
REAR…126
OUTLINE…128
FUNCTION…128
SUSPENSION CYLINDER…129
STRUCTURE AND OPERATION…130
OSCILLATION HITCH JOINT…131
OUTLINE…133
STEERING, HOIST OIL PIPING DIAGRAM…134
DUMP BODY CONTROL…135
FUNCTION…135
HYDRAULIC TANK AND FILTER…136
FLOW AMPLIFIER VALVE…137
OUTLINE…137
OPERATION…138
STEERING VALVE…140
OUTLINE…141
STRUCTURE…141
HAND PUMP AND SLEEVE CONNECTION…142
FUNCTION OF CENTER SPRING…143
STEERING CYLINDER…144
HOIST VALVE…145
HOIST VALVE AT HOLD POSITION…147
HOIST VALVE AT RAISE POSITION…148
HOIST VALVE AT FLOAT POSITION…149
HOIST VALVE AT LOWER POSITION…150
EPC VALVE…151
FUNCTION…151
PILOT CHECK VALVE…152
HOIST CYLINDER…153
HYDRAULIC PUMP…154
STEERING, HOIST + PILOT PUMP…154
TRANSMISSION + DIFFERENTIAL LOCK PUMP…155
BRAKE COOLING + BRAKE PUMP…156
AUXILIARY STEERING PUMP…157
DIFFERENTIAL LOCK PUMP…158
TRANSMISSION PUMP…159
CAB TILT SYSTEM VIEW…160
AIR CONDITIONING SYSTEM VIEW…161
FUNCTION…161
AIR CONDITIONER UNIT…162
RECEIVER DRYER…163
CONDENSER…164
REFRIGERANT COMPRESSOR…165
MACHINE MONITOR SYSTEM…166
NETWORK DATA…166
OUTLINE…167
MACHINE MONITOR PANEL…169
OPTION SETTING CONNECTOR DIAGRAM…171
ADJUSTING MACHINE MONITOR…171
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS…172
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH…175
CHECK FUNCTION OF MONITOR LAMPS AND METERS…176
SERVICE METER DISPLAY…176
ODOMETER…176
SERVICE MODE…176
OUTLINE…176
OPERATION METHOD…178
AUTOMATIC SHIFT CONTROL SYSTEM…179
OUTLINE…180
TRANSMISSION CONTROLLER…181
OUTLINE…181
SHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE…184
GEARSHIFTING CHARACTERISTICS…184
AUTOMATIC GEARSHIFTING GRAPH…185
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD…186
SHIFT HOLD FUNCTION…187
GEARSHIFTING TIME DELAY…187
SAFETY FUNCTIONS…187
SELF-DIAGNOSTIC FUNCTION…188
AUTO AUXILIARY STEERING SYSTEM…189
OUTLINE…189
SENSORS AND SWITCHES…190
ENGINE SPEED SENSOR…190
FUNCTION…190
ACCELERATOR PEDAL SENSOR…190
OUTLINE…191
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS…192
FUNCTION…192
STEERING OIL TEMPERATURE SENSOR…192
FUNCTION…192
FUEL LEVEL SENSOR…193
FUNCTION…193
TILT SENSOR…194
FUNCTION…194
AIR CLEANER CLOGGING SENSOR…195
FUNCTION…195
HYDRAULIC OIL LEVEL SENSOR…196
FUNCTION…196
BODY POSITIONER SENSOR…197
FUNCTION…197
RETARDER CONTROL SYSTEM…198
RETARDER CONTROLLER UNIT…199
OUTLINE…199
RETARDER CONTROL FUNCTION…203
SYSTEM DIAGRAM…203
HOIST CONTROL FUNCTION…205
SYSTEM DIAGRAM…205
DIFFERENTIAL LOCK CONTROL FUNCTION…207
SYSTEM DIAGRAM…207
BRAKE CONTROL SYSTEM (E-SPEC)…209
BRAKE CONTROLLER (E-SPEC) UNIT…210
OUTLINE…210
BRAKE CONTROL FUNCTION…214
SYSTEM DIAGRAM…214
HOIST CONTROL SYSTEM…215
SYSTEM DIAGRAM…215
DIFFERENTIAL LOCK CONTROL SYSTEM…217
SYSTEM DIAGRAM…217
DUMP CONTROL LEVER…220
FUNCTION…221
OPERATION…222
DUMP CONTROL LEVER OPERATED TO FLOAT…222
DUMP CONTROL LEVER FLOAT CANCELED…222
DUMP CONTROL LEVER OPERATED TO LOWER…222
DUMP CONTROL LEVER OPERATED TO RAISE…223
DUMP CONTROL LEVER RAISE CANCELED…223
20 TESTING, ADJUSTING AND TROUBLESHOOTING…225
STANDARD VALUE TABLE…227
FOR ENGINE…227
STANDARD VALUE TABLE…228
FOR CHASSIS…228
STANDARD VALUE TABLE…232
FOR ELECTRICAL COMPONENTS…232
TOOLS…246
FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…246
ENGINE COMPONENTS…248
MEASURING EXHAUST SMOKE…248
MEASURING EXHAUST TEMPERATURE…248
ADJUSTING VALVE CLEARANCE…248
MEASURING COMPRESSION PRESSURE…248
MEASURING CRANKCASE PRESSURE…248
MEASURING ENGINE OIL PRESSURE…248
MEASURING BOOST PRESSURE…248
MEASURING FUEL PRESSURE…248
BLEEDING AIR FROM FUEL SYSTEM…248
ADJUSTING ENGINE SPEED SENSOR…249
ADJUSTING ALTERNATOR BELT…251
ADJUSTING REFRIGERANT COMPRESSOR BELT…252
TESTING TORQUE CONVERTER STALL SPEED…253
MEASURING POWER TRAIN OIL PRESSURES…254
MEASURING POWER TRAIN MAIN RELIEF PRESSURE…255
MEASURING TORQUE CONVERTER ?INLET? OIL PRESSURE…255
MEASURING TORQUE CONVERTER ?OUTLET? OIL PRESSURE…255
MEASURING TORQUE CONVERTER ?LOCK-UP? CLUTCH PRESSURE…256
MEASURING TRANSMISSION ?LO? CLUTCH PRESSURE…257
MEASURING TRANSMISSION ?HI? CLUTCH PRESSURE…257
MEASURING TRANSMISSION ?1ST? CLUTCH PRESSURE…257
MEASURING TRANSMISSION ?2ND? CLUTCH PRESSURE…258
MEASURING TRANSMISSION ?3RD? CLUTCH PRESSURE…258
MEASURING TRANSMISSION ?R? CLUTCH PRESSURE…259
MEASURING INTER-AXLE ?DIFFERENTIAL LOCK? CLUTCH PRESSURE…259
TESTING AND ADJUSTING ?L? AND ?R? DIFFERENTIAL LOCK PRESSURE…260
TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE…260
TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE…261
TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE…261
ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE…262
ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE…263
ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE…263
ADJUSTING TRANSMISSION SPEED SENSOR…264
TESTING AND ADJUSTING BRAKE OIL PRESSURE…266
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE…266
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP…266
MEASURING ACTUATION PRESSURE ON PARKING BRAKE…267
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID…268
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE…269
TESTING BRAKE PERFORMANCE…270
TESTING BRAKING PERFORMANCE OF FOOT BRAKE…270
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE…270
TESTING PARKING BRAKE BRAKING PERFORMANCE…271
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE…271
BLEEDING AIR FROM BRAKE CIRCUIT…272
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE…272
BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT…273
BLEEDING AIR FROM PARKING BRAKE CIRCUIT…273
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD…274
CHECKING BRAKE DISC…274
CHECKING BRAKE PAD…275
ADJUSTING PAD CLEARANCE…276
RELEASING EMERGENCY PARKING BRAKE…277
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE …278
MEASURING STEERING RELIEF OIL PRESSURE…278
ADJUSTING STEERING RELIEF OIL PRESSURE…279
TESTING AND ADJUSTING SUSPENSION CYLINDER…280
CHECKING CYLINDER LENGTH…280
RELEASING NITROGEN GAS…280
ADJUSTING OIL LEVEL…281
CHARGING WITH NITROGEN GAS…282
ADJUSTING CYLINDER LENGTH…283
TILTING THE CAB UP…284
PREPARATORY WORK…284
TILTING CAB UP…284
USING EXTERNAL CRANE…285
HOLDING CAB IN POSITION…285
LOWERING CAB DOWN…285
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE…286
TESTING DUMP MAIN RELIEF OIL PRESSURE…286
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE…286
MEASURING DUMP PILOT RELIEF OIL PRESSURE…287
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE…287
ADJUSTING BODY POSITIONER SENSOR…288
CHECKING SENSOR OUTPUT/INPUT VOLTAGE…288
ADJUSTING LINK LENGTH…288
CALIBRATING SYSTEM…289
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…290
ADJUSTING TRANSMISSION CONTROLLER…291
SETTING ROTARY SWITCH…291
ADJUSTING TRANSMISSION…291
ESCAPE METHOD FOR ELECTRICAL SYSTEM…292
ADJUSTING MACHINE MONITOR…296
FUNCTIONS OF MACHINE MONITOR…300
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR…300
FLOW OF MODES AND FUNCTIONS…301
OPERATION AND DISPLAYS FOR OPERATOR MODE…303
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY…311
POINTS TO REMEMBER WHEN TROUBLESHOOTING…332
SEQUENCE OF EVENTS IN TROUBLESHOOTING…334
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…335
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…335
HANDLING ELECTRONIC CONTROL UNIT…340
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…341
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…342
CHECKS BEFORE TROUBLESHOOTING…344
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…345
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…346
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS…348
CONNECTOR TYPES AND MOUNTING LOCATIONS…350
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…358
T-ADAPTER TABLE…382
CONNECTOR LAYOUT DRAWING…385
CONNECTOR ARRANGEMENT AND LOCATIONS…393
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM…399
CONTENT OF CODE DISPLAY (1)…402
CONTENT OF CODE DISPLAY (2)…404
CONTENT OF CODE DISPLAY (3)…406
CONTENT OF CODE DISPLAY (4)…408
CONTENT OF CODE DISPLAY (5)…410
CONTENT OF CODE DISPLAY (6)…412
INFORMATION CONTAINED IN TESTING PROCEDURES…414
(ENG-1) FAILURE CODE [A000N1]…416
ENGINE OVERSPEEDS (N1)…416
(ENG-2) FAILURE CODE [A570NX]…417
ENGINE OIL FILTER CLOG SENSOR SYSTEM…417
(ENG-3) FAILURE CODE [AD00L2]…418
COMMON RAIL HIGHER THAN SET VALUE…418
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]…419
COMMON RAIL PRESSURE HIGH OR LOW…419
(ENG-6) FAILURE CODE [AD10MA]…421
(ENG-7) FAILURE CODE [AD10MB]…421
(ENG-8 OR 9) FAILURE CODE [AD11KA] OR [AD11KB]…422
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM…422
(ENG-10 OR 11) FAILURE CODE [AD51KA] OR [AD51KB]…424
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM…424
(ENG-12) FAILURE CODE [ADA1KA]…425
OPEN IN NO. 1 INJECTOR SOLENOID VALVE…425
(ENG-13) FAILURE CODE [ADZKKB]…427
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE…427
(ENG-14) FAILURE CODE [ADB1KA]…430
OPEN IN NO. 2 INJECTOR SOLENOID VALVE…430
(ENG-15) FAILURE CODE [ADC1KA]…432
OPEN IN NO. 3 INJECTOR SOLENOID VALVE…432
(ENG-16) FAILURE CODE [ADD1KA]…434
OPEN IN NO. 4 INJECTOR SOLENOID VALVE…434
(ENG-17) FAILURE CODE [ADDZKB]…436
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE…436
(ENG-18) FAILURE CODE [ADE1KA]…439
OPEN IN NO. 5 INJECTOR SOLENOID VALVE…439
(ENG-19) FAILURE CODE [ADF1KA]…441
OPEN IN NO. 6 INJECTOR SOLENOID VALVE…441
(ENG-20) FAILURE CODE [B@BAZG]…443
ENGINE OIL PRESSURE DROP (ZG)…443
(ENG-21) FAILURE CODE [B@BAZK]…445
ENGINE OIL LEVEL DROP (ZK)…445
(ENG-22) FAILURE CODE [B@BCNS]…446
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)…446
(ENG-23) FAILURE CODE [D181KZ]…448
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)…448
(ENG-24) FAILURE CODE [D182KZ]…450
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)…450
(ENG-25) FAILURE CODE [D1D0KB]…452
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)…452
(ENG-26) FAILURE CODE [D5ZAKX]…454
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX)…454
(ENG-27) FAILURE CODE [DB20KT]…456
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW…456
(ENG-28) FAILURE CODE [DB22KK]…457
DROP IN VOLTAGE LOAD POWER SUPPLY (KK)…457
(ENG-29) FAILURE CODE [DB29KQ]…459
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ)…459
(ENG-30) FAILURE CODE [DB2AMA]…461
?Q? ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA)…461
(ENG-31) FAILURE CODE [KK11KB]…462
TROUBLE IN INPUT OF IGNITION SWITCH C (KB)…462
(ENG-32) FAILURE CODE [DDA1L5]…463
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)…463
(ENG-33) FAILURE CODE [DDE2L6]…465
ENGINE OIL PRESSURE DROP (L6)…465
(ENG-34) FAILURE CODE [DGE2KX]…467
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)…467
(ENG-35) FAILURE CODE [DGE3LC]…468
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6)…468
(ENG-36) FAILURE CODE [DGE4KX]…469
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX)…469
(ENG-37) FAILURE CODE [DH30KX]…470
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)…470
(ENG-38) FAILURE CODE [DH40KX]…472
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)…472
(ENG-39) FAILURE CODE [DK10KX]…474
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)…474
(ENG-40) FAILURE CODE [DLE3LC]…476
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM…476
(ENG-41) FAILURE CODE [DLE1LC]…477
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)…477
(ENG-42) NO FAILURE CODE DISPLAYED…478
ENGINE DOES NOT CRANK…478
CONNECTOR ARRANGEMENT AND LOCATIONS…485
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM…491
CONTENT OF CODE DISPLAY (1)…498
CONTENT OF CODE DISPLAY (2)…500
CONTENT OF CODE DISPLAY (3)…502
CONTENT OF CODE DISPLAY (4)…504
CONTENT OF CODE DISPLAY (5)…506
CONTENT OF CODE DISPLAY (6)…508
CONTENT OF CODE DISPLAY (7)…510
CONTENT OF CODE DISPLAY (8)…512
CONTENT OF CODE DISPLAY (9)…514
CONTENT OF CODE DISPLAY (10)…516
CONTENT OF CODE DISPLAY (11)…518
CONTENT OF CODE DISPLAY (12)…520
CONTENT OF CODE DISPLAY (13)…522
INFORMATION CONTAINED IN TESTING PROCEDURES…524
(TM-1) FAILURE CODE [1380MW]…526
LOCK-UP CLUTCH SLIPPING (MW)…526
(TM-2) FAILURE CODE [1500LO]…528
TRANSMISSION CLUTCH (LO)…528
(TM-3) FAILURE CODE [15BONX]…529
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)…529
(TM-4) FAILURE CODE [15GOMW]…531
?R? CLUTCH SLIPPING (MW)…531
(TM-5) FAILURE CODE [15HOMW]…533
?HI? CLUTCH SLIPPING (MW)…533
(TM-6) FAILURE CODE [15JOMW]…535
?LO? CLUTCH SLIPPING (MW)…535
(TM-7) FAILURE CODE [15KOMW]…537
1ST. CLUTCH SLIPPING (MW)…537
(TM-8) FAILURE CODE [15LOMW]…539
2ND. CLUTCH SLIPPING (MW)…539
(TM-9) FAILURE CODE [15MOMW]…541
3RD. CLUTCH SLIPPING (MW)…541
(TM-10) FAILURE CODE [15SBL1]…543
ECMV FOR ?R? CLUTCH NOT DISENGAGING (L1)…543
(TM-11) FAILURE CODE [15SBMA]…545
ECMV FOR ?R? CLUTCH NOT ENGAGING (MA)…545
(TM-12) FAILURE CODE [15SCL1]…547
ECMV ?HI? CLUTCH NOT DISENGAGING (L1)…547
(TM-13) FAILURE CODE [15SCMA]…549
ECMV ?HI? CLUTCH NOT DISENGAGING (MA)…549
(TM-14) FAILURE CODE [15SDL1]…551
ECMV ?LO? CLUTCH NOT DISENGAGING (L1)…551
(TM-15) FAILURE CODE [15SDMA]…553
ECMV ?LO? CLUTCH NOT ENGAGING (MA)…553
(TM-16) FAILURE CODE [15SEL1]…555
ECMV ?1ST.? CLUTCH NOT DISENGAGING (L1)…555
(TM-17) FAILURE CODE [15SEMA]…557
ECMV ?1ST.? CLUTCH NOT ENGAGING (MA)…557
(TM-18) FAILURE CODE [15SFL1]…559
ECMV ?2ND.? CLUTCH NOT DISENGAGING (L1)…559
(TM-19) FAILURE CODE [15SFMA]…561
ECMV ?2ND.? CLUTCH NOT ENGAGING (MA)…561
(TM-20) FAILURE CODE [15SGL1]…563
ECMV ?3RD.? CLUTCH NOT DISENGAGING (L1)…563
(TM-21) FAILURE CODE [15SGMA]…565
ECMV ?3RD.? CLUTCH NOT ENGAGING (MA)…565
(TM-22) FAILURE CODE [15SJL1]…567
ECMV ?LOCK-UP? CLUTCH NOT DISENGAGING (l1)…567
(TM-23) FAILURE CODE [15SJMA]…569
ECMV ?LOCK-UP? CLUTCH NOT ENGAGING (MA)…569
(TM-24) FAILURE CODE [15SKL1]…571
ECMV ?INTER-AXLE? CLUTCH NOT DISENGAGING (L1)…571
(TM-25) FAILURE CODE [15SKMA]…573
ECMV ?INTER-AXLE? CLUTCH NOT ENGAGING (MA)…573
(TM-26) FAILURE CODE [2B61MW]…575
ECMV ?INTER-AXLE? CLUTCH SLIPPING (MW)…575
(TM-27) FAILURE CODE [2F00KM]…577
PARKING BRAKE SYSTEM INDICATING FAILURE (KM)…577
(TM-28) FAILURE CODE [6014NX]…579
HYDRAULIC TANK FILTER CLOGGED (NX)…579
(TM-29) FAILURE CODE [989A00]…581
POSSIBLE ENGINE OVER SPEED CONDITION (00)…581
(TM-30) FAILURE CODE [989AKZ]…582
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ)…582
(TM-31)FAILURE CODE [989D00]…584
REAR OVERTURN SIGNAL OUT OF RANGE (00)…584
(TM-32)FAILURE CODE [AA10NX]…586
AIR CLEANER CLOG INDICATION (NX)…586
(TM-33) FAILURE CODE [AB00MA]…588
ALTERNATOR NOT CHARGING PROPERLY (MA)…588
(TM-34) FAILURE CODE [B@BCZK]…589
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)…589
(TM-35) FAILURE CODE [B@HAZK]…591
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)…591
(TM-36) FAILURE CODE [B@JANS]…592
STEERING OIL OVERHEAT CONDITION INDICATED (ZK)…592
(TM-37) FAILURE CODE [D1B0KZ]…593
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)…593
(TM-38) FAILURE CODE [D5ZBKX]…595
DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX)…595
(TM-39) FAILURE CODE [D5ZCKZ]…597
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ)…597
(TM-40) FAILURE CODE [DF10KA]…599
FORCED NEUTRAL DEMAND SIGNAL (L4)…599
(TM-41) FAILURE CODE [D5ZEKX]…601
ENGINE LOAD SIGNAL OUT OF RANGE (KX)…601
(TM-42) FAILURE CODE [DAQ0KK]…603
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…603
(TM-43) FAILURE CODE [DAQ1KK]…605
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…605
(TM-44) FAILURE CODE [DAQ2KK]…607
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK)…607
(TM-45) FAILURE CODE [DAQ3KK]…609
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…609
(TM-46) FAILURE CODE [DAQ5KP]…611
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)…611
(TM-47) FAILURE CODE [DAQ9KM]…613
MISTAKEN OPERATION SETTING (KP)…613
(TM-48) FAILURE CODE [DAQ9KM]…614
NO MATCH IN MODEL SELECTION SIGNAL (KP)…614
(TM-49) FAILURE CODE [DAQAKQ]…615
TRANSMISSION CONTROLLER ROTARY SWITCH…615
(TM-50) FAILURE CODE [DAQSMA]…615
TRANSMISSION FUNCTION INOPERABLE…615
(TM-51) FAILURE CODE [DDTFKA]…616
?LOCK-UP? CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)…616
(TM-52) FAILURE CODE [DDTFKA]…618
?LOCK-UP? CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)…618
(TM-53) FAILURE CODE [DDTHKA]…620
?HI? CLUTCH SYSTEM OPEN OR SHORTED (KA)…620
(TM-54) FAILURE CODE [DDTJKA]…622
?LO? CLUTCH SYSTEM OPEN OR SHORTED (KA)…622
(TM-55) FAILURE CODE [DDTKKA]…624
1ST. CLUTCH SYSTEM OPEN OR SHORTED (KA)…624
(TM-56) FAILURE CODE [DDTLKA]…626
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)…626
(TM-57) FAILURE CODE [DDTMKA]…628
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KA)…628
(TM-58) FAILURE CODE [DDTNKA]…630
?R? CLUTCH SYSTEM OPEN OR SHORTED (KA)…630
(TM-59) FAILURE CODE [DF10KA]…632
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)…632
(TM-60) FAILURE CODE [DF10KB]…634
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)…634
(TM-61) FAILURE CODE [DGF1KX]…636
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)…636
(TM-63) FAILURE CODE [DGR3L8]…637
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)…637
(TM-64) FAILURE CODE [DGR4L8]…639
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)…639
(TM-65) FAILURE CODE [DGT1LX]…641
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)…641
(TM-66) FAILURE CODE [DHT5KX]…642
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX)…642
(TM-67) FAILURE CODE [DHT5L6]…644
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6)…644
(TM-68) FAILURE CODE [DJF1KA]…646
FUEL LEVEL SENSOR OUT OF RANGE (L6)…646
(TM-69) FAILURE CODE [DK11KX]…648
THROTTLE ANGLE SENSOR OUT OF RANGE (KX)…648
(TM-70) FAILURE CODE [DLE2KA]…650
ENGINE SPEED SENSOR OPEN OR SHORTED (KA)…650
(TM-71) FAILURE CODE [DLE2LC]…651
ENGINE SPEED SENSOR OPEN OR SHORTED (LC)…651
(TM-72) FAILURE CODE [DLF1KA]…652
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…652
(TM-73) FAILURE CODE [DLF1LC]…653
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…653
(TM-74) FAILURE CODE [DLF2KA]…654
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…654
(TM-75) FAILURE CODE [DLF2LC]…655
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…655
(TM-76) FAILURE CODE [DLT3KA]…656
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…656
(TM-77) FAILURE CODE [DLT3LC]…658
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…658
(TM-78) FAILURE CODE [DXH0KA]…660
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA)…660
(TM-79) FAILURE CODE [DXH0KB]…662
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB)…662
(TM-80) FAILURE CODE [DXH1KA]…664
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA)…664
(TM-81) FAILURE CODE [DXH1KB]…666
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB)…666
(TM-82) FAILURE CODE [DXH2KA]…668
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)…668
(TM-83) FAILURE CODE [DXH2KB]…670
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)…670
(TM-84) FAILURE CODE [DXH3KA]…672
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA)…672
(TM-85) FAILURE CODE [DXH3KB]…674
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB)…674
(TM-86) FAILURE CODE [DXH4KA]…676
1ST. CLUTCH SYSTEM OPEN OR SHORTED (KA)…676
(TM-87) FAILURE CODE [DXH4KB]…678
1ST. CLUTCH SYSTEM OPEN OR SHORTED (KB)…678
(TM-88) FAILURE CODE [DXH5KA]…680
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)…680
(TM-89) FAILURE CODE [DXH5KB]…682
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB)…682
(TM-90) FAILURE CODE [DXH6KA]…684
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)…684
(TM-91) FAILURE CODE [DXH6KB]…686
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)…686
(TM-92) FAILURE CODE [DXH7KA]…688
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA)…688
(TM-93) FAILURE CODE [DXH7KB]…690
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB)…690
(TM-94) NO FAILURE CODE DISPLAYED…692
BACK-UP LIGHTS AND ALARM DO NOT OPERATE…692
CONNECTOR ARRANGEMENT AND LOCATIONS…697
BK CONTROL SYSTEM CIRCUIT DIAGRAM…703
CONTENT OF CODE DISPLAY (1)…710
CONTENT OF CODE DISPLAY (2)…712
CONTENT OF CODE DISPLAY (3)…714
CONTENT OF CODE DISPLAY (4)…716
CONTENT OF CODE DISPLAY (5)…718
CONTENT OF CODE DISPLAY (6)…720
CONTENT OF CODE DISPLAY (7)…722
INFORMATION CONTAINED IN TESTING PROCEDURES…724
(BK-1) FAILURE CODE [2A62L1]…726
FRONT DIFFERENTIAL CONTROL VALVE (L1)…726
(BK-2) FAILURE CODE [2A62LH]…728
FRONT DIFFERENTIAL CONTROL VALVE (LH)…728
(BK-3) FAILURE CODE [2B62L1]…730
REAR DIFFERENTIAL LOCK CONTROL VALVE (L1)…730
(BK-4) FAILURE CODE [2B62LH]…732
REAR DIFFERENTIAL LOCK CONTROL VALVE (LH)…732
(BK-5) FAILURE CODE [2C4MNX]…734
BRAKE COOLING FILTER CLOG INDICATED (NX)…734
(BK-6) FAILURE CODE [2D02CA]…736
LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)…736
(BK-7) FAILURE CODE [2D01CA]…737
RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)…737
(BK-8) FAILURE CODE [2D03CA]…738
CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)…738
(BK-9) FAILURE CODE [2D04CA]…739
CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA)…739
(BK-12) FAILURE CODE [2G42ZG]…740
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)…740
(BK-13) FAILURE CODE [2G43ZG]…741
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)…741
(BK-14) FAILURE CODE [D1C0KZ]…742
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)…742
(BK-15) FAILURE CODE [D5ZFKZ]…744
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)…744
(BK-16) FAILURE CODE [D5ZGKZ]…746
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)…746
(BK-17) FAILURE CODE [DB10KK]…748
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…748
(BK-18) FAILURE CODE [DB11KK]…750
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…750
(BK-19) FAILURE CODE [DB12KK]…752
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)…752
(BK-20) FAILURE CODE [DB13KK]…754
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…754
(BK-21) FAILURE CODE [DB19KM]…756
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM)…756
(BK-22) FAILURE CODE [DB1SKQ]…757
RETARDER CONTROL S-NET LINE MISMATCHED (KQ)…757
(BK-23) FAILURE CODE [DHU2KX]…758
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)…758
(BK-24) FAILURE CODE [DHU3KX]…760
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX)…760
(BK-25) FAILURE CODE [DK51L5]…762
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)…762
(BK-26) FAILURE CODE [DK52KX]…764
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)…764
(BK-27) FAILURE CODE [DK53L8]…766
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)…766
(BK-28) FAILURE CODE [DK54KX]…768
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)…768
(BK-29) FAILURE CODE [DLF4KA]…770
TRANSMISSION OUTPUT SHAFT ?F? SPEED SENSOR OUT OF RANGE (KA)…770
(BK-30) FAILURE CODE [DLT3KA]…771
TRANSMISSION OUTPUT SHAFT ?R? SPEED SENSOR OUT OF RANGE (KA)…771
(BK-31) FAILURE CODE [DW71KZ]…773
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)…773
(BK-32) FAILURE CODE [DK72KX]…774
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)…774
(BK-33) FAILURE CODE [DW73KZ]…776
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ)…776
(BK-34) FAILURE CODE [DX11KA]…778
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)…778
(BK-35) FAILURE CODE [DX11KB]…779
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)…779
(BK-36) FAILURE CODE [DX11KY]…780
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY)…780
(BK-37) FAILURE CODE [DX12KA]…781
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)…781
(BK-38) FAILURE CODE [DX12KB]…782
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)…782
(BK-39) FAILURE CODE [DX13KA]…783
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)…783
(BK-40) FAILURE CODE [DX13KB]…785
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)…785
(BK-41) FAILURE CODE [DX13KY]…787
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)…787
(BK-42) FAILURE CODE [DX14KZ]…789
REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)…789
(BK-43) FAILURE CODE [DX15KZ]…790
FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)…790
(BK-44) NO FAILURE CODE DISPLAYED…792
PARKING BRAKE SYSTEM FAILURE…792
CONNECTOR ARRANGEMENT AND LOCATIONS…797
MON CONTROL SYSTEM CIRCUIT DIAGRAM…803
CONTENT OF CODE DISPLAY (1)…808
INFORMATION CONTAINED IN TESTING PROCEDURES…810
(MON-1) FAILURE CODE [B@C6NS]…812
FRONT BRAKE OIL OVERHEAT CONDITION (NS)…812
(MON-3) FAILURE CODE [B@C8NS]…813
CENTER BRAKE OIL OVERHEAT CONDITION (NS)…813
(MON-4) FAILURE CODE [B@CENS]…814
TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS)…814
(MON-5) FAILURE CODE [DAF0KM]…815
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)…815
(MON-6) FAILURE CODE [DAF9KM]…817
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)…817
(MON-7) FAILURE CODE [DAFSKQ]…818
MODEL SELECTION DOES NOT MATCH (KQ)…818
(MON-8) FAILURE CODE [AQSKR]…819
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…819
(MON-9) FAILURE CODE [DA1SKR]…821
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…821
(MON-10) FAILURE CODE [DA2SKR]…823
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…823
(MON-11) FAILURE CODE [DV00KB]…825
DEFECTIVE ALARM BUZZER (KB)…825
(MON-12) NO FAILURE CODE DISPLAYED…827
WITH IGNITION KEY ?ON? NO DISPLAY IS SHOWN ON MONITOR PANEL…827
(MON-13) NO FAILURE CODE DISPLAYED…829
WITH IGNITION KEY ?OFF? NO DISPLAY IS SHOWN ON MONITOR PANEL…829
(MON-14) NO FAILURE CODE DISPLAYED…831
ALARM BUZZER DOES NOT SOUND…831
(MON-15) NO FAILURE CODE DISPLAYED…833
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL…833
(MON-16) NO FAILURE CODE DISPLAYED…834
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED…834
(MON-17) NO FAILURE CODE DISPLAYED…835
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE…835
(MON-18) NO FAILURE CODE DISPLAYED…837
POWER MODE SWITCH DOES NOT WORK PROPERLY…837
(MON-19) NO FAILURE CODE DISPLAYED…838
AISS FUNCTION DOES NOT WORK PROPERLY…838
(MON-20) NO FAILURE CODE DISPLAYED…839
RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROPERLY…839
(MON-20) NO FAILURE CODE DISPLAYED…841
LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK PROPERLY…841
(MON-21) NO FAILURE CODE DISPLAYED…843
INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY…843
(MON-22) NO FAILURE CODE DISPLAYED…844
EXHAUST BRAKE DOES NOT WORK PROPERLY…844
(MON-23) NO FAILURE CODE DISPLAYED…846
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY…846
(MON-24) NO FAILURE CODE DISPLAYED…847
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY…847
(MON-25) NO FAILURE CODE DISPLAYED…850
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY…850
(H-1)…856
THE MACHINE DOES NOT MOVE…856
(H-2) AND (H-3)…857
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY)…857
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING)…857
(H-4) AND (H-5)…858
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS…858
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE…858
(H-6)…859
MACHINE LACKS POWER OR SPEED WHEN TRAVELING…859
(H-6)…860
ABNORMAL OPERATION AT SOME SPEED RANGES…860
(H-6)…861
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE…861
(H-7)…862
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES…862
(H-8)…863
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)…863
(H-9)…864
TORQUE CONVERTER OIL PRESSURE LOW…864
(H-10)…865
FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY…865
(H-11)…866
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE…866
(H-12)…867
STEERING EFFORT SEeMS HEAVY…867
(H-13)…868
STEERING SYSTEM DOES NOT OPERATE…868
(H-14)…869
STEERING WHEEL VIBRATES…869
(H-15)…870
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER…870
(H-16)…871
DUMP OPERATIONS DO NOT WORK…871
(H-17)…872
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY…872
30 DISASSEMBLY AND ASSEMBLY…873
HOW TO USE MANUAL…876
PRECAUTIONS WHEN CARRYING OUT REPAIR…877
SPECIAL TOOL LIST…880
SKETCHES OF SPECIAL TOOLS…885
CONNECTOR REPAIR PROCEDURES…897
CONTACT TERMINAL REMOVAL (HD30 TYPE)…897
STRIPING INSULATION…898
CRIMPING CONTACT TERMINAL (HD30 TYPE)…899
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…900
CONTACT TERMINAL REMOVAL (DT TYPE)…901
STRIPING INSULATION…902
CRIMPING CONTACT TERMINAL (DT TYPE)…903
INSERTION OF CONTACT TERMINAL (DT TYPE)…904
ENGINE REMOVAL AND INSTALLATION PROCEDURES…905
REMOVAL…905
INSTALLATION…908
RADIATOR REMOVAL AND INSTALLATION PROCEDURES…910
REMOVAL…910
INSTALLATION…912
OUTPUT SHAFT SYSTEM…913
REMOVAL…913
INSTALLATION…915
OUTPUT SHAFT DIAGRAM…917
OUTPUT SHAFT ASSEMBLY PROCEDURES…918
TRANSMISSION AND FRONT DIFFERENTIAL…921
REMOVAL…921
INSTALLATION…928
SPLITTING DIFFERENTIAL AND TRANSMISSION ASSEMBLY…930
SEPARATING…930
REATTACHING…931
TORQUE CONVERTER OVERHAUL PROCEDURES…932
DISASSEMBLY…932
ASSEMBLY…937
TRANSMISSION OVERHAUL PROCEDURES…942
DISASSEMBLY…942
ASSEMBLY…960
FRONT DIFFERENTIAL OVERHAUL PROCEDURES…991
DISASSEMBLY…991
ASSEMBLY…1000
CENTER DIFFERENTIAL…1014
REMOVAL…1014
REMOVING DIFFERENTIAL COUPLING FLANGE…1016
INSTALLATION…1017
OVERHAUL PROCEDURES…1019
DISASSEMBLY…1019
ASSEMBLY…1026
REAR DIFFERENTIAL…1038
REMOVAL…1038
INSTALLATION…1039
OVERHAUL PROCEDURES…1040
DISASSEMBLY…1040
ASSEMBLY…1044
FRONT FINAL DRIVE AND BRAKE…1053
REMOVAL…1053
INSTALLATION…1055
OVERHAUL PROCEDURES…1056
DISASSEMBLY…1056
ASSEMBLY…1063
CENTER FINAL DRIVE AND BRAKE…1073
REMOVAL…1073
INSTALLATION…1074
OVERHAUL PROCEDURES…1075
DISASSEMBLY…1075
ASSEMBLY…1081
REAR FINAL DRIVE…1090
REMOVAL…1090
INSTALLATION…1091
OVERHAUL PROCEDURES…1092
DISASSEMBLY…1092
ASSEMBLY…1094
AXLE REMOVAL AND INSTALLATION PROCEDURES…1100
CENTER AXLE REMOVAL…1100
CENTER AXLE INSTALLATION…1103
REAR AXLE REMOVAL…1104
REAR AXLE INSTALLATION…1106
PARKING BRAKE SYSTEM…1107
REMOVAL…1107
INSTALLATION…1108
CALIPER OVERHAUL PROCEDURES…1109
DISASSEMBLY…1109
ASSEMBLY…1109
BRAKE PAD REPLACEMENT…1111
REMOVAL…1111
INSTALLATION…1111
SUSPENSION SYSTEM…1112
FRONT CYLINDER REMOVAL…1112
FRONT CYLINDER INSTALLATION…1113
REAR CYLINDER REMOVAL…1113
REAR CYLINDER INSTALLATION…1114
EQUALIZER BAR REMOVAL…1114
EQUALIZER BAR INSTALLATION…1116
TRUCK WHEELS…1117
FRONT WHEEL REMOVAL…1117
INSTALLATION OF FRONT WHEEL…1117
REAR TANDEM WHEELS…1118
CENTER WHEEL REMOVAL…1118
CENTER WHEEL INSTALLATION…1118
REAR WHEEL REMOVAL…1118
REAR WHEEL INSTALLATION…1118
ARTICULATED HITCH SYSTEM…1119
REMOVAL…1119
INSTALLATION…1124
OVERHAUL PROCEDURES…1126
DISASSEMBLY…1126
ASSEMBLY…1127
ORBITAL STEERING UNIT…1130
UNIT BREAKDOWN VIEW…1130
OVERHAUL PROCEDURES…1132
DISASSEMBLY…1132
ASSEMBLY…1135
FLOW AMPLIFIER VALVE…1141
REMOVAL…1141
INSTALLATION…1141
HOIST VALVE UNIT…1142
REMOVAL…1142
INSTALLATION…1142
OVERHAUL PROCEDURES…1143
DISASSEMBLY…1143
ASSEMBLY…1144
HYDRAULIC CYLINDER OVERHAUL PROCEDURES…1145
STEERING CYLINDER DISASSEMBLY…1145
STEERING CYLINDER ASSEMBLY…1146
HOIST CYLINDER DISASSEMBLY…1149
HOIST CYLINDER ASSEMBLY…1151
TRUCK BODY ASSEMBLY…1155
REMOVAL…1155
INSTALLATION…1156
OPERATOR?S SEAT…1157
DISASSEMBLY…1157
ASSEMBLY…1164
90 OTHERS…1171
CAB…1173
CLIMATE CONTROL SYSTEM…1173
CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER…1175
CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER…1177
LIGHTING WIPER AND RELAY BANK…1179
RELAY AND SWITCH CIRCUITS…1181
MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS…1183
DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS…1185
DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT…1187
RETARDER SYSTEM…1189
RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING…1191
TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL…1193
TRANSMISSION CONTROLLER…1195
TO HARNESS OUTSIDE OF CAB…1197
TO HARNESS OUTSIDE OF CAB AND TO ENGINE…1199
CHASSIS…1201
SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OF CAB…1201
TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS…1203
TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS…1205
CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS…1207
CHASSIS SENSOR SYSTEMS…1209
CONNECTORS OUTSIDE OF CAB…1211
ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS…1213
DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM…1215
BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR…1217
TRANSMISSION SELECTOR SYSTEM…1219

Komatsu Articulated Dump Truck GALEO HM350-1L Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-2R, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM300-2R workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 2,023 pages
File Format: PDF
Language: English

SEN02269-06 – Articulated Dump Truck HM300-2R Shop Manual.pdf
GEN00091-00 – Articulated Dump Truck HM300-2R Field Assembly Instruction.pdf
PEN00193-09 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf
PEN00470-11 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual.pdf

MAIN SECTIONS
GEN00091-00 – Articulated Dump Truck HM300-2R Field Assembly Instruction…2
COVER…2
Contents…3
1 Drawings of removed units…5
2 Dimensions of removed units…5
3 Assembly procedure, necessary equipments, and schedule…6
4 Necessary tools and equipments…6
5 Assembly procedure No…7
0100 Positioning bare machine…7
0150 Installation of rear monitor…8
0200 Installing engine hood mirrors…9
0250 Installation of right and left mudguards…10
0300 Adjusting N2 gas of front and rear suspensions…11
Attached sheet: Mirror adjustment for reference…12
PEN00193-09 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual…15
COVER…15
FOREWORD…16
BEFORE READING THIS MANUAL…17
SAFETY INFORMATION…18
INTENDED USE…19
USE OF MACHINE…19
DIRECTIONS OF MACHINE…19
VISIBILITY FROM OPERATOR'S SEAT…19
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…20
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…20
ENGINE SERIAL NO. PLATE…20
SERVICE METER POSITION…21
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…21
CONTENTS…22
SAFETY…26
SAFETY…27
SAFETY LABELS…30
POSITION FOR ATTACHING SAFETY LABELS…31
SAFETY LABELS…32
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…38
PRECAUTIONS BEFORE STARTING OPERATION…38
PREPARATIONS FOR SAFE OPERATION…38
FIRE PREVENTION…40
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…41
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…43
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…43
UNAUTHORIZED MODIFICATION…43
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…44
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…44
PRECAUTIONS FOR OPERATION…45
PRECAUTIONS FOR JOBSITE…45
STARTING ENGINE…47
OPERATION…50
TRANSPORTATION…54
TOWING…55
PRECAUTIONS FOR MAINTENANCE…56
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…56
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…61
TIRES…66
OPERATION…68
GENERAL VIEW…69
GENERAL VIEW OF MACHINE…69
GENERAL VIEW OF CONTROLS AND GAUGES…70
EXPLANATION OF COMPONENTS…72
MACHINE MONITOR…72
OTHER FUNCTIONS OF MACHINE MONITOR…93
SWITCHES…97
CONTROL LEVERS AND PEDALS…107
BODY PIVOT PIN…112
ARTICULATE LOCK…112
LOCATION OF FIRE EXTINGUISHER…113
DUST INDICATOR…113
CIRCUIT BREAKER…113
FUSES…114
CAR RADIO…117
CAR STEREO…123
AIR CONDITIONER…131
OPERATION…136
CHECK BEFORE STARTING ENGINE…136
STARTING ENGINE…153
OPERATIONS, CHECKS AFTER STARTING ENGINE…155
STOPPING ENGINE…156
CHECKS AFTER STOPPING ENGINE…156
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…157
SHIFTING GEAR…162
TRAVELING DOWNHILL…164
STEERING THE MACHINE…170
OPERATION USING DIFFERENTIAL LOCK…171
LOADING OPERATIONS…172
DUMP OPERATIONS…174
CAB TILT OPERATION…176
PRECAUTIONS FOR OPERATION…179
PARKING MACHINE…180
CHECKS AFTER COMPLETION OF WORK…181
LOCKING…181
HANDLING TIRES…182
DETERMINING AND MAINTAINING TRAVEL ROAD…183
DETERMINING TRAVEL ROAD…183
MAINTAINING TRAVEL ROAD…183
TRANSPORTATION…184
PRECAUTIONS WHEN TRANSPORTING…184
STEPS FOR TRANSPORTATION…184
METHOD OF SECURING MACHINE…185
METHOD OF LIFTING MACHINE…186
COLD WEATHER OPERATION…190
PRECAUTIONS FOR LOW TEMPERATURE…190
PRECAUTIONS AFTER COMPLETION OF WORK…191
AFTER COLD WEATHER…192
LONG-TERM STORAGE…193
BEFORE STORAGE…193
DURING STORAGE…193
AFTER STORAGE…193
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…193
TROUBLESHOOTING…194
AFTER RUNNING OUT OF FUEL…194
IF TRANSMISSION HAS TROUBLE…194
METHOD OF LOWERING DUMP BODY IN EMERGENCY…194
METHOD OF TOWING MACHINE…195
IF BATTERY IS DISCHARGED…199
OTHER TROUBLE…203
MAINTENANCE…210
GUIDES TO MAINTENANCE…211
OUTLINE OF SERVICE…213
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…213
OUTLINE OF ELECTRIC SYSTEM…217
WEAR PARTS…218
WEAR PARTS LIST…218
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…219
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…220
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…221
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…222
TORQUE LIST…222
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…224
SAFETY CRITICAL PARTS…225
MAINTENANCE SCHEDULE CHART…226
MAINTENANCE SCHEDULE CHART…226
SERVICE PROCEDURE…229
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…229
WHEN REQUIRED…230
CHECK BEFORE STARTING…254
EVERY 50 HOURS SERVICE…255
EVERY 250 HOURS SERVICE…256
EVERY 500 HOURS SERVICE…267
EVERY 1000 HOURS SERVICE…274
EVERY 2000 HOURS SERVICE…284
EVERY 4000 HOURS SERVICE…291
EVERY 6000 HOURS SERVICE…294
EVERY 8000 HOURS SERVICE…295
SPECIFICATIONS…296
SPECIFICATIONS…297
ATTACHMENTS, OPTIONS…298
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…299
EXPLANATION OF COMPONENTS…299
METHOD OF OPERATION…300
HANDLING PAYLOAD METER HM…301
FEATURES OF PAYLOAD METER HM…301
METHOD OF USING ACCURATELY…302
GENERAL LOCATIONS…304
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…307
EXTERNAL DISPLAY LAMPS…309
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…311
OPERATION OF SWITCHES…314
ABNORMALITY AND WARNING DISPLAY (ERROR CODE)…327
WHEN ERROR CODE F-09 IS DISPLAYED…328
PROCEDURE WHEN DOWNLOADING…329
OTHERS…332
USE OF REAR VIEW MONITOR…333
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…333
SETTING OF REAR VIEW MONITOR…336
CAUTIONS WHEN USING REAR VIEW MONITOR…336
HANDLING DUMPING COUNTER…337
HANDLING BATTERY DISCONNECTOR SWITCH…338
HANDLING MACHINES EQUIPPED WITH KOMTRAX…340
BASIC PRECAUTIONS…340
INDEX…342
PEN00470-11 – Articulated Dump Truck HM300-2R Operation & Maintenance Manual…346
COVER…346
FOREWORD…347
BEFORE READING THIS MANUAL…348
SAFETY INFORMATION…349
INTENDED USE…350
USE OF MACHINE…350
DIRECTIONS OF MACHINE…350
VISIBILITY FROM OPERATOR'S SEAT…351
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…352
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…352
ENGINE SERIAL NO. PLATE…352
SERVICE METER POSITION…353
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…353
CONTENTS…354
SAFETY…359
SAFETY…360
SAFETY LABELS…363
POSITION FOR ATTACHING SAFETY LABELS…364
SAFETY LABELS…365
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…372
PREPARATIONS FOR SAFE OPERATION…372
EPARATIONS FOR SAFE OPERATION…372
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…375
DO NOT GET CAUGHT IN ARTICULATING PORTION AND DUMP BODY…377
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…377
UNAUTHORIZED MODIFICATION…377
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…378
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…378
PRECAUTIONS FOR OPERATION…379
PRECAUTIONS FOR JOBSITE…379
STARTING ENGINE…381
OPERATION…384
TRANSPORTATION…388
TOWING…389
PRECAUTIONS FOR MAINTENANCE…390
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…390
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…395
TIRES…400
OPERATION…403
GENERAL VIEW…404
GENERAL VIEW OF MACHINE…404
GENERAL VIEW OF CONTROLS AND GAUGES…405
EXPLANATION OF COMPONENTS…407
MACHINE MONITOR…407
OTHER FUNCTIONS OF MACHINE MONITOR…428
SWITCHES…432
CONTROL LEVERS AND PEDALS…443
BODY PIVOT PIN…448
ARTICULATE LOCK…448
LOCATION OF FIRE EXTINGUISHER…449
DUST INDICATOR…449
CIRCUIT BREAKER…449
FUSES…450
CAR RADIO…453
CAR STEREO…459
AIR CONDITIONER…467
OPERATION…472
CHECK BEFORE STARTING ENGINE…472
STARTING ENGINE…490
OPERATIONS, CHECKS AFTER STARTING ENGINE…492
CANCELING DUMP BODY HOLD CONDITION…493
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…494
SHIFTING GEAR…499
TRAVELING DOWNHILL…501
STEERING THE MACHINE…507
OPERATION USING DIFFERENTIAL LOCK…508
LOADING OPERATIONS…509
DUMP OPERATIONS…511
CAB TILT OPERATION…513
PRECAUTIONS FOR OPERATION…516
PARKING MACHINE…517
CHECKS AFTER COMPLETION OF WORK…518
LOCKING…518
HANDLING TIRES…519
DETERMINING AND MAINTAINING TRAVEL ROAD…520
DETERMINING TRAVEL ROAD…520
MAINTAINING TRAVEL ROAD…520
TRANSPORTATION…521
PRECAUTIONS WHEN TRANSPORTING…521
STEPS FOR TRANSPORTATION…521
METHOD OF SECURING MACHINE…522
METHOD OF LIFTING MACHINE…523
COLD WEATHER OPERATION…527
PRECAUTIONS FOR LOW TEMPERATURE…527
PRECAUTIONS AFTER COMPLETION OF WORK…528
AFTER COLD WEATHER…529
LONG-TERM STORAGE…530
BEFORE STORAGE…530
DURING STORAGE…530
AFTER STORAGE…530
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…530
TROUBLESHOOTING…531
AFTER RUNNING OUT OF FUEL…531
IF TRANSMISSION HAS TROUBLE…532
METHOD OF LOWERING DUMP BODY IN EMERGENCY…532
METHOD OF TOWING MACHINE…533
IF BATTERY IS DISCHARGED…537
OTHER TROUBLE…541
MAINTENANCE…547
GUIDES TO MAINTENANCE…548
OUTLINE OF SERVICE…550
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…550
OUTLINE OF ELECTRIC SYSTEM…554
WEAR PARTS…555
WEAR PARTS LIST…555
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…556
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…557
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…559
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…560
TORQUE LIST…560
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…562
SAFETY CRITICAL PARTS…563
MAINTENANCE SCHEDULE CHART…564
MAINTENANCE SCHEDULE CHART…564
SERVICE PROCEDURE…567
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…567
WHEN REQUIRED…568
CHECK BEFORE STARTING…590
EVERY 50 HOURS SERVICE…591
EVERY 250 HOURS SERVICE…592
EVERY 500 HOURS SERVICE…603
EVERY 1000 HOURS SERVICE…610
EVERY 2000 HOURS SERVICE…628
EVERY 4000 HOURS SERVICE…635
EVERY 6000 HOURS SERVICE…638
EVERY 8000 HOURS SERVICE…639
SPECIFICATIONS…641
SPECIFICATIONS…642
ATTACHMENTS, OPTIONS…645
HANDLING AUTOMATIC RETARDER, ACCELERATOR CONTROL(ARAC)…646
EXPLANATION OF COMPONENTS…646
METHOD OF OPERATION…647
HANDLING PAYLOAD METER HM…648
FEATURES OF PAYLOAD METER HM…648
METHOD OF USING ACCURATELY…649
GENERAL LOCATIONS…651
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…654
EXTERNAL DISPLAY LAMPS…656
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…658
OPERATION OF SWITCHES…661
ABNORMALITY AND WARNING DISPLAY (ERROR CODE)…674
WHEN ERROR CODE F-09 IS DISPLAYED…675
PROCEDURE WHEN DOWNLOADING…676
OTHERS…679
USE OF REAR VIEW MONITOR…680
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…680
SETTING OF REAR VIEW MONITOR…683
CAUTIONS WHEN USING REAR VIEW MONITOR…683
HANDLING DUMPING COUNTER…684
HANDLING BATTERY DISCONNECTOR SWITCH…685
HANDLING MACHINES EQUIPPED WITH KOMTRAX…687
BASIC PRECAUTIONS…687
INDEX…689
SEN02269-06 – Articulated Dump Truck HM300-2R Shop Manual…693
COVER…693
00 Index and foreword…0
Index…695
Composition of shop manual…696
Table of contents…698
Foreword and general information…709
Safety notice…710
How to read the shop manual…715
Explanation of terms for maintenance standard…717
Handling of electric equipment and hydraulic component…719
Handling of connectors newly used for engines…728
How to read electric wire code…731
Precautions when carrying out operation…734
Method of disassembling and connecting push-pull type coupler…737
Standard tightening torque table…740
Conversion table…744
01 Specification…0
Specification and technical data…751
Specification drawings…752
Specifications…753
Weight table…756
Fuel, coolant and lubricants…757
10 Structure, function and maintenance standard…0
Engine and cooling system…761
Radiator, oil cooler, aftercooler…762
Output shaft…763
Power train, Part 1…767
Power train skeleton…768
Torque converter and transmission hydraulic piping…770
Brake cooling oil control valve (BCV)…772
Power train pump…773
Torque converter…776
Transmission…782
Transmission control valve…810
ECMV…811
Main relief, torque converter relief valve…818
Power train, Part 2…821
Drive shaft…822
Axle…823
Differential…826
Limited slip differential…832
Final drive…836
Steering system…843
Steering column…844
Brake system…847
Brake piping…848
Brake valve…850
Accumulator charge valve…853
Accumulator…857
Slack adjuster…858
Brake…860
Proportional reducing valve…865
Brake system tank…866
Parking brake…868
Parking brake solenoid…872
Undercarriage and frame…875
Suspension…876
Suspension cylinder…882
Oscillation hitch…884
Hydraulic system…889
Steering, hoist oil pressure piping diagram…890
Dump body control…891
Hydraulic tank and filter…892
Flow amp valve…893
Steering valve…896
Steering cylinder…900
Hoist valve…902
EPC valve…908
Hoist cylinder…909
Hydraulic pump…910
Cab and its attachments…913
ROPS cab…914
Cab tilt…915
Air conditioner…916
Rear view monitor…924
Controller related…927
Electrical system, Part 1…929
Machine monitor system…930
Electrical system, Part 2…951
Automatic shift control system…952
Retarder control system…984
Auto emergency steering system…996
Dump control lever…997
Electrical system, Part 3…1003
Payload meter (Card type)…1004
Electrical system, Part 4…1037
Sensors, switches…1038
KOMTRAX terminal system (If equipped)…1046
20 Standard value table…0
Standard service value table…1049
Standard value table for engine…1050
Standard value table for chassis…1051
30 Testing and adjusting…0
Testing and adjusting, Part 1…1059
Tools for testing, adjusting, and troubleshooting…1061
Sketches of special tools…1066
Measuring engine speed…1067
Measuring intake air pressure (boost pressure)…1068
Measuring exhaust temperature…1069
Measuring exhaust gas color…1071
Adjusting valve clearance…1072
Measuring compression pressure…1074
Measuring blow-by pressure…1076
Measuring engine oil pressure…1077
Handling of fuel system devices…1078
Releasing residual pressure from fuel system…1078
Testing fuel pressure…1079
Testing fuel return and leak amount…1080
Bleeding air from fuel circuit…1083
Testing fuel circuit for leakage…1085
Testing and adjusting alternator belt tension…1086
Testing and adjusting air conditioner compressor belt tension…1086
Adjusting the body mount…1087
Testing and adjusting, Part 2…1089
Measuring torque converter stall speed…1091
Measuring power train oil pressure…1092
Adjusting transmission speed sensor…1100
Testing and adjusting brake oil pressure…1102
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas…1106
Testing brake performance…1109
Bleeding air from brake circuit…1110
Measuring wear of wheel brake disc…1111
Measuring wear of parking brake pad…1112
Method for emergency release of parking brake…1114
Testing and adjusting steering circuit oil pressure…1115
Testing and adjusting suspension cylinder…1117
Method of tilting cab up…1121
Testing and adjusting dump circuit oil pressure…1123
Adjusting body positioner sensor…1126
Procedure for adjusting length of spring in body heating spherical joint…1127
Handling engine controller high voltage circuit…1127
Adjusting transmission controller…1128
Method for emergency escape at electrical system failure…1129
Testing and adjusting, Part 3…1135
Setting and adjusting various equipments…1136
Special function of machine monitor (EMMS)…1147
How to start operation of KOMTRAX terminal…1181
Lamp display of KOMTRAX terminal…1184
Pm Clinic check sheet…1187
40 Troubleshooting…0
Failure code table and fuse locations…1191
Failure code table…1192
Before troubleshooting by failure codes…1199
General information on troubleshooting…1203
Points to remember when troubleshooting…1204
Sequence of events in troubleshooting…1205
Checks before troubleshooting…1206
Classification and procedures for troubleshooting…1207
Information in troubleshooting table…1208
Connection table for connector pin numbers…1210
T-branch box and T- branch adapter table…1246
Troubleshooting by failure code (Display of code), Part 1…1251
Failure code [1500L0] (Dual engagement)…1253
Failure code [15B0NX] (Transmission oil filter: Clogged)…1254
Failure code [15F0KM] (R → F shifting abuse 1: Operational error or incorrect setting)…1256
Failure code [15F0MB] (R → F shifting abuse 2: Functional deterioration)…1256
Failure code [15F7KM] (forward clutch disc abuse)…1257
Failure code [15G0MW] (R clutch: Slipping)…1258
Failure code [15G7KM] (reverse clutch disc abuse)…1260
Failure code [15H0MW] (Hi clutch: Slipping)…1261
Failure code [15J0MW] (Lo clutch: Slipping)…1264
Failure code [15K0MW] (1st clutch: Slipping)…1266
Failure code [15L0MW] (2nd clutch: Slipping)…1268
Failure code [15M0MW] (3rd clutch: Slipping)…1270
Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)…1272
Failure code [15SBMA] (R clutch solenoid: Malfunction)…1276
Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)…1278
Failure code [15SCMA] (Hi clutch solenoid: Malfunction)…1282
Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.)…1284
Failure code [15SDMA] (Lo clutch solenoid: Malfunction)…1286
Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)…1290
Failure code [15SEMA] (1st clutch solenoid: Malfunction)…1294
Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.)…1296
Failure code [15SFMA] (2nd clutch solenoid: Malfunction)…1300
Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.)…1302
Failure code [15SGMA] (3rd clutch solenoid: Malfunction)…1306
Failure code [15SJMA] (Lockup clutch solenoid: Malfunction)…1308
Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)…1310
Failure code [2F00KM] (Parking brake: Error in operation or setting)…1312
Failure code [2G42ZG] (Front accumulator: Oil pressure too low)…1314
Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)…1314
Troubleshooting by failure code (Display of code), Part 2…1317
Failure code [989A00] (Engine over run prevention command signal: Operating)…1319
Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)…1319
Failure code [AA10NX] (Air cleaner element: Clogged)…1320
Failure code [AB00MA] (Alternator: Malfunction)…1322
Failure code [B@BAZK] (Engine oil : Level too low)…1323
Failure code [B@BCNS] (Eng overheat)…1324
Failure code [B@BCZK] (Radiator coolant: Level too low)…1325
Failure code [B@BFZK] (Fuel level: Level too low)…1326
Failure code [B@C6NS] (Front brake oil: Overheat)…1327
Failure code [B@C8NS] (Center brake oil: Overheat)…1327
Failure code [B@CENS] (Torque converter: Overheat)…1328
Failure code [B@HAZK] (Hydraulic tank oil: Level too low)…1329
Failure code [B@JANS] (Steering oil: Overheat)…1330
Failure code [CA111] (Abnormality in engine controller)…1331
Failure code [CA115] (Abnormal engine Ne and Bkup sensors)…1332
Failure code [CA122] (Charge pressure sensor too high)…1334
Failure code [CA123] (Charge pressure sensor too low)…1336
Failure code [CA131] (Throttle sensor tool high)…1338
Failure code [CA132] (Throttle sensor tool low)…1340
Failure code [CA135] (Oil pressure sensor too high)…1342
Failure code [CA141] (Oil pressure sensor too low)…1344
Failure code [CA144] (Coolant temperature sensor too high)…1346
Failure code [CA145] (Coolant temperature sensor too low)…1348
Failure code [CA153] (Charge temperature sensor too high)…1350
Failure code [CA154] (Charge temperature sensor too low)…1352
Failure code [CA187] (Sensor power source 2 too low)…1352
Failure code [CA221] (Atmospheric sensor too high)…1354
Failure code [CA222] (Atmospheric sensor too low)…1356
Failure code [CA227] (Sensor power source 2 too high)…1358
Failure code [CA234] (Engine over speed)…1360
Failure code [CA238] (Abnormal power source for Ne speed sensor)…1362
Failure code [CA263] (Fuel temperature sensor too high)…1364
Failure code [CA265] (Fuel temperature sensor too low)…1366
Failure code [CA271] (PCV1 short circuit)…1367
Failure code [CA272] (PCV1 disconnection)…1368
Failure code [CA273] (PCV2 short circuit)…1369
Failure code [CA274] (PCV2 disconnection)…1370
Failure code [CA322] (Injector No. 1 system disconnection or short circuit)…1372
Failure code [CA323] (Injector No. 5 system disconnection or short circuit)…1374
Failure code [CA324] (Injector No. 3 system disconnection or short circuit)…1376
Failure code [CA325] (Injector No. 6 system disconnection or short circuit)…1378
Failure code [CA331] (Injector No. 2 system disconnection or short circuit)…1380
Failure code [CA332] (Injector No. 4 system disconnection or short circuit)…1382
Troubleshooting by failure code (Display of code), Part 3…1385
Failure code [CA342] (Abnormal engine controller data consistency)…1387
Failure code [CA351] (Abnormal injector drive circuit)…1388
Failure code [CA352] (Sensor power source 1 too low)…1389
Failure code [CA386] (Sensor power source 1 too high)…1390
Failure code [CA431] Idle validation switch error…1392
Failure code [CA432] (Abnormal process with idle validation switch)…1396
Failure code [CA441] (Power source voltage too low)…1397
Failure code [CA442] (Power source voltage too high)…1397
Failure code [CA449] (Common rail pressure too high 2)…1398
Failure code [CA451] (Common rail pressure sensor too high)…1400
Failure code [CA452] (Common rail pressure sensor too low)…1402
Failure code [CA553] (Common rail pressure too high 1)…1402
Failure code [CA554] (In-range error of common rail pressure sensor)…1403
Failure code [CA559] (Loss of pressure feed from supply pump 1)…1404
Failure code [CA689] (Abnormal engine Ne speed sensor)…1408
Failure code [CA731] (Abnormal engine Bkup speed sensor phase)…1410
Failure code [CA757] (Loss of all engine controller data)…1410
Failure code [CA778] (Abnormal engine Bkup speed sensor)…1412
Failure code [CA1633] (Abnormal KOMNET)…1414
Failure code [CA2185] (Throttle sensor power source too high)…1416
Failure code [CA2186] (Throttle sensor power source too low)…1418
Failure code [CA2249] (Loss of pressure feed from supply pump 2)…1418
Failure code [CA2555] (Disconnection in intake air heater relay)…1419
Failure code [CA2556] (Intake air heater relay short circuit)…1420
Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)…1422
Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)…1424
Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)…1426
Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)…1428
Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)…1429
Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)…1430
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)…1432
Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)…1432
Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low)…1433
Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low)…1434
Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal)…1435
Failure code [DB1QMA] (Retarder controller option setting: Malfunction)…1435
Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled)…1436
Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled)…1438
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)…1440
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection)…1442
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)…1444
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)…1445
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)…1446
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)…1447
Failure code [DF10KA] (Gear shift lever: Disconnection)…1448
Failure code [DF10KB] (Gear shift lever: Short circuit)…1451
Troubleshooting by failure code (Display of code), Part 4…1455
Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)…1458
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit)…1460
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)…1462
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)…1464
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)…1466
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)…1468
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)…1470
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)…1472
Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop)…1474
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)…1476
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range)…1478
Failure code [DJF1KA] (Fuel level sensor: Disconnection)…1480
Failure code [DK51L5] (Retarder lever potentiometer: Potentiometer signal is inconsistent with switch signal)…1482
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range)…1484
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)…1486
Failure code [DK54KX] (Body positioner sensor: Input signal out of range)…1488
Failure code [DKH0KX] (Inclination sensor: Inclination out of range)…1490
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)…1492
Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)…1493
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)…1494
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal)…1495
Failure code [DLF4KA] (Differential speed sensor: Disconnection)…1496
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)…1497
Failure code [DV00KB] (Alarm buzzer output: Short circuit)…1498
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit)…1500
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)…1502
Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)…1504
Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)…1506
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1…1508
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)…1510
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)…1511
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)…1512
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)…1514
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)…1516
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection)…1518
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)…1519
Troubleshooting by failure code (Display of code), Part 5…1521
Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line)…1523
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)…1524
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)…1526
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)…1527
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)…1528
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)…1529
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)…1530
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)…1531
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)…1532
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)…1533
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)…1534
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)…1536
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)…1538
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)…1540
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)…1544
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)…1546
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)…1548
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)…1552
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)…1554
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)…1556
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)…1560
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)…1562
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)…1564
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)…1568
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)…1570
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)…1572
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)…1576
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)…1578
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)…1580
Troubleshooting of electrical system (E-mode)…1585
Before troubleshooting of electrical system…1587
Contents of troubleshooting table…1590
E-1 Engine does not start…1591
E-2 Automatic preheating does not operate…1594
E-3 Machine monitor does not display all, when starting switch is turned ON…1598
E-4 Machine monitor does not operate when starting switch is OFF…1600
E-5 Alarm buzzer does not sound…1602
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly…1603
E-7 Selection of display in character display section cannot be changed…1604
E-8 Power mode selecting function does not operate properly…1608
E-9 AISS function does not operate properly…1609
E-10 Seat belt caution lamp does not display properly…1610
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly…1611
E-12 Night illumination (lighting) does not work properly…1614
E-13 Emergency steering does not operate…1621
E-14 Dump lever does not operate normally…1626
E-15 KOMTRAX system does not operate normally…1628
E-16 Electric priming pump does not operate or does not stop automatically…1632
E-17 Air conditioner does not operate normally…1634
Troubleshooting of hydraulic and mechanical system (H-mode)…1641
Contents of troubleshooting table…1643
H-1 Machine does not start…1644
H-2 Machine does not travel smoothly (machine jerks)…1646
H-3 Lockup cannot be cancelled…1646
H-4 Excessive shock when starting or shifting…1647
H-5 Transmission does not shift up…1648
H-6 Machine lacks power or speed when traveling…1649
H-7 Time lag is excessive when starting or shifting gear…1651
H-8 Torque converter oil temperature is high…1652
H-9 Torque converter oil pressure is low…1653
H-10 Front brake is ineffective…1654
H-11 Center brake is ineffective…1655
H-12 Steering wheel is heavy…1656
H-13 Steering wheel does not work…1657
H-14 Steering wheel vibrates…1658
H-15 Dump body lifting speed is slow…1659
H-16 Dump body does not work…1660
H-17 Excessive hydraulic drift of dump body…1661
Troubleshooting of engine (S-mode)…1663
How to use a troubleshooting chart…1665
S-1 Engine is hard to start…1668
S-2 Engine does not start…1669
S-3 Engine does not pick up smoothly…1672
S-4 Engine stops during operations…1673
S-5 Engine does not rotate smoothly…1674
S-6 Engine lacks output (or lacks power)…1675
S-7 Exhaust gas color is black (incomplete combustion)…1676
S-8 Oil consumption is excessive (or exhaust gas color is blue)…1677
S-9 Oil gets contaminated prematurely…1678
S-10 Fuel consumption is excessive…1679
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…1680
S-12 Oil pressure drops…1681
S-13 Oil level rises (coolant or fuel mixes)…1682
S-14 Coolant temperature rises too high (overheat)…1683
S-15 Abnormal noise comes out…1684
S-16 Vibration is excessive…1685
S-17 Air cannot be bled from fuel circuit…1686
50 Disassembly and assembly…0
General information on disassembly and assembly…1689
How to read this manual…1690
Coating materials list…1692
Special tool list…1695
Sketches of special tools…1700
Engine and cooling system (SAA6D125E-5)…1715
Removal and installation of fuel supply pump assembly…1716
Removal and installation of fuel injector assembly…1721
Removal and installation of cylinder head assembly…1726
Removal and installation of engine front seal…1738
Removal and installation of engine rear seal…1740
Removal and installation of engine assembly…1744
Removal and installation of radiator assembly…1752
Removal and installation of cooling assembly…1754
Removal and installation of output shaft assembly…1757
Disassembly and assembly of output shaft assembly…1762
Power train, Part 1…1767
Removal and installation of transmission and front differential assembly…1768
Disconnection and connection of front differential assembly and transmission assembly…1774
Disassembly and assembly of front differential assembly…1776
Disassembly and assembly of torque converter assembly…1791
Power train, Part 2…1799
Disassembly and assembly of transmission assembly…1800
Power train, Part 3…1843
Removal and installation of center differential assembly…1844
Disassembly and assembly of center differential assembly…1848
Removal and installation of rear differential assembly…1865
Disassembly and assembly of rear differential assembly…1867
Power train, Part 4…1883
Removal and installation of front final drive and brake assembly…1884
Disassembly and assembly of front final drive and brake assembly…1887
Removal and installation of center final drive and brake assembly…1897
Disassembly and assembly of center final drive and brake assembly…1899
Power train, Part 5…1909
Disassembly and assembly of rear final drive assembly…1910
Removal and installation of center axle assembly…1917
Removal and installation of rear axle assembly…1920
Undercarriage and frame…1923
Removal and installation of front suspension cylinder assembly…1924
Removal and installation of rear suspension cylinder assembly…1926
Removal and installation of equalizer bar…1927
Removal and installation of hitch frame assembly…1929
Disassembly and assembly of hitch frame assembly…1939
Hydraulic system…1947
Removal and installation of flow amp valve…1948
Removal and installation of hoist valve assembly…1950
Disassembly and assembly of steering cylinder assembly…1953
Disassembly and assembly of hoist cylinder assembly…1957
Body…1963
Removal and installation of body assembly…1964
Cab and its attachments…1967
Removal and installation of operator’s cab…1968
Removal and installation of operator’s cab glass (Stuck glass)…1973
Disassembly and assembly of operator’s seat assembly (If equipped)…1980
Electrical system…1991
Removal and installation of air conditioner unit assembly…1992
Removal and installation of engine controller…1997
Removal and installation of retarder controller…1999
Removal and installation of transmission controller assembly…2001
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…2003
Power train hydraulic circuit diagram…2005
Steering and hoist hydraulic circuit diagram…2006
Brake hydraulic circuit diagram…2008
Brake cooling hydraulic circuit diagram…2009
Electrical diagrams and drawings…2011
Electrical circuit diagram for inside cab (1/4)…2013
Electrical circuit diagram for inside cab (2/4)…2014
Electrical circuit diagram for inside cab (3/4)…2015
Electrical circuit diagram for inside cab (4/4)…2016
Electrical circuit diagram for outside cab (1/3)…2017
Electrical circuit diagram for outside cab (2/3)…2018
Electrical circuit diagram for outside cab (3/3)…2019
Electrical circuit diagram for payload meter…2020
Connectors table and arrangement drawing…2021

Komatsu Articulated Dump Truck HM300-2R Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-1L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM300-1L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM015200 – Articulated Dump Truck HM300-1L Shop Manual.pdf
CEAM015401 – Articulated Dump Truck HM300-1L Operation & Maintenance Manual.pdf

Total Pages: 1,491 pages
File Format: PDF
Language: English

MAIN SECTIONS
COVER…1
FOREWORD…2
SAFETY…3
SAFETY NOTICE…3
IMPORTANT SAFETY NOTICE…3
GENERAL PRECAUTIONS…3
PREPARATIONS FOR WORK…3
PRECAUTIONS DURING WORK…3
CONTENTS…2
GENERAL…5
GENERAL…5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…5
TESTING, ADJUSTING AND TROUBLESHOOTING…5
DISASSEMBLY AND ASSEMBLY…5
DRAWINGS AND SCHEMATICS…5
HOW TO READ THE SHOP MANUAL…6
Volumes…6
Distribution And Updating…6
Filing Method…6
Revised Edition Mark…6
Revisions…6
Symbols…6
HOISTING INSTRUCTIONS…7
HOISTING…7
Wire Ropes…7
PUSH PULL COUPLER…8
Type 1…8
Disconnection…8
Connection…8
Type 2…9
Disconnection…9
Connection…9
Type 3…10
Disconnection…10
Connection…10
COATING MATERIALS…11
STANDARD TIGHTENING TORQUE…13
Torque For Bolts And Nuts…13
Torque For Hose Nuts…14
Torque For Split Flange Bolts…14
Torque For Flared Nuts…14
Torques For O-ring Boss Piping Joints…15
Tightening Torques For O-ring Boss Plugs…15
Torque Table For Hoses (Taper Seal Type And Face Seal Type)…15
ELECTRIC WIRE CODE…16
Classification By Thickness…16
Classification By Color And Code…16
CONVERSION TABLES…17
Method Of Using The Conversion Table…17
01 GENERAL…23
SPECIFICATION DRAWING…24
SPECIFICATIONS…25
WEIGHT TABLE…28
FUEL, COOLANT AND LUBRICANTS…29
ENGINE OIL SPECIFICATIONS…30
NORMAL OPERATION…30
ARCTIC OPERATION…30
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS…31
FINAL DRIVE OIL SPECIFICATIONS…31
DRIVE AXLE OIL SPECIFICATIONS…31
DIESEL FUEL SPECIFICATIONS…31
COOLANT SPECIFICATIONS…32
GENERAL…32
WATER…32
ANTIFREEZE…32
SUPPLEMENTAL COOLANT ADDITIVES…34
COOLING SYSTEM TEST KIT…38
10 STRUCTURE AND FUNCTION…39
COOLING SYSTEMS…42
POWER TRAIN…43
DRIVE SYSTEM…43
OUTPUT SHAFT…45
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…47
TORQUE CONVERTER…48
TRANSMISSION POWER FLOW…52
WHEN LOCK-UP CLUTCH IS DISENGAGED…52
WHEN LOCK-UP CLUTCH IS ENGAGED…52
OIL FLOW…53
TRANSMISSION…54
FL – R CLUTCH…59
FH – 1ST CLUTCH…60
2ND – 3RD CLUTCH…61
DIFFERENTIAL LOCK…62
CLUTCH AND TRANSMISSION OPERATIONS…64
FORWARD 1ST…65
FORWARD 2ND…66
FORWARD 3RD…67
FORWARD 4TH…68
FORWARD 5TH…69
FORWARD 6TH…70
REVERSE 1ST…71
TRANSMISSION VALVE…72
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…73
ECMV LOCK-UP CLUTCH…74
DURING DIRECT TRAVEL…75
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL…75
ECMV SPEED CLUTCH…76
ECMV OUTLINE…76
ECMV AND PROPORTIONAL SOLENOID…76
ECMV AND FILL SWITCH…76
ECMV OPERATION…77
ECMV FOR DIFFERENTIAL LOCK…79
MAIN AND TORQUE CONVERTER RELIEF VALVE…80
TORQUE CONVERTER RELIEF VALVE…81
MAIN RELIEF VALVE…81
DRIVE SHAFT…82
DRIVE AXLE…83
FRONT…83
CENTER…84
REAR…85
LOCKING DIFFERENTIAL…86
FRONT…86
CENTER…88
REAR…90
LIMITED SLIP DIFFERENTIAL…92
FINAL DRIVE SYSTEM…96
FRONT…96
CENTER…98
REAR…100
STEERING COLUMN…102
WHEEL BRAKING SYSTEM…103
PIPING DIAGRAM…103
BRAKE VALVE…105
ACCUMULATOR CHARGE VALVE…108
ACCUMULATOR…112
SLACK ADJUSTER…113
FRONT BRAKE…115
CENTER, REAR BRAKE…117
PROPORTIONAL REDUCING VALVE…120
BRAKE SYSTEM TANK…121
PARKING BRAKE…122
PARKING BRAKE CALIPER…124
SPRING CYLINDER…125
PARKING BRAKE SOLENOID…126
SUSPENSION SYSTEM…128
FRONT…128
REAR…130
SUSPENSION CYLINDER…134
OSCILLATION HITCH JOINT…136
STEERING, HOIST OIL PIPING DIAGRAM…139
DUMP BODY CONTROL…140
HYDRAULIC TANK AND FILTER…141
FLOW AMPLIFIER VALVE…142
STEERING VALVE…145
HAND PUMP AND SLEEVE CONNECTION…147
FUNCTION OF CENTER SPRING…148
STEERING CYLINDER…149
HOIST VALVE…150
HOIST VALVE AT HOLD POSITION…152
HOIST VALVE AT RAISE POSITION…153
HOIST VALVE AT FLOAT POSITION…154
HOIST VALVE AT LOWER POSITION…155
EPC VALVE…156
PILOT CHECK VALVE…157
HOIST CYLINDER…158
HYDRAULIC PUMP…159
STEERING, HOIST + PILOT PUMP…159
TRANSMISSION + FRONT BRAKE COOLING PUMP…160
BRAKE COOLING + BRAKE PUMP…161
AUXILIARY STEERING PUMP…162
CAB TILT SYSTEM VIEW…163
AIR CONDITIONING SYSTEM VIEW…164
AIR CONDITIONER UNIT…165
RECEIVER DRYER…166
CONDENSER…167
REFRIGERANT COMPRESSOR…168
MACHINE MONITOR SYSTEM…169
NETWORK DATA…169
MACHINE MONITOR PANEL…172
OPTION SETTING CONNECTOR DIAGRAM…174
ADJUSTING MACHINE MONITOR…174
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS…175
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH…178
CHECK FUNCTION OF MONITOR LAMPS AND METERS…179
SERVICE METER DISPLAY…179
ODOMETER…179
SERVICE MODE…179
OPERATION METHOD…181
AUTOMATIC SHIFT CONTROL SYSTEM…182
TRANSMISSION CONTROLLER…184
SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGE…187
GEAR SHIFTING CHARACTERISTICS…187
AUTOMATIC GEAR SHIFTING GRAPH…188
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD…189
SHIFT HOLD FUNCTION…190
GEAR SHIFTING TIME DELAY…190
SAFETY FUNCTIONS…190
SELF-DIAGNOSTIC FUNCTION…191
EMERGENCY STEERING SYSTEM…192
SENSORS AND SWITCHES…193
ENGINE SPEED SENSOR…193
ACCELERATOR PEDAL SENSOR…193
ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS…195
STEERING OIL TEMPERATURE SENSOR…195
FUEL LEVEL SENSOR…196
TILT SENSOR…197
AIR CLEANER CLOGGING SENSOR…198
HYDRAULIC OIL LEVEL SENSOR…199
BODY POSITIONER SENSOR…200
RETARDER CONTROL SYSTEM…201
RETARDER CONTROLLER UNIT…202
RETARDER CONTROL FUNCTION…206
HOIST CONTROL FUNCTION…208
DIFFERENTIAL LOCK CONTROL FUNCTION…210
BRAKE CONTROL SYSTEM (E-SPEC)…212
BRAKE CONTROLLER (E-SPEC) UNIT…213
BRAKE CONTROL FUNCTION…217
HOIST CONTROL SYSTEM…218
DIFFERENTIAL LOCK CONTROL SYSTEM…220
DUMP CONTROL LEVER…222
20 TESTING, ADJUSTING AND TROUBLESHOOTING…227
STANDARD VALUE TABLE FOR ENGINE…229
STANDARD VALUE TABLE FOR CHASSIS…230
STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS…234
TOOLS FOR TESTING AND ADJUSTING…248
ENGINE COMPONENTS…249
MEASURING EXHAUST SMOKE…249
MEASURING EXHAUST TEMPERATURE…249
ADJUSTING VALVE CLEARANCE…249
MEASURING COMPRESSION PRESSURE…249
MEASURING CRANKCASE PRESSURE…249
MEASURING ENGINE OIL PRESSURE…249
MEASURING BOOST PRESSURE…249
MEASURING FUEL PRESSURE…249
BLEEDING AIR FROM FUEL SYSTEM…249
ADJUSTING ENGINE SPEED SENSOR…250
ADJUSTING ALTERNATOR BELT…252
TESTING TORQUE CONVERTER STALL SPEED…253
POWER TRAIN OIL PRESSURES…254
MEASURING POWER TRAIN MAIN RELIEF PRESSURE…255
MEASURING TORQUE CONVERTER INLET OIL PRESSURE…255
MEASURING TORQUE CONVERTER OUTLET OIL PRESSURE…255
MEASURING TORQUE CONVERTER LOCK-UP CLUTCH PRESSURE…256
MEASURING TRANSMISSION LO CLUTCH PRESSURE…257
MEASURING TRANSMISSION HI CLUTCH PRESSURE…257
MEASURING TRANSMISSION 1ST CLUTCH PRESSURE…257
MEASURING TRANSMISSION 2ND CLUTCH PRESSURE…258
MEASURING TRANSMISSION 3RD CLUTCH PRESSURE…258
MEASURING TRANSMISSION R CLUTCH PRESSURE…259
MEASURING INTER-AXLE DIFFERENTIAL LOCK CLUTCH PRESSURE…259
ADJUSTING TRANSMISSION SPEED SENSOR…260
BRAKE OIL PRESSURE…262
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE…262
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP…262
MEASURING ACTUATION PRESSURE ON PARKING BRAKE…263
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID…264
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE…265
TESTING BRAKE PERFORMANCE…266
TESTING BRAKING PERFORMANCE OF FOOT BRAKE…266
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE…266
TESTING PARKING BRAKE BRAKING PERFORMANCE…267
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE…267
BLEEDING AIR FROM BRAKE CIRCUIT…268
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE…268
BLEEDING AIR FROM WHEEL BRAKE…269
BLEEDING AIR FROM PARKING BRAKE CIRCUIT…269
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD…270
CHECKING BRAKE DISC…270
CHECKING BRAKE PAD…271
ADJUSTING PAD CLEARANCE…272
RELEASING EMERGENCY PARKING BRAKE…273
STEERING CIRCUIT PRESSURE…273
MEASURING STEERING RELIEF OIL PRESSURE…273
ADJUSTING STEERING RELIEF OIL PRESSURE…274
SUSPENSION CYLINDER…275
CHECKING CYLINDER LENGTH…275
RELEASING NITROGEN GAS…275
ADJUSTING OIL LEVEL…276
CHARGING WITH NITROGEN GAS…277
ADJUSTING CYLINDER LENGTH…278
TILTING THE CAB…279
PREPARATORY WORK…279
TILTING CAB UP…279
USING EXTERNAL CRANE…280
HOLDING CAB IN POSITION…280
LOWERING CAB DOWN…280
DUMP CIRCUIT PRESSURE…281
TESTING DUMP MAIN RELIEF OIL PRESSURE…281
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE…282
MEASURING DUMP PILOT RELIEF OIL PRESSURE…282
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE…283
BODY POSITIONER SENSOR…284
CHECKING SENSOR OUTPUT/INPUT VOLTAGE…284
ADJUSTING LINK LENGTH…284
CALIBRATING SYSTEM…285
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…286
TRANSMISSION CONTROLLER…287
SETTING ROTARY SWITCH…287
ADJUSTING TRANSMISSION…287
ESCAPE METHOD FOR ELECTRICAL SYSTEM…288
MACHINE MONITOR…292
FUNCTIONS OF MACHINE MONITOR…296
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR…296
FLOW OF MODES AND FUNCTIONs…297
OPERATION AND DISPLAYS FOR OPERATOR MODE…299
SWITCHING TO SERVICE MODE AND SCREEN DISPLAY…307
POINTS TO REMEMBER WHEN TROUBLESHOOTING…328
SEQUENCE OF EVENTS IN TROUBLESHOOTING…330
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…331
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT…331
HANDLING ELECTRONIC CONTROL UNIT…336
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…337
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…338
CHECKS BEFORE TROUBLESHOOTING…340
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS…341
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS…342
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS…344
CONNECTOR TYPES AND MOUNTING LOCATIONS…346
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…354
T-ADAPTER TABLE…379
CONNECTOR LAYOUT DRAWING…382
CONNECTOR ARRANGEMENT AND LOCATIONS…391
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM…397
CONTENT OF CODE DISPLAY (1)…400
CONTENT OF CODE DISPLAY (2)…402
CONTENT OF CODE DISPLAY (3)…404
CONTENT OF CODE DISPLAY (4)…406
CONTENT OF CODE DISPLAY (5)…408
CONTENT OF CODE DISPLAY (6)…410
INFORMATION CONTAINED IN TESTING PROCEDURES…412
(ENG-1) FAILURE CODE [A000N1]…414
ENGINE OVERSPEEDS (N1)…414
(ENG-2) FAILURE CODE [A570NX]…415
ENGINE OIL FILTER CLOG SENSOR SYSTEM…415
(ENG-3) FAILURE CODE [AD00L2]…416
COMMON RAIL HIGHER THAN SET VALUE…416
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]…417
COMMON RAIL PRESSURE HIGH OR LOW…417
(ENG-6) FAILURE CODE [AD10MA]…419
(ENG-7) FAILURE CODE [AD10MB]…419
(ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB]…420
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM…420
(ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB]…422
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC2 SYSTEM…422
(ENG-12) FAILURE CODE [ADA1KA]…423
OPEN IN NO. 1 INJECTOR SOLENOID VALVE…423
(ENG-13) FAILURE CODE [ADZKKB]…424
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE…424
(ENG-14) FAILURE CODE [ADB1KA]…428
OPEN IN NO. 2 INJECTOR SOLENOID VALVE…428
(ENG-15) FAILURE CODE [ADC1KA]…430
OPEN IN NO. 3 INJECTOR SOLENOID VALVE…430
(ENG-16) FAILURE CODE [ADD1KA]…432
OPEN IN NO. 4 INJECTOR SOLENOID VALVE…432
(ENG-17) FAILURE CODE [ADDZKB]…434
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE…434
(ENG-18) FAILURE CODE [ADE1KA]…438
OPEN IN NO. 5 INJECTOR SOLENOID VALVE…438
(ENG-19) FAILURE CODE [ADF1KA]…440
OPEN IN NO. 6 INJECTOR SOLENOID VALVE…440
(ENG-20) FAILURE CODE [B@BAZG]…442
ENGINE OIL PRESSURE DROP (ZG)…442
(ENG-21) FAILURE CODE [B@BAZK]…444
ENGINE OIL LEVEL DROP (ZK)…444
(ENG-22) FAILURE CODE [B@BCNS]…446
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)…446
(ENG-23) FAILURE CODE [D181KZ]…448
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)…448
(ENG-24) FAILURE CODE [D182KZ]…450
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)…450
(ENG-25) FAILURE CODE [D1D0KB]…452
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)…452
(ENG-26) FAILURE CODE [D5ZAKX]…454
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX)…454
(ENG-27) FAILURE CODE [DB20KT]…456
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW…456
(ENG-28) FAILURE CODE [DB22KK]…458
DROP IN VOLTAGE LOAD POWER SUPPLY (KK)…458
(ENG-29) FAILURE CODE [DB29KQ]…460
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ)…460
(ENG-30) FAILURE CODE [DB2AMA]…462
?Q? ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA)…462
(ENG-31) FAILURE CODE [KK11KB]…463
TROUBLE IN INPUT OF ignition switch C (KB)…463
(ENG-32) FAILURE CODE [DDA1L5]…464
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)…464
(ENG-33) FAILURE CODE [DDE2L6]…466
ENGINE OIL PRESSURE DROP (L6)…466
(ENG-34) FAILURE CODE [DGE2KX]…468
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)…468
(ENG-35) FAILURE CODE [DGE3LC]…469
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6)…469
(ENG-36) FAILURE CODE [DGE4KX]…470
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX)…470
(ENG-37) FAILURE CODE [DH30KX]…471
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)…471
(ENG-38) FAILURE CODE [DH40KX]…472
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)…472
(ENG-39) FAILURE CODE [DK10KX]…474
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)…474
(ENG-40) FAILURE CODE [DLE3LC]…476
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM…476
(ENG-41) FAILURE CODE [DLE1LC]…477
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)…477
(ENG-42) NO FAILURE CODE DISPLAYED…478
ENGINE DOES NOT CRANK…478
CONNECTOR ARRANGEMENT AND LOCATIONS…486
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM…492
CONTENT OF CODE DISPLAY (1)…498
CONTENT OF CODE DISPLAY (2)…500
CONTENT OF CODE DISPLAY (3)…502
CONTENT OF CODE DISPLAY (4)…504
CONTENT OF CODE DISPLAY (5)…506
CONTENT OF CODE DISPLAY (6)…508
CONTENT OF CODE DISPLAY (7)…510
CONTENT OF CODE DISPLAY (8)…512
CONTENT OF CODE DISPLAY (9)…514
CONTENT OF CODE DISPLAY (10)…516
CONTENT OF CODE DISPLAY (11)…518
CONTENT OF CODE DISPLAY (12)…520
CONTENT OF CODE DISPLAY (13)…522
INFORMATION CONTAINED IN TESTING PROCEDURES…524
(TM-1) FAILURE CODE [1380MW]…526
LOCK-UP CLUTCH SLIPPING (MW)…526
(TM-2) FAILURE CODE [1500LO]…528
TRANSMISSION CLUTCH (LO)…528
(TM-3) FAILURE CODE [15BONX]…530
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)…530
(TM-4) FAILURE CODE [15GOMW]…532
?R? CLUTCH SLIPPING (MW)…532
(TM-5) FAILURE CODE [15HOMW]…534
?HI? CLUTCH SLIPPING (MW)…534
(TM-6) FAILURE CODE [15JOMW]…536
?LO? CLUTCH SLIPPING (MW)…536
(TM-7) FAILURE CODE [15KOMW]…538
1ST CLUTCH SLIPPING (MW)…538
(TM-8) FAILURE CODE [15LOMW]…540
2ND CLUTCH SLIPPING (MW)…540
(TM-9) FAILURE CODE [15MOMW]…542
3RD CLUTCH SLIPPING (MW)…542
(TM-10) FAILURE CODE [15SBL1]…544
ECMV FOR ?R? CLUTCH NOT DISENGAGING (L1)…544
(TM-11) FAILURE CODE [15SBMA]…546
ECMV FOR ?R? CLUTCH NOT ENGAGING (MA)…546
(TM-12) FAILURE CODE [15SCL1]…548
ECMV ?HI? CLUTCH NOT DISENGAGING (L1)…548
(TM-13) FAILURE CODE [15SCMA]…550
ECMV ?HI? CLUTCH NOT DISENGAGING (MA)…550
(TM-14) FAILURE CODE [15SDL1]…552
ECMV ?LO? CLUTCH NOT DISENGAGING (L1)…552
(TM-15) FAILURE CODE [15SDMA]…554
ECMV ?LO? CLUTCH NOT ENGAGING (MA)…554
(TM-16) FAILURE CODE [15SEL1]…556
ECMV ?1ST? CLUTCH NOT DISENGAGING (L1)…556
(TM-17) FAILURE CODE [15SEMA]…558
ECMV ?1ST? CLUTCH NOT ENGAGING (MA)…558
(TM-18) FAILURE CODE [15SFL1]…560
ECMV ?2ND? CLUTCH NOT DISENGAGING (L1)…560
(TM-19) FAILURE CODE [15SFMA]…562
ECMV ?2ND? CLUTCH NOT ENGAGING (MA)…562
(TM-20) FAILURE CODE [15SGL1]…564
ECMV ?3RD? CLUTCH NOT DISENGAGING (L1)…564
(TM-21) FAILURE CODE [15SGMA]…566
ECMV ?3RD? CLUTCH NOT ENGAGING (MA)…566
(TM-22) FAILURE CODE [15SJL1]…568
ECMV ?LOCK-UP? CLUTCH NOT DISENGAGING (l1)…568
(TM-23) FAILURE CODE [15SJMA]…570
ECMV ?LOCK-UP? CLUTCH NOT ENGAGING (MA)…570
(TM-24) FAILURE CODE [15SKL1]…572
ECMV ?INTER-AXLE? CLUTCH NOT DISENGAGING (L1)…572
(TM-25) FAILURE CODE [15SKMA]…574
ECMV ?INTER-AXLE? CLUTCH NOT ENGAGING (MA)…574
(TM-26) FAILURE CODE [2B61MW]…576
ECMV ?INTER-AXLE? CLUTCH SLIPPING (MW)…576
(TM-27) FAILURE CODE [2F00KM]…578
PARKING BRAKE SYSTEM INDICATING FAILURE (KM)…578
(TM-28) FAILURE CODE [6014NX]…580
HYDRAULIC TANK FILTER CLOGGED (NX)…580
(TM-29) FAILURE CODE [989A00]…582
POSSIBLE ENGINE OVER SPEED CONDITION (00)…582
(TM-30) FAILURE CODE [989AKZ]…584
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ)…584
(TM-31)FAILURE CODE [989D00]…586
REAR OVERTURN SIGNAL OUT OF RANGE (00)…586
(TM-32)FAILURE CODE [AA10NX]…588
AIR CLEANER CLOG INDICATION (NX)…588
(TM-33) FAILURE CODE [AB00MA]…590
ALTERNATOR NOT CHARGING PROPERLY (MA)…590
(TM-34) FAILURE CODE [B@BCZK]…592
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)…592
(TM-35) FAILURE CODE [B@HAZK]…594
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)…594
(TM-36) FAILURE CODE [B@JANS]…595
STEERING OIL OVERHEAT CONDITION INDICATED (ZK)…595
(TM-37) FAILURE CODE [D1B0KZ]…596
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)…596
(TM-38) FAILURE CODE [D5ZBKX]…598
DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX)…598
(TM-39) FAILURE CODE [D5ZCKZ]…600
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ)…600
(TM-40) FAILURE CODE [DF10KA]…602
FORCED NEUTRAL DEMAND SIGNAL (L4)…602
(TM-41) FAILURE CODE [D5ZEKX]…604
ENGINE LOAD SIGNAL OUT OF RANGE (KX)…604
(TM-42) FAILURE CODE [DAQ0KK]…606
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…606
(TM-43) FAILURE CODE [DAQ1KK]…608
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…608
(TM-44) FAILURE CODE [DAQ2KK]…610
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK)…610
(TM-45) FAILURE CODE [DAQ3KK]…612
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)…612
(TM-46) FAILURE CODE [DAQ5KP]…614
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)…614
(TM-47) FAILURE CODE [DAQ9KM]…616
MISTAKEN OPERATION SETTING (KP)…616
(TM-48) FAILURE CODE [DAQ9KM]…617
NO MATCH IN MODEL SELECTION SIGNAL (KP)…617
(TM-49) FAILURE CODE [DAQAKQ]…618
TRANSMISSION CONTROLLER ROTARY SWITCH…618
(TM-50) FAILURE CODE [DAQSMA]…618
TRANSMISSION FUNCTION INOPERABLE…618
(TM-51) FAILURE CODE [DDTFKA]…620
?LOCK-UP? CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)…620
(TM-52) FAILURE CODE [DDTFKA]…622
?LOCK-UP? CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)…622
(TM-53) FAILURE CODE [DDTHKA]…624
?HI? CLUTCH SYSTEM OPEN OR SHORTED (KA)…624
(TM-54) FAILURE CODE [DDTJKA]…626
?LO? CLUTCH SYSTEM OPEN OR SHORTED (KA)…626
(TM-55) FAILURE CODE [DDTKKA]…628
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)…628
(TM-56) FAILURE CODE [DDTLKA]…630
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA)…630
(TM-57) FAILURE CODE [DDTMKA]…632
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA)…632
(TM-58) FAILURE CODE [DDTNKA]…634
?R? CLUTCH SYSTEM OPEN OR SHORTED (KA)…634
(TM-59) FAILURE CODE [DF10KA]…636
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)…636
(TM-60) FAILURE CODE [DF10KB]…638
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)…638
(TM-61) FAILURE CODE [DGF1KX]…640
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)…640
(TM-63) FAILURE CODE [DGR3L8]…642
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)…642
(TM-64) FAILURE CODE [DGR4L8]…644
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)…644
(TM-65) FAILURE CODE [DGT1LX]…646
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)…646
(TM-66) FAILURE CODE [DHT5KX]…648
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX)…648
(TM-67) FAILURE CODE [DHT5L6]…650
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6)…650
(TM-68) FAILURE CODE [DJF1KA]…652
FUEL LEVEL SENSOR OUT OF RANGE (L6)…652
(TM-69) FAILURE CODE [DK11KX]…654
THROTTLE ANGLE SENSOR OUT OF RANGE (KX)…654
(TM-70) FAILURE CODE [DLE2KA]…656
ENGINE SPEED SENSOR OPEN OR SHORTED (KA)…656
(TM-71) FAILURE CODE [DLE2LC]…657
ENGINE SPEED SENSOR OPEN OR SHORTED (LC)…657
(TM-72) FAILURE CODE [DLF1KA]…658
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…658
(TM-73) FAILURE CODE [DLF1LC]…659
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…659
(TM-74) FAILURE CODE [DLF2KA]…660
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…660
(TM-75) FAILURE CODE [DLF2LC]…661
TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…661
(TM-76) FAILURE CODE [DLT3KA]…662
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)…662
(TM-77) FAILURE CODE [DLT3LC]…664
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)…664
(TM-78) FAILURE CODE [DXH0KA]…666
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA)…666
(TM-79) FAILURE CODE [DXH0KB]…668
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB)…668
(TM-80) FAILURE CODE [DXH1KA]…670
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA)…670
(TM-81) FAILURE CODE [DXH1KB]…672
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB)…672
(TM-82) FAILURE CODE [DXH2KA]…674
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)…674
(TM-83) FAILURE CODE [DXH2KB]…676
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)…676
(TM-84) FAILURE CODE [DXH3KA]…678
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA)…678
(TM-85) FAILURE CODE [DXH3KB]…680
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB)…680
(TM-86) FAILURE CODE [DXH4KA]…682
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)…682
(TM-87) FAILURE CODE [DXH4KB]…684
1ST CLUTCH SYSTEM OPEN OR SHORTED (KB)…684
(TM-88) FAILURE CODE [DXH5KA]…686
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA)…686
(TM-89) FAILURE CODE [DXH5KB]…688
2ND CLUTCH SYSTEM OPEN OR SHORTED (KB)…688
(TM-90) FAILURE CODE [DXH6KA]…690
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB)…690
(TM-91) FAILURE CODE [DXH6KB]…692
3RD CLUTCH SYSTEM OPEN OR SHORTED (KB)…692
(TM-92) FAILURE CODE [DXH7KA]…694
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA)…694
(TM-93) FAILURE CODE [DXH7KB]…696
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB)…696
(TM-94) NO FAILURE CODE DISPLAYED…698
BACK-UP LIGHTS AND ALARM DO NOT OPERATE…698
CONNECTOR ARRANGEMENT AND LOCATIONS…704
BK CONTROL SYSTEM CIRCUIT DIAGRAM…710
CONTENT OF CODE DISPLAY (1)…716
CONTENT OF CODE DISPLAY (2)…718
CONTENT OF CODE DISPLAY (3)…720
CONTENT OF CODE DISPLAY (4)…722
CONTENT OF CODE DISPLAY (5)…724
CONTENT OF CODE DISPLAY (6)…726
INFORMATION CONTAINED IN TESTING PROCEDURES…728
(BK-1) FAILURE CODE [2G42ZG]…730
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)…730
(BK-2) FAILURE CODE [2G43ZG]…731
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)…731
(BK-3) FAILURE CODE [D1C0KZ]…732
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)…732
(BK-4) FAILURE CODE [D5ZFKZ]…734
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)…734
(BK-5) FAILURE CODE [D5ZGKZ]…736
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)…736
(BK-6) FAILURE CODE [DB10KK]…738
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…738
(BK-7) FAILURE CODE [DB11KK]…740
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…740
(BK-8) FAILURE CODE [DB12KK]…742
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)…742
(BK-9) FAILURE CODE [DB13KK]…744
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)…744
(BK-10) FAILURE CODE [DB19KM]…746
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM)…746
(BK-11) FAILURE CODE [DB1SKQ]…747
RETARDER CONTROL S-NET LINE MISMATCHED (KQ)…747
(BK-12) FAILURE CODE [DHU2KX]…748
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)…748
(BK-13) FAILURE CODE [DHU3KX]…750
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX)…750
(BK-14) FAILURE CODE [DK51L5]…752
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)…752
(BK-15) FAILURE CODE [DK52KX]…754
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)…754
(BK-16) FAILURE CODE [DK53L8]…756
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)…756
(BK-17) FAILURE CODE [DK54KX]…758
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)…758
(BK-18) FAILURE CODE [DLF4KA]…760
TRANSMISSION OUTPUT SHAFT ?F? SPEED SENSOR OUT OF RANGE (KA)…760
(BK-19) FAILURE CODE [DLT3KA]…762
TRANSMISSION OUTPUT SHAFT ?R? SPEED SENSOR OUT OF RANGE (KA)…762
(BK-20) FAILURE CODE [DW71KZ]…764
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)…764
(BK-21) FAILURE CODE [DK72KX]…766
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)…766
(BK-22) FAILURE CODE [DW73KZ]…768
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ)…768
(BK-23) FAILURE CODE [DX11KA]…770
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)…770
(BK-24) FAILURE CODE [DX11KB]…771
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)…771
(BK-25) FAILURE CODE [DX11KY]…772
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY)…772
(BK-26) FAILURE CODE [DX12KA]…773
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)…773
(BK-27) FAILURE CODE [DX12KB]…774
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)…774
(BK-28) FAILURE CODE [DX12KY]…775
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)…775
(BK-29) FAILURE CODE [DX13KA]…776
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)…776
(BK-30) FAILURE CODE [DX13KB]…778
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)…778
(BK-31) FAILURE CODE [DX13KY]…780
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)…780
(BK-32) NO FAILURE CODE DISPLAYED…782
PARKING BRAKE SYSTEM FAILURE…782
CONNECTOR ARRANGEMENT AND LOCATIONS…788
MON CONTROL SYSTEM CIRCUIT DIAGRAM…794
CONTENT OF CODE DISPLAY (1)…798
INFORMATION CONTAINED IN TESTING PROCEDURES…801
(MON-1) FAILURE CODE [B@C6NS]…803
FRONT BRAKE OIL OVERHEAT CONDITION (NS)…803
(MON-2) FAILURE CODE [B@C8NS]…804
CENTER BRAKE OIL OVERHEAT CONDITION (NS)…804
(MON-3) FAILURE CODE [B@CENS]…805
TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS)…805
(MON-4) FAILURE CODE [DAF0KM]…806
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)…806
(MON-5) FAILURE CODE [DAF9KM]…808
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)…808
(MON-6) FAILURE CODE [DAFSKQ]…809
MODEL SELECTION DOES NOT MATCH (KQ)…809
(MON-7) FAILURE CODE [DAQSKR]…810
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…810
(MON-8) FAILURE CODE [DB1SKR]…812
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…812
(MON-9) FAILURE CODE [DB2SKR]…814
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)…814
(MON-10) FAILURE CODE [DV00KB]…816
DEFECTIVE ALARM BUZZER (KB)…816
(MON-11) NO FAILURE CODE DISPLAYED…818
WITH IGNITION KEY ?ON? NO DISPLAY IS SHOWN ON MONITOR PANEL…818
(MON-12) NO FAILURE CODE DISPLAYED…820
WITH IGNITION KEY ?OFF? NO DISPLAY IS SHOWN ON MONITOR PANEL…820
(MON-13) NO FAILURE CODE DISPLAYED…822
ALARM BUZZER DOES NOT SOUND…822
(MON-14) NO FAILURE CODE DISPLAYED…824
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL…824
(MON-15) NO FAILURE CODE DISPLAYED…825
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED…825
(MON-16) NO FAILURE CODE DISPLAYED…826
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE…826
(MON-17) NO FAILURE CODE DISPLAYED…828
POWER MODE SWITCH DOES NOT WORK PROPERLY…828
(MON-18) NO FAILURE CODE DISPLAYED…829
AISS FUNCTION DOES NOT WORK PROPERLY…829
(MON-19) NO FAILURE CODE DISPLAYED…830
EXHAUST BRAKE DOES NOT WORK PROPERLY…830
(MON-20) NO FAILURE CODE DISPLAYED…832
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY…832
(MON-21) NO FAILURE CODE DISPLAYED…833
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY…833
(MON-22) NO FAILURE CODE DISPLAYED…836
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY…836
(H-1)…840
THE MACHINE DOES NOT MOVE…840
(H-2) AND (H-3)…841
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY)…841
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING)…841
(H-4) AND (H-5)…842
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS…842
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE…842
(H-6)…843
MACHINE LACKS POWER OR SPEED WHEN TRAVELING…843
(H-6)…844
ABNORMAL OPERATION AT SOME SPEED RANGES…844
(H-6)…845
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE…845
(H-7)…846
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES…846
(H-8)…847
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)…847
(H-9)…848
TORQUE CONVERTER OIL PRESSURE LOW…848
(H-10)…849
FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY…849
(H-11)…850
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE…850
(H-12)…851
STEERING EFFORT SEAMS HEAVY…851
(H-13)…852
STEERING SYSTEM DOES NOT OPERATE…852
(H-14)…853
STEERING WHEEL VIBRATES…853
(H-15)…854
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER…854
(H-16)…855
DUMP OPERATIONS DO NOT WORK…855
(H-17)…856
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY…856
HYDRAULIC POWER TRAIN CIRCUIT DIAGRAM…857
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…858
USING TROUBLESHOOTING CHARTS…860
S-7 Exhaust gas is black (incomplete combustion)…862
(S-1) STARTING PERFORMANCE IS POOR…864
(S-2) ENGINE DOES NOT CRANK…865
(1) ENGINE DOES NOT TURN…865
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT OF STACK (FUEL IS NOT BEING INJECTED)…866
(3) EXHAUST SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…867
(S-3) ENGINE RPM DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…868
(S-4) ENGINE STOPS DURING OPERATIONS…869
(S-5) ENGINE DOES NOT RUN SMOOTHLY (HUNTING)…870
(S-6) ENGINE LACKS OUTPUT (OR LACKS POWER)…871
(S-7) EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…872
(S-8) OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…873
(S-9) OIL BECOMES CONTAMINATED QUICKLY…874
(S-10) FUEL CONSUMPTION IS EXCESSIVE…875
(S-11) OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR LEVEL GOES DOWN…876
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…877
(S-13) OIL LEVEL RISES (COOLANT, FUEL IN OIL)…878
(S-14) COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…879
(S-15) ABNORMAL NOISE IS HEARD…880
(S-16) VIBRATION IS EXCESSIVE…881
30 DISASSEMBLY AND ASSEMBLY…883
HOW TO USE MANUAL…887
Removal and Installation of Assemblies…887
Disassembly and Assembly of Assemblies…889
PRECAUTIONS WHEN CARRYING OUT REPAIR OPERATION…891
SPECIAL TOOL LIST…894
SKETCHES OF SPECIAL TOOLS…898
CONNECTOR REPAIR PROCEDURES…910
Stripping Insulation…910
Wire Inspection…910
Contact Terminal Removal (HD30 Type)…911
Crimping Contact Terminal (HD30 Type)…912
Insertion Of Contact Terminal (HD30 Type)…913
Contact Terminal Removal (DT Type)…914
Crimping Contact Terminal (DT Type)…915
Insertion Of Contact Terminal (DT Type)…916
ENGINE…917
REMOVAL…917
INSTALLATION…922
RADIATOR…924
REMOVAL…924
INSTALLATION…926
OUTPUT SHAFT SYSTEM…927
REMOVAL…927
INSTALLATION…929
DISASSEMBLY…931
ASSEMBLY…933
TRANSMISSION AND FRONT DIFFERENTIAL…935
REMOVAL…935
INSTALLATION…941
SEPARATING FRONT DIFFERENTIAL FROM TRANSMISSION…944
REMOVAL…944
INSTALLATION…945
TORQUE CONVERTER…946
DISASSEMBLY…946
ASSEMBLY…950
TRANSMISSION…956
DISASSEMBLY…956
ASSEMBLY…981
FRONT DIFFERENTIAL…1011
DISASSEMBLY…1011
ASSEMBLY…1017
CENTER AXLE AND DIFFERENTIAL…1029
AXLE ASSEMBLY…1029
REMOVAL…1029
INSTALLATION…1031
DIFFERENTIAL…1032
REMOVAL…1032
INSTALLATION…1034
DISASSEMBLY…1037
ASSEMBLY…1044
REAR AXLE AND DIFFERENTIAL…1058
AXLE ASSEMBLY…1058
REMOVAL…1058
INSTALLATION…1060
DIFFERENTIAL ASSEMBLY…1061
REMOVAL…1061
INSTALLATION…1063
DISASSEMBLY…1064
ASSEMBLY…1069
FRONT FINAL DRIVE AND BRAKE ASSEMBLY…1080
REMOVAL…1080
INSTALLATION…1082
DISASSEMBLY…1083
ASSEMBLY…1089
CENTER FINAL DRIVE AND BRAKE ASSEMBLY…1097
REMOVAL…1097
INSTALLATION…1099
DISASSEMBLY…1100
ASSEMBLY…1103
REAR FINAL DRIVE AND BRAKE ASSEMBLY…1110
REMOVAL…1110
INSTALLATION…1111
DISASSEMBLY…1112
ASSEMBLY…1114
SUSPENSION SYSTEM…1119
FRONT SUSPENSION…1119
REMOVAL…1119
INSTALLATION…1121
REAR SUSPENSION…1122
REMOVAL…1122
INSTALLATION…1122
EQUALIZER BEAM…1123
REMOVAL…1123
INSTALLATION…1125
HITCH FRAME SYSTEM…1126
REMOVAL…1126
INSTALLATION…1133
DISASSEMBLY…1137
ASSEMBLY…1139
ORBITAL STEERING UNIT…1144
UNIT BREAKDOWN VIEW…1144
DISASSEMBLY…1146
ASSEMBLY…1149
FLOW AMP VALVE…1155
REMOVAL…1155
INSTALLATION…1156
HOIST VALVE…1157
REMOVAL…1157
INSTALLATION…1158
HYDRAULIC CYLINDER…1159
STEERING CYLINDER…1159
DISASSEMBLY…1159
ASSEMBLY…1161
HOIST CYLINDER…1164
DISASSEMBLY…1164
ASSEMBLY…1166
TRUCK BODY ASSEMBLY…1170
REMOVAL…1170
INSTALLATION…1171
OPERATOR?S SEAT…1172
DISASSEMBLY…1172
ASSEMBLY…1179
90 DIAGRAMS AND SCHEMATICS…1185
CAB…1187
CLIMATE CONTROL SYSTEM…1187
CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER…1189
CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER…1191
LIGHTING WIPER AND RELAY BANK…1193
RELAY AND SWITCH CIRCUITS…1195
MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS…1197
DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS…1199
DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT…1201
RETARDER SYSTEM…1203
RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING…1205
TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL…1207
TRANSMISSION CONTROLLER…1209
TO HARNESS OUTSIDE OF CAB…1211
TO HARNESS OUTSIDE OF CAB AND TO ENGINE…1213
CHASSIS…1215
SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OD CAB…1215
TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS…1217
TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS…1219
CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS…1221
CHASSIS SENSOR SYSTEMS…1223
CONNECTORS OUTSIDE OF CAB…1225
ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS…1227
DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM…1229
BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR…1231
TRANSMISSION SELECTOR SYSTEM…1233
BRAKE HYDRAULIC CIRCUIT DIAGRAM…1235

Komatsu Articulated Dump Truck HM300-1L Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 27,061 pages
File Format: PDF
Language: English

SEBM024805 – Dump Truck HM300-1 Shop Manual.pdf
SEBM024815 – Articulated Dump Truck HM300-1 Shop Manual.pdf
SEN00237-04 – Dump Truck GALEO HM300-2 Shop Manual.pdf
SEN00237-13 – Articulated Dump Truck HM300-2 Shop Manual.pdf
SEN00237-14 – Articulated Dump Truck HM300-2 Shop Manual.pdf
SEN05629-04 – Articulated Dump Truck HM300-3 Shop Manual.pdf
SEN05629-05 – Articulated Dump Truck HM300-3 Shop Manual.pdf
SEN06511-05 – Articulated Dump Truck HM300-5 Shop Manual.pdf
CEAM017504 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
CEBM007700 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM022402 – Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
EEAM024700 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM027303 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM030700 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EENAM03082 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
EENAM03312 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
EENAM03372 – Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
EENAM03491 – Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
EPAM022402 – Camião Basculante Articulado HM300-1 Manual de Operação e Manutenção.pdf
EPAM024700 – Camião Basculante Articulado HM300-2 Manual de Operação e Manutenção.pdf
EPAM027303 – Camião Basculante Articulado HM300-2 Manual de Operação e Manutenção.pdf
EPTAM03490 – Camião Basculante Articulado HM300-5 Manual de Operação e Manutenção.pdf
GEN00017-00 – Articulated Dump Truck HM300-1 Field Assembly Instruction.pdf
GEN00037-03 – Articulated Dump Truck HM300-2 Field Assembly Manual.pdf
GEN00111-03 – Articulated Dump Truck HM300-3 Field Assembly Instruction.pdf
GEN00131-00 – Articulated Dump Truck HM300-5 Field Assembly Instruction.pdf
PEN00044-11 – Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
PEN00101-04 – Articulated Dump Truck GALEO HM300-2 Operation & Maintenance Manual.pdf
PEN00231-06 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00239-00 – Articulated Dump Truck GALEO HM300-1 Operation & Maintenance Manual.pdf
PEN00372-01 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00474-11 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00554-03 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
PEN00661-04 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
PEN00833-01 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00044-10 – Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
TEN00112-04 – Articulated Dump Truck GALEO HM300-2 Operation & Maintenance Manual.pdf
TEN00228-06 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00238-00 – Articulated Dump Truck GALEO HM300-1 Operation & Maintenance Manual.pdf
TEN00344-01 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00442-07 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00442-11 – Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00517-03 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00631-01 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00662-01 – Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
TEN00745-02 – Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
TEN00747-01 – Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf

TABLE OF CONTENTS
SEBM024805 – Dump Truck HM300-1 Shop Manual…2
SAFETY …8
SAFETY NOTICE …8
FOREWORD …10
GENERAL …10
STANDARD TIGHTENING TORQUE …17
CONVERSION TABLE …21
01 GENERAL …28
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD …36
RADIATOR, OIL COOLER, AFTERCOOLER …37
POWER TRAIN SKELETON OUTPUT SHAFT …41
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING TORQUE CONVERTER …45
TRANSMISSION …51
TRANSMISSION VALVE …71
ECMV ( Electronic Control Modulation Valve) …72
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE …79
DRIVE SHAFT …81
AXLE …82
DIFFERENTIAL …85
LIMITED SLIP DIFFERENTIAL …91
FINAL DRIVE …97
STEERING COLUMN …102
BRAKE PIPING BRAKE VALVE …105
ACCUMULATOR CHARGE VALVE …108
ACCUMULATOR …112
SLACK ADJUSTER …113
BRAKE …115
PROPORTIONAL REDUCING VALVE …120
BRAKE SYSTEM TANK …121
PARKING BRAKE …123
PARKING BRAKE CALIPER …125
PARKING BRAKE SOLENOID VALVE …127
SPRING CYLINDER …126
SUSPENSION …129
SUSPENSION CYLINDER …135
OSCILLATION HITCH …137
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM …141
DUMP BODY CONTROL …142
HYDRAULIC TANK AND FILTER …143
FLOW AMP VALVE …144
STEERING CYLINDER …151
EPC VALVE …159
HOIST CYLINDER …162
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP …163
HYDRAULIC PUMP …163
STEERING · HOIST+ PILOT PUMP SAR( 3) 63+ 63+( 1) 6 …163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP …164
TORQUE CONVERTER, TRANSMISSION AND FRONT BRAKE COOLING PUMP SAR( 3) 90 …164
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB TILT …167
CAB TILT …167
AIR CONDITIONER …168
FUNCTION …168
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER …169
AIR CONDITIONER UNIT …169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER …170
RECEIVER DRYER …170
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER …171
CONDENSER …171
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER …172
COMPRESSOR …172
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM …173
MACHINE MONITOR SYSTEM …173
Network data …173
AUTOMATIC SHIFT CONTROL SYSTEM …186
TRANSMISSION CONTROLLER …188
AUTO EMERGENCY STEERING SYSTEM …194
SENSORS, SWITCHES …195
20 TESTING AND ADJUSTING …228
STANDARD VALUE TABLE FOR ENGINE …229
STANDARD VALUE TABLE FOR CHASSIS …230
STANDARD VALUE TABLE FOR ELECTRICAL PARTS …234
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING …247
MEASURING ENGINE SPEED …249
MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) …250
MEASURING EXHAUST TEMPERATURE …251
MEASURING EXHAUST COLOR …253
MEASURING COMPRESSION PRESSURE …254
ADJUSTING VALVE CLEARANCE …255
MEASURING BLOW- BY PRESSURE …256
MEASURING ENGINE OIL PRESSURE …257
HANDLING EQUIPMENT IN FUEL CIRCUIT …258
RELEASING REMAINING PRESSURE IN FUEL SYSTEM …258
MEASURING FUEL PRESSURE …259
BLEEDING AIR FROM FUEL CIRCUIT …260
REDUCED CYLINDER MODE OPERATION FOR ENGINE …262
CHECKING FOR LEAKAGE IN FUEL CIRCUIT …263
ADJUSTING ENGINE SPEED SENSOR …264
TESTING AND ADJUSTING ALTERNATOR BELT TENSION …265
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION …265
TESTING TORQUE CONVERTER STALL SPEED …266
MEASURING POWER TRAIN OIL PRESSURE …267
ADJUSTING TRANSMISSION SPEED SENSOR …274
TESTING AND ADJUSTING BRAKE OIL PRESSURE …275
TESTING BRAKE PERFORMANCE …279
BLEEDING AIR FROM BRAKE CIRCUIT …282
TESTING WEAR OF WHEEL BRAKE DISC …285
TESTING WEAR OF PARKING BRAKE PAD …286
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE …287
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE …288
TESTING AND ADJUSTING SUSPENSION CYLINDER …290
METHOD OF TILTING CAB UP …294
TESTING DUMP CIRCUIT PRESSURE …295
ADJUSTING BODY POSITIONER SENSOR …298
HANDLING ENGINE CONTROLLER HIGH- VOLTAGE CIRCUIT …299
ADJUSTING TRANSMISSION CONTROLLER …300
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM …301
ADJUSTING MACHINE MONITOR …305
SPECIAL FUNCTIONS OF MACHINE MONITOR …309
CHECKS BEFORE TROUBLESHOOTING …359
CONNECTOR TYPES AND MOUNTING LOCATIONS …360
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS …375
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS …397
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM …439
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …443
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM …515
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …521
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM …659
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …665
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM …721
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …725
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM ( ENG MODE) …436
ENG- 1 FAILURE CODE [ A000N1] ( ENGINE: OVERRUN N1)) …455
ENG- 2 FAILURE CODE [ A570NX] ( ENGINE OIL FILTER: CLOGGED ( NX)) …456
ENG- 3 FAILURE CODE [ AD00L2] ( COMMON RAIL: * SEE CONTENTS ( L2)) …457
ENG- 4 FAILURE CODE [ AD00MA] ( COMMON RAIL: FUNCTION IMPOSSIBLE ( MA)) …457
ENG- 5 FAILURE CODE [ AD10L3] ( FUEL SUPPLY PUMP: * SEE CONTENTS ( L3)) …458
ENG- 6 FAILURE CODE [ AD10MA] ( FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE ( MA)) …460
ENG- 7 FAILURE CODE [ AD10MB] ( FUEL SUPPLY PUMP: DROP IN FUNCTION ( MB)) …460
ENG- 8 FAILURE CODE [ AD11KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION ( KA)) …461
ENG- 9 FAILURE CODE [ AD11KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT ( KB)) …462
ENG- 10 FAILURE CODE [ AD51KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION ( KA)) …463
ENG- 11 FAILURE CODE [ AD51KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT ( KB)) …464
ENG- 12 FAILURE CODE [ ADA1KA] ( NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …465
ENG- 13 FAILURE CODE [ ADAZKB] ( NO. 1, 2, 3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) …466
ENG- 14 FAILURE CODE [ ADB1KA] ( NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …470
ENG- 15 FAILURE CODE [ ADC1KA] ( NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …471
ENG- 16 FAILURE CODE [ ADD1KA] ( NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …472
ENG- 17 FAILURE CODE [ ADDZKB] ( NO. 4, 5, 6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) …473
ENG- 18 FAILURE CODE [ ADE1KA] ( NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …477
ENG- 19 FAILURE CODE [ ADF1KA] ( NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) …478
ENG- 20 FAILURE CODE [ B@ BAZG] ( ENGINE OIL: DROP IN OIL PRESSURE ( ZG)) …479
ENG- 21 FAILURE CODE [ B@ BAZK] ( ENGINE OIL: DROP IN LEVEL ( ZK)) …480
ENG- 22 FAILURE CODE [ B@ BCNS] ( RADIATOR WATER: OVERHEAT ( NS)) …481
ENG- 23 FAILURE CODE [ D181KZ] ( PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …482
ENG- 24 FAILURE CODE [ D182KZ] ( PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …484
ENG- 25 FAILURE CODE [ D1D0KB] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT ( KB)) …485
ENG- 26 FAILURE CODE [ D5ZAKX] ( ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) …487
ENG- 27 FAILURE CODE [ DB20KT] ( ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER ( KT)) …488
ENG- 28 FAILURE CODE [ DB22KK] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) …490
ENG- 29 FAILURE CODE [ DB29KQ] ( ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH ( KQ)) …492
ENG- 30 FAILURE CODE [ DB2AMA] ( ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE ( MA)) …493
ENG- 31 FAILURE CODE [ DD11KB] ( STARTING SWITCH: SHORT CIRCUIT ( KB)) …494
ENG- 32 FAILURE CODE [ DDA1L5] ( ACCELERATION SWITCH: * SEE CONTENTS ( L5)) …495
ENG- 33 FAILURE CODE [ DDE2L6] ( ENGINE OIL PRESSURE SWITCH: * SEE CONTENTS ( L6)) …497
ENG- 34 FAILURE CODE [ DGE2KX] ( ENGINE WATER TEMPERATURE SENSOR ( FOR HIGH- TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE ( KX)) …499
ENG- 35 FAILURE CODE [ DGE3L6] ( ENGINE WATER TEMPERATURE SENSOR ( FOR LOW- TEMPERATURE): * SEE CONTENTS ( L6)) …500
ENG- 36 FAILURE CODE [ DH30KX] ( BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …501
ENG- 37 FAILURE CODE [ DH40KX] ( COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …503
ENG- 38 FAILURE CODE [ DK10KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …505
ENG- 39 FAILURE CODE [ DLE3LC] ( ENGINE NE SPEED SENSOR: * SEE CONTENTS ( LC)) …507
ENG- 40 FAILURE CODE [ DLH1LC] ( ENGINE G SPEED SENSOR: * SEE CONTENTS ( LC)) …508
ENG- 41 ENGINE DOES NOT START ( STARTING MOTOR DOES NOT TURN) …509
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM ( TM MODE) …512
TM- 1 FAILURE CODE [ 1380MW] ( LOCK- UP CLUTCH: SLIPPING ( MW)) …547
TM- 2 FAILURE CODE [ 1500LO] ( TRANSMISSION CLUTCH: * SEE THE TABLE IN CONTENTS. ( LO)) …548
TM- 3 FAILURE CODE [ 15BONX] ( TRANSMISSION OIL FILTER: CLOGGED ( NX)) …549
TM- 4 FAILURE CODE [ 15GOMW] ( R CLUTCH: SLIPPING ( MW)) …550
TM- 5 FAILURE CODE [ 15HOMW] ( HI CLUTCH: SLIPPING ( MW)) …551
TM- 6 FAILURE CODE [ 15JOMW] ( LO CLUTCH: SLIPPING ( MW)) …552
TM- 7 …553
TM- 8 FAILURE CODE [ 15LOMW] ( 2ND CLUTCH: SLIPPING ( MW)) …554
TM- 9 FAILURE CODE [ 15MOMW] ( 3RD CLUTCH: SLIPPING ( MW)) …555
TM- 10 FAILURE CODE [ 15SBL1] ( ECMV FOR R CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …556
TM- 11 FAILURE CODE [ 15SBMA] ( ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …557
TM- 12 FAILURE CODE [ 15SCL1] ( ECMV FOR HI CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …558
TM- 13 FAILURE CODE [ 15SCMA] ( ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …559
TM- 14 FAILURE CODE [ 15SDL1] ( ECMV FOR LO CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …560
TM- 15 FAILURE CODE [ 15SDMA] ( ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …561
TM- 16 FAILURE CODE [ 15SEL1] ( ECMV FOR 1ST CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …562
TM- 17 FAILURE CODE [ 15SEMA] ( ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …563
TM- 18 FAILURE CODE [ 15SFL1] ( ECMV FOR 2ND CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …564
TM- 19 FAILURE CODE [ 15SFMA] ( ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …565
TM- 20 FAILURE CODE [ 15SGL1] ( ECMV FOR 3RD CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …566
TM- 21 FAILURE CODE [ 15SGMA] ( ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …567
TM- 22 FAILURE CODE [ 15SJL1] ( ECMV FOR LOCK- UP CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …568
TM- 23 FAILURE CODE [ 15SJMA] ( ECMV FOR LOCK- UP CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …569
TM- 24 FAILURE CODE [ 15SKL1] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) …570
TM- 25 FAILURE CODE [ 15SKMA] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE ( MA)) …571
TM- 26 FAILURE CODE [ 2B61MW] ( INTER- AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING ( MW)) …572
TM- 27 FAILURE CODE [ 2F00KM] ( PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) …573
TM- 28 FAILURE CODE [ 989A00] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED ( 00)) …575
TM- 29 FAILURE CODE [ 989AKZ] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …576
TM- 30 FAILURE CODE [ 989D00] ( REAR OVERTURN SIGNAL: ACTUATED ( 00)) …577
TM- 31 FAILURE CODE [ AA10NX] ( AIR CLEANER ELEMENT: CLOGGED ( NX)) …579
TM- 32 FAILURE CODE [ AB00MA] ( ALTERNATOR: FUNCTION IMPOSSIBLE ( MA)) …581
TM- 33 FAILURE CODE [ B@ BCZK] ( RADIATOR COOLING WATER: DROP IN LEVEL ( ZK)) …582
TM- 34 FAILURE CODE [ B@ HAZK] ( HYDRAULIC TANK OIL: DROP IN LEVEL ( ZK)) …583
TM- 35 FAILURE CODE [ B@ JANS] ( STEERING OIL: OVERHEAT ( NS)) …584
TM- 36 FAILURE CODE [ D1B0KZ] ( TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …585
TM- 37 FAILURE CODE [ D5ZBKX] ( INTER- AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) …587
TM- 38 FAILURE CODE [ D5ZCKZ] ( EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …589
TM- 39 FAILURE CODE [ D5ZDL4] ( FORCED NEUTRAL DEMAND SIGNAL: * SEE THE TABLE IN CONTENTS. ( L4)) …590
TM- 40 FAILURE CODE [ D5ZEKX] ( ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) …592
TM- 41 FAILURE CODE [ DAQ0KK] ( TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) …593
TM- 42 FAILURE CODE [ DAQ1KK] ( TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) …595
TM- 43 FAILURE CODE [ DAQ2KK] ( TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) …596
TM- 44 FAILURE CODE [ DAQ3KK] ( TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) …597
TM- 45 FAILURE CODE [ DAQ5KP] ( TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE ( KP)) …598
TM- 46 FAILURE CODE [ DAQ9KM] ( TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) …599
TM- 47 FAILURE CODE [ DAQ9KQ] ( TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) …600
TM- 48 FAILURE CODE [ DAQAKQ] ( TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) …601
TM- 49 FAILURE CODE [ DAQSMA] ( TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE ( MA) …601
TM- 50 FAILURE CODE [ DDTFKA] ( FILL SWITCH FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION ( KA)) …602
TM- 51 FAILURE CODE [ DDTGKA] ( FILL SWITCH FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) …603
TM- 52 FAILURE CODE [ DDTHKA] ( FILL SWITCH FOR HI CLUTCH: DISCONNECTION ( KA)) …604
TM- 53 FAILURE CODE [ DDTJKA] ( FILL SWITCH FOR LO CLUTCH: DISCONNECTION ( KA)) …605
TM- 54 FAILURE CODE [ DDTKKA] ( FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION ( KA)) …606
TM- 55 FAILURE CODE [ DDTLKA] ( FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION ( KA)) …607
TM- 56 FAILURE CODE [ DDTMKA] ( FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION ( KA)) …608
TM- 57 FAILURE CODE [ DDTNKA] ( FILL SWITCH FOR R CLUTCH: DISCONNECTION ( KA)) …609
TM- 58 FAILURE CODE [ DF10KA] ( GEARSHIFT LEVER: DISCONNECTION ( KA)) …610
TM- 59 FAILURE CODE [ DF10KB] ( GEARSHIFT LEVER: SHORT CIRCUIT ( KB)) …612
TM- 60 FAILURE CODE [ DGF1KX] ( TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …614
TM- 61 FAILURE CODE [ DGR3L8] ( BRAKE OIL TEMPERATURE SENSOR ( CENTER): * SEE THE TABLE IN CONTENTS. ( L8)) …616
TM- 62 FAILURE CODE [ DGR4L8] ( BRAKE OIL TEMPERATURE SENSOR ( FRONT): * SEE THE TABLE IN CONTENTS. ( L8)) …618
TM- 63 FAILURE CODE [ DGT1LX] ( TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …620
TM- 64 FAILURE CODE [ DHT5KX] ( TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …622
TM- 65 FAILURE CODE [ DHT5L6] ( TORQUE CONVERTER OIL PRESSURE SENSOR: * SEE THE TABLE IN CONTENTS. ( L6)) …624
TM- 66 FAILURE CODE [ DJF1KA] ( FUEL LEVEL SENSOR: DISCONNECTION ( KA)) …625
TM- 67 FAILURE CODE [ DK11KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …626
TM- 68 FAILURE CODE [ DLE2KA] ( ENGINE SPEED SENSOR: DISCONNECTION ( KA)) …628
TM- 69 FAILURE CODE [ DLE2LC] ( ENGINE SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) …629
TM- 70 FAILURE CODE [ DLF1KA] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION ( KA)) …630
TM- 71 FAILURE CODE [ DLF1LC] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) …631
TM- 72 FAILURE CODE [ DLF2KA] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) …632
TM- 73 FAILURE CODE [ DLF2LC] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) …633
TM- 74 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) …634
TM- 75 FAILURE CODE [ DLT3LC] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) …635
TM- 76 FAILURE CODE [ DXH0KA] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: DISCONNECTION ( KA)) …637
TM- 77 FAILURE CODE [ DXH0KB] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT ( KB)) …638
TM- 78 FAILURE CODE [ DXH1KA] ( SOLENOID FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) …639
TM- 79 FAILURE CODE [ DXH1KB] ( SOLENOID FOR LOCK- UP CLUTCH: SHORT CIRCUIT ( KB)) …640
TM- 80 FAILURE CODE [ DXH2KA] ( SOLENOID FOR HI CLUTCH: DISCONNECTION ( KA)) …641
TM- 81 FAILURE CODE [ DXH2KB] ( SOLENOID FOR HI CLUTCH: SHORT CIRCUIT ( KB)) …642
TM- 82 FAILURE CODE [ DXH3KA] ( SOLENOID FOR LO CLUTCH: DISCONNECTION ( KA)) …643
TM- 83 FAILURE CODE [ DXH3KB] ( SOLENOID FOR LO CLUTCH: SHORT CIRCUIT ( KB)) …644
TM- 84 FAILURE CODE [ DXH4KA] ( SOLENOID FOR 1ST CLUTCH: DISCONNECTION ( KA)) …645
TM- 85 FAILURE CODE [ DXH4KB] ( SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT ( KB)) …646
TM- 86 FAILURE CODE [ DXH5KA] ( SOLENOID FOR 2ND CLUTCH: DISCONNECTION ( KA)) …647
TM- 87 FAILURE CODE [ DXH5KB] ( SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT ( KB)) …648
TM- 88 FAILURE CODE [ DXH6KA] ( SOLENOID FOR 3RD CLUTCH: DISCONNECTION ( KA)) …649
TM- 89 FAILURE CODE [ DXH6KB] ( SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT ( KB)) …650
TM- 90 FAILURE CODE [ DXH7KA] ( SOLENOID FOR R CLUTCH: DISCONNECTION ( KA)) …651
TM- 91 FAILURE CODE [ DXH7KB] ( SOLENOID FOR R CLUTCH: SHORT CIRCUIT ( KB)) …652
TM- 92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY …653
TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM ( BK MODE) …656
BK- 1 FAILURE CODE [ 2G42ZG] ( ACCUMULATOR ( FRONT): DROP IN OIL PRESSURE ( ZG)) …677
BK- 2 FAILURE CODE [ 2G43ZG] ( ACCUMULATOR ( REAR): DROP IN OIL PRESSURE ( ZG)) …677
BK- 3 FAILURE CODE [ D1C0KZ] ( BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …678
BK- 4 FAILURE CODE [ D5ZFKZ] ( NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …680
BK- 5 FAILURE CODE [ D5ZGKZ] ( NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …681
BK- 6 FAILURE CODE [ DB10KK] ( RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) …682
BK- 7 FAILURE CODE [ DB11KK] ( RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) …684
BK- 8 FAILURE CODE [ DB12KK] ( RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) …685
BK- 9 FAILURE CODE [ DB13KK] ( RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) …686
BK- 10 FAILURE CODE [ DB19KM] ( RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) …687
BK- 11 FAILURE CODE [ DB1SKQ] ( RETARDER CONTROLLER S- NET LINE: MODEL SELECTION SIGNAL MISMATCH ( KQ)) …688
BK- 12 FAILURE CODE [ DHU2KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( FRONT): INPUT SIGNAL OUTSIDE RANGE ( KX)) …689
BK- 13 FAILURE CODE [ DHU3KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( REAR): INPUT SIGNAL OUTSIDE RANGE ( KX)) …691
BK- 14 FAILURE CODE [ DK51L5] ( RETARDER LEVER POTENTIOMETER: * SEE SEPARATE TABLE ( L5)) …693
BK- 15 FAILURE CODE [ DK52KX] ( DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE ( KX)) …696
BK- 16 FAILURE CODE [ DK53L8] ( DUMP LEVER POTENTIOMETER 2: * SEE THE TABLE IN CONTENTS. ( L8)) …698
BK- 17 FAILURE CODE [ DK54KX] ( BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) …699
BK- 18 FAILURE CODE [ DLF4KA] ( TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION ( KA)) …701
BK- 19 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) …702
BK- 20 FAILURE CODE [ DW71KZ] ( EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …703
BK- 21 FAILURE CODE [ DW72KZ] ( DUMP LEVER KICK- OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …704
BK- 22 FAILURE CODE [ DW73KZ] ( DUMP SELECTOR VALVE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) …706
BK- 23 FAILURE CODE [ DX11KA] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) …708
BK- 24 FAILURE CODE [ DX11KB] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) …709
BK- 25 FAILURE CODE [ DX11KY] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) …710
BK- 26 FAILURE CODE [ DX12KA] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) …711
BK- 27 FAILURE CODE [ DX12KB] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) …712
BK- 28 FAILURE CODE [ DX12KY] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) …713
BK- 29 FAILURE CODE [ DX13KA] ( DUMP EPC VALVE SOLENOID: DISCONNECTION ( KA)) …714
BK- 30 FAILURE CODE [ DX13KB] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT ( KB)) …715
BK- 31 FAILURE CODE [ DX13KY] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) …716
BK- 32 PARKING BRAKE DOES NOT WORK PROPERLY …717
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM ( MON MODE) …720
MON- 1 FAILURE CODE [ B@ C6NS] ( FRONT BRAKE OIL: OVERHEAT ( NS)) …729
MON- 2 FAILURE CODE [ B@ C8NS] ( CENTER BRAKE OIL: OVERHEAT ( NS)) …729
MON- 3 FAILURE CODE [ B@ CENS] ( TORQUE CONVERTER: OVERHEAT ( NS)) …729
MON- 4 FAILURE CODE [ DAF0KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) …730
MON- 5 FAILURE CODE [ DAF9KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) …731
MON- 6 FAILURE CODE [ DAFSKQ] ( MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) …732
MON- 7 FAILURE CODE [ DAQSKR] ( TRANSMISSION CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) …733
MON- 8 FAILURE CODE [ DB1SKR] ( RETARDER CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) …735
MON- 9 FAILURE CODE [ DB2SKR] ( ENGINE CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) …737
MON- 10 FAILURE CODE [ DV00KB] ( ALARM BUZZER: SHORT CIRCUIT ( KB)) …739
MON- 11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY …740
MON- 12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED …741
MON- 13 ALARM BUZZER DOES NOT SOUND …742
MON- 14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY …743
MON- 15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY …744
MON- 16 …745
MON- 17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY …748
MON- 18 AISS FUNCTION DOES NOT WORK PROPERLY …749
MON- 19 EXHAUST BRAKE DOES NOT WORK PROPERLY ( MACHINES EQUIPPED WITH EXHAUST BRAKE) …750
MON- 20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY …752
MON- 21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY …754
MON- 22 NIGHT LIGHTING IS NOT NORMAL …759
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ( H MODE) …766
H- 1 MACHINE DOES NOT START …767
H- 2 MACHINE DOES NOT TRAVEL SMOOTHLY ( MACHINE JERKS) H- 3 LOCK- UP CLUTCH CANNOT BE DISENGAGED ( ENGINE STALLS) …768
H- 4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING …769
H- 5 …770
H- 6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING …771
H- 7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR …774
H- 8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH …775
H- 9 TORQUE CONVERTER OIL PRESSURE IS LOW …776
H- 10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE …777
H- 11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE …778
H- 12 STEERING WHEEL IS HEAVY …779
H- 13 STEERING WHEEL DOES NOT WORK …780
H- 14 STEERING WHEEL VIBRATES …781
H- 15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER …782
H- 16 DUMP DOES NOT WORK …783
H- 17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY …784
30 DISASSEMBLY AND ASSEMBLY …810
HOW TO READ THIS MANUAL …812
REMOVAL AND INSTALLATION OF ASSEMBLIES …812
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES …813
2. Precautions when carrying out installation work …815
3. Precautions when completing the operation …815
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY …820
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY …823
REMOVAL AND INSTALLATION OF NOZZLE TIP …827
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY …830
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY …838
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY …843
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY …846
ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY …849
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY …852
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY …859
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY …861
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY …870
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY …916
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY …931
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY …935
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY …955
DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY …957
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY …972
DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY …974
REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY …988
DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY …990
DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY …1001
REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY …1009
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY …1011
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY …1014
INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY …1016
REMOVAL AND INSTALLATION OF EQUALIZER BAR …1017
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY …1019
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY …1029
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY …1036
REMOVAL AND INSTALLATION OF FLOW AMP VALVE …1046
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY …1047
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY …1049
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY …1052
REMOVAL AND INSTALLATION OF BODY ASSEMBLY …1056
90 OTHERS …1070
SEBM024815 – Articulated Dump Truck HM300-1 Shop Manual…1090
COVER…1090
CONTENTS…1091
01 GENERAL…1116
SPECIFICATION DRAWINGS…1117
SPECIFICATIONS…1118
WEIGHT TABLE…1121
FUEL, COOLANT AND LUBRICANTS…1122
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…1125
RADIATOR, OIL COOLER, AFTERCOOLER…1126
POWER TRAIN SKELETON…1127
OUTPUT SHAFT…1129
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…1131
TORQUE CONVERTER…1133
TRANSMISSION…1139
TRANSMISSION VALVE…1158
ECMV (ELECTRONIC CONTROL MODULATION VALVE)…1159
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…1166
DRIVE SHAFT…1168
AXLE…1169
DIFFERENTIAL…1172
LIMITED SLIP DIFFERENTIAL…1178
FINAL DRIVE…1182
STEERING COLUMN…1187
BRAKE PIPING…1188
BRAKE VALVE…1190
ACCUMULATOR CHARGE VALVE…1193
ACCUMULATOR…1197
SLACK ADJUSTER…1198
BRAKE…1200
PROPORTIONAL REDUCING VALVE…1205
BRAKE SYSTEM TANK…1206
PARKING BRAKE…1207
PARKING BRAKE CALIPER…1209
SPRING CYLINDER…1210
PARKING BRAKE SOLENOID…1211
SUSPENSION…1212
SUSPENSION CYLINDER…1217
OSCILLATION HITCH…1219
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM…1222
DUMP BODY CONTROL…1223
HYDRAULIC TANK AND FILTER…1224
FLOW AMP VALVE…1225
STEERING VALVE…1228
STEERING CYLINDER…1232
HOIST VALVE…1233
EPC VALVE…1239
PILOT CHECK VALVE…1240
HOIST CYLINDER…1241
HYDRAULIC PUMP…1242
CAB TILT…1246
AIR CONDITIONER…1247
HEARTER…1252
MACHINE MONITOR SYSTEM…1255
AUTOMATIC SHIFT CONTROL SYSTEM…1268
TRANSMISSION CONTROLLER…1270
AUTO EMERGENCY STEERING SYSTEM…1276
SENSORS, SWITCHES…1277
RETARDER CONTROL SYSTEM…1285
BRAKE CONTROL SYSTEM (E-SPEC)…1295
DUMP CONTROL LEVER…1304
20 TESTING AND ADJUSTING…1309
STANDARD VALUE TABLE FOR ENGINE…1310
STANDARD VALUE TABLE FOR CHASSIS…1311
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…1315
TESTING AND ADJUSTING…1327
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…1328
MEASURING ENGINE SPEED…1330
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…1331
MEASURING EXHAUST TEMPERATURE…1332
MEASURING EXHAUST COLOR…1334
MEASURING COMPRESSION PRESSURE…1335
ADJUSTING VALVE CLEARANCE…1336
MEASURING BLOW-BY PRESSURE…1337
MEASURING ENGINE OIL PRESSURE…1338
HANDING EQUIPMENT IN FUEL CIRCUIT…1339
RELEASING REMAINING PRESSURE IN FUEL SYSTEM…1339
MEASURING FUEL PRESSURE…1340
BLEEDING AIR FROM FUEL CIRCUIT…1341
REDUCED CYLINDER MODE OPERATION FOR ENGINE…1343
CHECKING FOR LEAKAGE IN FUEL CIRCUIT…1344
ADJUSTING ENGINE SPEED SENSOR…1345
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…1346
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…1346
ADJUSTING THE BODY MOUNT…1347
TESTING TORQUE CONVERTER STALL SPEED…1349
MEASURING POWER TRAIN OIL PRESSURE…1350
ADJUSTING TRANSMISSION SPEED SENSOR…1357
TESTING AND ADJUSTING BRAKE OIL PRESSURE…1359
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS…1363
TESTING BRAKE PERFORMANCE…1367
BLEEDING AIR FROM BRAKE CIRCUIT…1369
TESTING WEAR OF WHEEL BRAKE DISC…1371
TESTING WEAR OF PARKING BRAKE PAD…1372
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE…1373
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE…1374
TESTING AND ADJUSTING SUSPENSION CYLINDER…1376
METHOD OF TILTING CAB UP…1380
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE…1383
ADJUSTING BODY POSITIONER SENSOR…1386
PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT…1387
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT…1387
ADJUSTING TRANSMISSION CONTROLLER…1388
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM…1389
ADJUSTING MACHINE MONITOR…1393
SPECIAL FUNCTIONS OF MACHINE MONITOR…1397
PM-CLINIC INSPECTION SHEET…1431
TROUBLESHOOTING…1434
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1435
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1436
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…1437
CHECKS BEFORE TROUBLESHOOTING…1445
CONNECTOR TYPES AND MOUNTING LOCATIONS…1446
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1461
T-ADAPTER TABLE…1484
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS…1487
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)…1491
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1493
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…1496
ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))…1508
ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))…1509
ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))…1510
ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))…1510
ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))…1511
ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))…1513
ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))…1513
ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))…1514
ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))…1515
ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))…1516
ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))…1517
ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1518
ENG-13 FAILURE CODE [ADAZKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…1519
ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1523
ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1524
ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1525
ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))…1526
ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1530
ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))…1531
ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))…1532
ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))…1533
ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))…1534
ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))…1535
ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))…1537
ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))…1538
ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…1540
ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))…1541
ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))…1543
ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))…1545
ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))…1546
ENG-31 FAILURE CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))…1547
ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))…1548
ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))…1550
ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))…1552
ENG-35 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))…1553
ENG-36 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1554
ENG-37 FAILURE CODE [DH40KX] (COMMON PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1556
ENG-38 FAILURE CODE [DH10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1558
ENG-39 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))…1560
ENG-40 FAILURE CODE [DLH1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))…1561
ENG-41 ENGINE DOES NOT STARTS (STARTING MOTOR DOES NOT TURN)…1562
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)…1565
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1568
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…1574
TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))…1600
TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE THE TABLE IN CONTENTS (LO))…1601
TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))…1602
TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))…1603
TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))…1604
TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))…1605
TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))…1606
TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))…1607
TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))…1608
TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE THE TABLE CONTENTS (L1)) …1609
TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))…1610
TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1611
TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))…1612
TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1613
TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))…1614
TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1615
TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))…1616
TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1617
TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))…1618
TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE HTE TABLE IN CONTENTS (L1))…1619
TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))…1620
TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1621
TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))…1622
TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE THE TABLE IN CONTENTS (L1))…1623
TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))…1624
TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))…1625
TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) …1626
TM-28 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))…1628
TM-29 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…1629
TM-30 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))…1630
TM-31 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))…1632
TM-32 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))…1634
TM-33 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))…1635
TM-34 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))…1636
TM-35 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (NS))…1637
TM-36 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…1638
TM-37 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…1640
TM-38 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))…1642
TM-39 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE THE TABLE IN CONTENTS (L4))…1643
TM-40 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))…1645
TM-41 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…1646
TM-42 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…1648
TM-43 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…1649
TM-44 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))…1650
TM-45 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))…1651
TM-46 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…1652
TM-47 FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…1653
TM-48 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…1654
TM-49 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))…1654
TM-50 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))…1655
TM-51 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…1656
TM-52 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))…1657
TM-53 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))…1658
TM-54 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))…1659
TM-55 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))…1660
TM-56 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))…1661
TM-57 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))…1662
TM-58 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))…1663
TM-59 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))…1665
TM-60 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1667
TM-61 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE THE TABLE IN CONTENTS (L8))…1669
TM-62 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE THE TABLE IN CONTENTS (L8))…1671
TM-63 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1673
TM-64 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1675
TM-65 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE THE TABLE IN CONTENTS (L6))…1677
TM-66 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (KA))…1678
TM-67 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1679
TM-68 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))…1681
TM-69 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))…1682
TM-70 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))…1683
TM-71 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))…1684
TM-72 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION (KA))…1685
TM-73 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))…1686
TM-74 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))…1687
TM-75 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))…1688
TM-76 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))…1690
TM-77 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))…1691
TM-78 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))…1692
TM-79 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))…1693
TM-80 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))…1694
TM-81 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))…1695
TM-82 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))…1696
TM-83 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))…1697
TM-84 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))…1698
TM-85 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))…1699
TM-86 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))…1700
TM-87 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))…1701
TM-88 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))…1702
TM-89 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))…1703
TM-90 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))…1704
TM-91 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))…1705
TM-92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY…1706
TM-93 EMERGENCY STEERING DOES NOT OPERATE…1709
TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)…1713
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1715
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE…1720
BK-1 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))…1732
BK-2 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))…1732
BK-3 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))…1733
BK-4 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))…1735
BK-5 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))…1736
BK-6 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…1737
BK-7 FAILURE CODE [DB11KK] (RETARDER CONTROLLER (*1) MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…1739
BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER (*1) LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…1740
BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER (*1) BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)…1741
BK-10 FAILURE CODE [DB19KM] (RETARDER CONTROLLER (*1) WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…1742
BK-11 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER (*1) S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))…1743
BK-12 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))…1744
BK-13 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))…1746
BK-14 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (L5))…1748
BK-15 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))…1751
BK-16 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE THE TABLE IN CONTENTS (L8))…1753
BK-17 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))…1754
BK-18 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))…1756
BK-19 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))…1757
BK-20 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)…1758
BK-21 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…1759
BK-22 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))…1761
BK-23 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…1763
BK-24 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…1764
BK-25 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…1765
BK-26 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))…1766
BK-27 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))…1767
BK-28 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…1768
BK-29 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))…1769
BK-30 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))…1770
BK-31 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))…1771
BK-32 PARKING BRAKE DOES NOT WORK PROPERLY…1772
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)…1775
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM…1776
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE …1780
MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))…1784
MON-2 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))…1784
MON-3 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))…1784
MON-4 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…1785
MON-5 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))…1786
MON-6 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))…1787
MON-7 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…1788
MON-8 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…1790
MON-9 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))…1792
MON-10 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))…1794
MON-11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY…1795
MON-12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED…1796
MON-13 ALARM BUZZER DOES NOT SOUND…1797
MON-14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY…1798
MON-15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY…1799
MON-16 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY…1800
MON-17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY…1803
MON-18 AISS FUNCTION DOES NOT WORK PROPERLY…1804
MON-19 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)…1805
MON-20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY…1807
MON-21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY…1809
MON-22 NIGHT LIGHTING IS NOT NORMAL…1814
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…1821
H-1 MACHINE DOES NOT START…1822
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…1823
H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)…1823
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…1824
H-5 TRANSMISSION DOES NOT SHIFT UP…1825
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…1826
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…1829
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…1830
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…1831
H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…1832
H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE…1833
H-12 STEERING WHEEL IS HEAVY…1834
H-13 STEERING WHEEL DOES NOT WORK…1835
H-14 STEERING WHEEL VIBRATES…1836
H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER…1837
H-16 DUMP DOES NOT WORK…1838
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…1839
TROUBLESHOOTING OF THE ENGINE BODY (S MODE)…1840
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1841
METHOD OF USING TROUBLESHOOTING CHARTS…1842
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…1845
S-2 ENGINE DOES NOT START…1846
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…1849
S-4 ENGINE STOPS DURING OPERATIONS…1850
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…1851
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…1852
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…1853
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…1854
S-9 OIL BECOMES CONTAMINATED QUICKLY…1855
S-10 FUEL CONSUMPTION IS EXCESSIVE…1856
S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)…1857
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…1858
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…1859
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1860
S-15 ABNORMAL NOISE IS MADE…1861
S-16 VIBRATION IS EXCESSIVE…1862
30 DISASSEMBLY AND ASSEMBLY…1863
HOW TO READ THIS MANUAL…1865
REMOVAL AND INSTALLATION OF ASSEMBLIES…1865
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES…1866
PRECAUTIONS WHEN CARRYING OUT OPERATION…1867
SPECIAL TOOL LIST…1869
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…1873
SPECIAL TOOL…1873
REMOVAL…1873
INSTALLATION…1876
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…1878
REMOVAL…1878
INSTALLATION…1879
REMOVAL AND INSTALLATION OF NOZZLE TIP…1882
SPECIAL TOOL…1882
REMOVAL…1882
INSTALLATION…1883
SKETCHES OF SPECIAL TOOLS…1884
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…1885
SPECIAL TOOL…1885
REMOVAL…1885
INSTALLATION…1889
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY…1893
SPECIAL TOOL…1893
REMOVAL…1893
INSTALLATION…1897
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…1898
REMOVAL…1898
INSTALLATION…1900
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY…1901
SPECIAL TOOL…1901
REMOVAL…1901
INSTALLATION…1903
ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY…1906
DISASSEMBLY…1906
ASSEMBLY…1907
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…1909
SPECIAL TOOL…1909
REMOVAL…1909
INSTALLATION…1914
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY…1916
DISCONNECTION…1916
CONNECTION…1917
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…1918
SPECIAL TOOL…1918
DISASSEMBLY…1918
ASSEMBLY…1921
SKETCHES OF SPECIAL TOOLS…1926
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY…1927
SPECIAL TOOL…1927
DISASSEMBLY…1927
ASSEMBLY…1944
SKETCHES OF SPECIAL TOOLS…1970
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…1973
SPECIAL TOOL…1973
DISASSEMBLY…1973
ASSEMBLY…1977
SKETCHES OF SPECIAL TOOLS…1987
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…1988
SPECIAL TOOL…1988
REMOVAL…1988
INSTALLATION…1990
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…1992
SPECIAL TOOL…1992
DISASSEMBLY…1992
ASSEMBLY…1997
SKETCHES OF SPECIAL TOOLS…2009
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…2012
REMOVAL…2012
INSTALLATION…2013
DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY …2014
SPECIAL TOOL…2014
DISASSEMBLY…2014
ASSEMBLY…2018
SKETCHES OF SPECIAL TOOLS…2028
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…2029
REMOVAL…2029
INSTALLATION…2030
DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…2031
SPECIAL TOOL…2031
DISASSEMBLY…2031
ASSEMBLY…2035
SKETCHES OF SPECIAL TOOLS…2042
REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…2045
REMOVAL…2045
INSTALLATION…2046
DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…2047
SPECIAL TOOL…2047
DISASSEMBLY…2047
ASSEMBLY…2049
SKETCHES OF SPECIAL TOOLS…2055
DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…2058
SPECIAL TOOL…2058
DISASSEMBLY…2058
ASSEMBLY…2060
SKETCHES OF SPECIAL TOOLS…2065
REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY…2066
REMOVAL…2066
INSTALLATION…2067
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY…2068
REMOVAL…2068
INSTALLATION…2070
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY…2071
REMOVAL…2071
INSTALLATION…2072
INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY…2073
REMOVAL…2073
INSTALLATION…2073
REMOVAL AND INSTALLATION OF EQUALIZER BAR…2076
REMOVAL…2076
INSTALLATION…2077
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY…2078
SPECIAL TOOL…2078
REMOVAL…2078
INSTALLATION…2083
SKETCHES OF SPECIAL TOOLS…2087
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY…2088
SPECIAL TOOL…2088
DISASSEMBLY…2088
ASSEMBLY…2089
SKETCHES OF SPECIAL TOOLS…2094
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY…2095
DISASSEMBLY…2097
ASSEMBLY…2100
REMOVAL AND INSTALLATION OF FLOW AMP VALVE…2105
SPECIAL TOOL…2105
REMOVAL…2105
INSTALLATION…2106
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY…2107
SPECIAL TOOL…2107
REMOVAL…2107
INSTALLATION…2108
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY…2110
SPECIAL TOOL…2110
DISASSEMBLY…2110
ASSEMBLY…2111
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY…2113
SPECIAL TOOL…2113
DISASSEMBLY…2113
ASSEMBLY…2115
REMOVAL AND INSTALLATION OF BODY ASSEMBLY…2117
REMOVAL…2117
INSTALLATION…2118
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY…2120
DISASSEMBLY…2120
ASSEMBLY…2125
90 OTHERS…2130
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…2131
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…2132
BRAKE HYDRAULIC CIRCUIT DIAGRAM…2133
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…2134
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM (-30°C SPECIFICATION)…2135
DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER…2136
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)…2137
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)…2138
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)…2139
DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)…2140
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3)…2141
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/3)…2142
DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (3/3)…2143
DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER…2144
DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR…2145
SEN00237-04 – Dump Truck GALEO HM300-2 Shop Manual…2146
COVER…2146
00 INDEX AND FOREWORD…0
INDEX…2147
COMPOSITION OF SHOP MANUAL…2148
TABLE OF CONTENTS…2150
FOREWORD AND GENERAL INFORMATION…2161
SAFETY NOTICE…2162
HOW TO READ THE SHOP MANUAL …2167
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…2169
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT…2171
HOW TO READ ELECTRIC WIRE CODE…2183
PRECAUTIONS WEHN CARRYING OUT OPERATION…2186
MENTHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER…2189
STANDARD TIGHTENING TORQUE TABLE…2192
CONVERSION TABLE…2196
01 SPECIFICATION…0
SPECIFICATION AND TECHNICAL DATA…2203
SPECIFICATION DRAWINGS…2204
SPECIFICATIONS…2205
WEIGHT TABLE…2208
FUEL, COOLANT AND LUBRICANTS…2209
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…0
ENGINE AND COOLING SYSTEM…2213
RADIATOR, OIL COOLER, AFTERCOOLER…2214
OUTPUT SHAFT…2215
POWER TRAIN, PART 1…2219
POWER TRAIN SKELETON…2220
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…2222
BRAKE COOLING OIL CONTROL VALVE (BCV)…2224
POWER TRAIN PUMP…2225
TORQUE CONVERTER…2228
TRANSMISSION…2234
TRANSMISSION CONTROL VALVE…2262
ECMV…2263
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE…2270
POWER TRAIN, PART 2…2273
DRIVE SHAFT…2274
AXLE…2275
DIFFERENTIAL…2278
LIMITED SLIP DIFFERENTIAL…2284
FINAL DRIVE…2288
STEERING SYSTEM…2295
STEERING COLUMN…2296
BRAKE SYSTEM…2299
BRAKE PIPING…2300
BRAKE VALVE…2302
ACCUMULATOR CHARGE VALVE…2305
ACCUMULATOR…2309
SLACK ADJUSTER…2310
BRAKE…2312
PROPORTIONAL REDUCING VALVE…2317
BRAKE SYSTEM TANK…2318
PARKING BRAKE …2320
PARKING BRAKE SOLENOID…2324
UNDERCARRIAGE AND FRAME…2327
SUSPENSION…2328
SUSPENSION CYLINDER…2334
OSCILLATION HITCH…2336
HYDRAULIC SYSTEM…2341
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM…2342
DUMP BODY CONTROL…2343
HYDRAULIC TANK AND FILTER…2344
FLOW AMP VALVE…2345
STEERING VALVE…2348
STEERING CYLINDER…2352
HOIST VALVE…2354
EPC VALVE…2360
HOIST CYLINDER…2361
HYDRAULIC PUMP…2362
CAB AND ITS ATTACHMENTS…2365
ROPS CAB…2366
CAB TILT…2367
AIR CONDITIONER…2368
REAR VIEW MONITOR…2376
CONTROLLER RELATED…2379
ELECTRICAL SYSTEM, PART 1…2381
MACHINE MONITOR SYSTEM…2382
ELECTRICAL SYSTEM, PART 2…2403
AUTOMATIC SHIFT CONTROL SYSTEM…2404
RETARDER CONTROL SYSTEM…2436
AUTO EMERGENCY STEERING SYSTEM…2448
DUMP CONTROL LEVER…2449
ELECTRICAL SYSTEM, PART 3…2455
SENSORS, SWITCHES…2456
KOMTRAX TERMINAL SYSTEM (IF EQUIPPED)…2464
20 STANDARD VALUE TABLE…0
STANDARD SERVICE VALUE TABLE…2467
STANDARD VALUE TABLE FOR ENGINE…2468
STANDARD VALUE TABLE FOR CHASSIS…2469
30 TESTING AND ADJUSTING …0
TESTING AND ADJUSTING, PART 1…2475
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING …2477
MEASURING ENGINE SPEED…2481
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)…2482
MEASURING EXHAUST TEMPERATURE…2483
MEASURING EXHAUST GAS COLOR…2485
ADJUSTING VALVE CLEARANCE…2486
MEASURING COMPRESSION PRESSURE…2488
MEASURING BLOW-BY PRESSURE…2490
MEASURING ENGINE OIL PRESSURE…2491
MEASURING EGR VALVE AND BYPASS VALVE DRIVE PRESSURE…2492
HANDLING OF FUEL SYSTEM DEVICES…2493
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM…2493
TESTING FUEL PRESSURE…2494
TESTING FUEL RETURN AND LEAK AMOUNT…2495
BLEEDING AIR FROM FUEL CIRCUIT…2498
TESTING THE FUEL CIRCUIT FOR LEAKAGE…2499
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…2500
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…2500
TESTING AND ADJUSTING, PART 2…2503
MEASURING TORQUE CONVERTER STALL SPEED…2505
MEASURING POWER TRAIN OIL PRESSURE…2506
ADJUSTING TRANSMISSION SPEED SENSOR…2514
TESTING AND ADJUSTING BRAKE OIL PRESSURE…2516
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS…2520
TESTING BRAKE PERFORMANCE…2523
BLEEDING AIR FROM BRAKE CIRCUIT…2524
MEASURING WEAR OF WHEEL BRAKE DISC…2525
MEASURING WEAR OF PARKING BRAKE PAD…2526
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE…2528
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE…2529
TESTING AND ADJUSTING SUSPENSION CYLINDER…2531
METHOD OF TILTING CAB UP…2535
TESTING AND ADJUSTING DUMP CIRCUIT OIL PRESSURE…2537
ADJUSTING BODY POSITIONER SENSOR…2540
PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT…2541
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT…2541
ADJUSTING TRANSMISSION CONTROLLER…2542
METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILURE…2543
TESTING AND ADJUSTING, PART 3…2549
SETTING AND ADJUSTING VARIOUS EQUIPMENTS…2550
SPECIAL FUNCTION OF MACHINE MONITOR (EMMS)…2561
HOW TO START OPERATION OF KOMTRAX TERMINAL…2595
LAMP DISPLAY OF KOMTRAX TERMINAL…2598
40 TROUBLESHOOTING…0
FAILURE CODE TABLE AND FUSE LOCATIONS…2603
FAILURE CODE TABLE…2604
BEFORE TROUBLESHOOTING BY FAILURE CODES…2612
GENERAL INFORMATION ON TROUBLESHOOTING…2617
POINTS TO REMEMBER WHEN TROUBLESHOOTING …2618
SEQUENCE OF EVENTS IN TROUBLESHOOTING…2619
CHECKS BEFORE TROUBLESHOOTING…2620
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING…2621
INFORMATION IN TROUBLESHOOTING TABLE…2622
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2624
T-ADAPTER BOX AND T-BRANCH ADAPTER TABLE…2658
TROUBLESHOOTING BY FAILURE CODE, PART 1…2663
FAILURE CODE [1500L0] (DUAL ENGAGEMENT)…2665
FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED)…2666
FAILURE CODE [15FOKM] (R→F SHIFTING ABUSE 1: OPERATIONAL ERROR OR INCORRECT SETTING)…2668
FAILURE CODE [15FOMB] (R→F SHIFTING ABUSE 2: FUNCTIONAL DETERIORATION)…2668
FAILURE CODE [15F7KM] (FORWARD CLUTCH DISK ABUSE)…2669
FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING)…2670
FAILURE CODE [15G7KM] (REVERSE CLUTCH DISK ABUSE)…2672
FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING)…2673
FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING)…2676
FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING)…2678
FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING)…2680
FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING)…2682
FAILURE CODE [15SBL1] (R CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)…2684
FAILURE CODE [15SBMA] (R CLUTCH SOLENOID: MALFUNCTION)…2688
FAILURE CODE [15SCL1] (HI CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)…2690
FAILURE CODE [15SCMA] (HI CLUTCH SOLENOID: MALFUNCTION)…2694
FAILURE CODE [15SDL1] (LO CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)…2696
FAILURE CODE [15SDMA] (LO CLUTCH SOLENOID: MALFUNCTION)…2698
FAILURE CODE [15SEL1] (1ST CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF)…2702
FAILURE CODE [15SEMA] (1ST CLUTCH SOLENOID: MALFUNCTION)…2706
FAILURE CODE [15SFL1] (2ND CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)…2708
FAILURE CODE [15SFMA] (2ND CLUTCH SOLENOID: MALFUNCTION)…2712
FAILURE CODE [15SGL1] (3RD CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)…2714
FAILURE CODE [15SGMA] (3RD CLUTCH SOLENOID: MALFUNCTION)…2718
FAILURE CODE [15SJMA] (LOCKUP CLUTCH SOLENOID: MALFUNCTION)…2720
FAILURE CODE [15SKMA] (INTER-AXLE DIFFERENTIAL LOCKUP PRESSURE CONTROL VALVE: MALFUNCTION)…2722
FAILURE CODE [2F00KM] (PARKING BRAKE: ERROR IN OPERATION OR SETTING)…2724
FAILURE CODE [2G42ZG] (FRONT ACCUMULATOR: OIL PRESSURE TOO LOW)…2726
FAILURE CODE [2G43ZG] (REAR ACCUMULATOR: OIL PRESSURE TOO LOW)…2726
FAILURE CODE [989A00] (ENGINE OVER RUN PREVENTION COMMAND SIGNAL: OPERATING)…2727
FAILURE CODE [989D00] (REAR SECTION TIPPING OVER ALARM: ALARM IS ACTIVATED.)…2727
FAILURE CODE [AA10NX] (AIR CLEANER ELEMENT: CLOGGED)…2728
FAILURE CODE [AB00MA] (ALTERNATOR: MALFUNCTION)…2730
FAILURE CODE [B@BAZK] (ENGINE OIL: LOW TOO LOW)…2731
FAILURE CODE [B@BCNS] (ENGINE: OVERHEAT)…2732
FAILURE CODE [B@BCZK] (RADIATOR COOLANT: LEVEL TOO LOW)…2733
FAILURE CODE [B@BFZK] (FUEL LEVEL: LEVEL TOO LOW)…2734
FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT)…2735
FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT)…2735
FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT)…2736
FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: LEVEL TOO LOW)…2737
FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT)…2738
TROUBLESHOOTING BY FAILURE CODE, PART 2…2741
FAILURE CODE [CA111] (ABNORMALITY IN ENGINE CONTROLLER)…2743
FAILURE CODE [CA115] (ABNORMAL ENGINE NE AND BKUP SENSORS)…2744
FAILURE CODE [CA122] (CHARGE PRESSURE SENSOR TOO HIGH)…2746
FAILURE CODE [CA123] (CHARGE PRESSURE SENSOR TOO LOW)…2748
FAILURE CODE [CA131] (THROTTLE SENSOR TOO HIGH)…2750
FAILURE CODE [CA132] (THROTTLE SENSOR TOOL LOW)…2752
FAILURE CODE [CA135] (OIL PRESSURE SENSOR TOO HIGH)…2754
FAILURE CODE [CA141] (OIL PRESSURE SENSOR TOO LOW)…2756
FAILURE CODE [CA144] (COOLANT TEMPERATURE SENSOR TOO HIGH)…2758
FAILURE CODE [CA145] (COOLANT TEMPERATURE SENSOR TOO LOW)…2760
FAILURE CODE [CA153] (CHARGE TEMPERATURE SENSOR TOO HIGH)…2762
FAILURE CODE [CA154] (CHARGE TEMPERATURE SENSOR TOO LOW)…2764
FAILURE CODE [CA187] (SENSOR POWER SOURCE 2 TOO LOW)…2764
FAILURE CODE [CA221] (ATMOSPHERIC SENSOR TOO HIGH)…2766
FAILURE CODE [CA222] (ATMOSPHERIC SENSOR TOO LOW)…2768
FAILURE CODE [CA227] (SENSOR POWER SOURCE 2 TOO HIGH)…2770
FAILURE CODE [CA234] (ENGINE OVER SPEED)…2772
FAILURE CODE [CA238] (ABNORMAL POWER SOURCE FOR NE SPEED SENSOR)…2774
FAILURE CODE [CA263] (FUEL TEMPERATURE SENSOR TOO HIGH)…2776
FAILURE CODE [CA265] (FUEL TEMPERATURE SENSOR TOO LOW)…2778
FAILURE CODE [CA271] (PCV1 SHORT CIRCUIT)…2779
FAILURE CODE [CA272] (PCV1 SHORT DISCONNECTION)…2780
FAILURE CODE [CA273] (PCV2 SHORT CIRCUIT)…2781
FAILURE CODE [CA274] (PCV2 DISCONNECTION)…2782
FAILURE CODE [CA322] (INJECTOR NO.1 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2784
FAILURE CODE [CA323] (INJECTOR NO.5 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2786
FAILURE CODE [CA324] (INJECTOR NO.3 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2788
FAILURE CODE [CA325] (INJECTOR NO.6 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2790
FAILURE CODE [CA331] (INJECTOR NO.2 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2792
FAILURE CODE [CA332] (INJECTOR NO.4 SYSTEM DISCONNECTION OR SHORT CIRCUIT)…2794
FAILURE CODE [CA342] (ABNORMAL ENGINE CONTROLLER DATA CONSISTENCY)…2796
FAILURE CODE [CA351] (ABNORMAL INJECTOR DRIVE CIRCUIT)…2797
FAILURE CODE [CA352] (SENSOR POWER SOURCE 1 TOO LOW)…2798
FAILURE CODE [CA386] (SENSOR POWER SOURCE 1 TOO HIGH)…2800
FAILURE CODE [CA431] (ABNORMAL IDLE VALIDATION SWITCH)…2802
FAILURE CODE [CA432] (ABNORMAL PROCESS WITH IDLE VALIDATION SWITCH)…2804
FAILURE CODE [CA441] (POWER SOURCE VOLTAGE TOO LOW)…2805
FAILURE CODE [CA442] (POWER SOURCE VOLTAGE TOO HIGH)…2805
FAILURE CODE [CA449] (COMMON RAIL PRESSURE TOO HIGH 2)…2806
FAILURE CODE [CA451] (COMMON RAIL PRESSURE SENSOR TOO HIGH)…2808
FAILURE CODE [CA452] (COMMON RAIL PRESSURE SENSOR TOO LOW)…2810
FAILURE CODE [CA553] (COMMON RAIL PRESSURE TOO HIGH 1)…2810
FAILURE CODE [CA554] (IN-RANGE ERROR OF COMMON RAIL PRESSURE SENSOR)…2811
FAILURE CODE [CA559] (LOSS OF PRESSURE FEED FROM SUPPLY PUMP 1)…2812
FAILURE CODE [CA689] (ABNORMAL ENGINE NE SPEED SENSOR)…2816
FAILURE CODE [CA697] (ENGINE CONTROLLER INSIDE TEMPERATURE SENSOR TOO HIGH)…2818
FAILURE CODE [CA698] (ENGINE CONTROLLER INSIDE TEMPERATURE SENSOR TOO LOW)…2818
FAILURE CODE [CA731] (ABNORMAL ENGINE BKUP SPEED SENSOR PHASE)…2819
FAILURE CODE [CA757] (LOSS OF ALL ENGINE CONTROLLER DATA)…2819
FAILURE CODE [CA778] (ABNORMAL ENGINE BKUP SPEED SENSOR)…2820
FAILURE CODE [CA1117] (LOSS OF PARTIAL ENGINE CONTROLLER DATA)…2822
FAILURE CODE [CA1228] (ABNORMAL EGR VALVE SERVO 1)…2823
FAILURE CODE [CA1625] (ABNORMAL EGR VALVE SERVO 2)…2824
FAILURE CODE [CA1626] (SHORT CIRCUIT OF BYPASS VALVE SOLENOID DRIVE)…2826
FAILURE CODE [CA1627] (DISCONNECTION IN BYPASS VALVE SOLENOID DRIVE)…2828
FAILURE CODE [CA1628] (ABNORMAL BYPASS VALVE SERVO 1)…2829
FAILURE CODE [CA1629] (ABNORMAL BYPASS VALVE SERVO 2)…2830
TROUBLESHOOTING BY FAILURE CODE, PART 3…2833
FAILURE CODE [CA1631] (BYPASS VALVE LIFT SENSOR TOO HIGH)…2836
FAILURE CODE [CA1632] (BYPASS VALVE LIFT SENSOR TOO LOW)…2838
FAILURE CODE [CA1633] (ABNORMAL KOMNET)…2840
FAILURE CODE [CA1642] (EGR INLET PRESSURE SENSOR TOO LOW)…2842
FAILURE CODE [CA1653] (EGR INLET PRESSURE SENSOR TOO HIGH)…2844
FAILURE CODE [CA2185] (THROTTLE SENSOR POWER SOURCE TOO HIGH)…2846
FAILURE CODE [CA2186] (THROTTLE SENSOR POWER SOURCE TOO LOW)…2848
FAILURE CODE [CA2249] (LOSS OF PRESSURE FEED FROM SUPPLY PUMP 2)…2848
FAILURE CODE [CA2271] (EGR VALVE LIFT SENSOR TOO HIGH)…2850
FAILURE CODE [CA2272] (EGR VALVE LIFT SENSOR TOO LOW)…2852
FAILURE CODE [CA2351] (EGR VALVE SOLENOID DRIVE SHORT CIRCUT)…2854
FAILURE CODE [CA2352] (EGR VALVE SOLENOID DRIVE DISCONNECTION)…2856
FAILURE CODE [CA2555] (INTAKE AIR HEATER RELAY DISCONNECTION)…2856
FAILURE CODE [CA2556] (INTAKE AIR HEATER RELAY SHORT CIRCUIT)…2858
FAILURE CODE [DAF9KM] (MACHINE MONITOR CONNECTOR: ERROR IN OPERATION OR SETTING)…2860
FAILURE CODE [DAFRKR] (ABNORMAL CAN COMMUNICATION (MACHINE MONITOR): ABNORMAL COMMUNICATION)…2862
FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE TOO LOW)…2864
FAILURE CODE [DAQ0KT] (TRANSMISSION NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)…2866
FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER SOLENOID POWER SOURCE: VOLTAGE TOO LOW)…2867
FAILURE CODE [DAQRKR] (COMMUNICATION LOST: DEFECTIVE COMMUNICATION)…2868
FAILURE CODE [DAQRMA] (TRANSMISSION CONTROLLER OPTION SETTING: MALFUNCTION)…2870
FAILURE CODE [DB10KT] (RETARDER CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)…2870
FAILURE CODE [DB12KK] (RETARDER CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)…2871
FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)…2872
FAILURE CODE [DB19KQ] (RETARDER CONTROLLER MODEL SELECT SIGNAL: INCONSISTENT MODEL SELECTION SIGNAL)…2873
FAILURE CODE [DB1QMA] (RETARDER CONTROLLER OPTION SETTING: MALFUNCTION)…2873
FAILURE CODE [DB1RKR] (CAN COMMUNICATION (RETARDER CONTROLLER): COMMUNICATION DISABLED)…2874
FAILURE CODE [DB2RKR] (CAN COMMUNICATION (ENGINE CONTROLLER): COMMUNICATION DISABLED)…2876
FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION)…2878
FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION)…2880
FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION)…2882
FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION)…2883
FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION)…2884
FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION)…2885
FAILURE CODE [DF10KA] (GEAR SHIFT LEVER: DISCONNECTION)…2886
FAILURE CODE [DF10KB] (GEAR SHIFT LEVER: SHORT CIRCUIT)…2889
FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2892
FAILURE CODE [DGR3KZ] (CENTER BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION OR SHORT CIRCUIT)…2894
FAILURE CODE [DGR3L8] (CENTER BRAKE OIL TEMPERATURE SENSOR: INCONSISTENT ANALOG SIGNALS)…2896
FAILURE CODE [DGR4KZ] (FRONT BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION OR SHORT CIRCUIT)…2898
FAILURE CODE [DGR4L8] (FRONT BRAKE OIL TEMPERATURE SENSOR: INCONSISTENT ANALOG SIGNALS)…2900
FAILURE CODE [DGR6KX] (STEERING OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2902
FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2904
FAILURE CODE [DGT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2906
FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: INCONSISTENT SIGNALS DURING A TRAVEL AND STOP)…2908
FAILURE CODE [DHU2KX] (FRONT ACCUMULATOR OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2910
FAILURE CODE [DHU3KX] (REAR ACCUMULATOR OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)…2912
FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION)…2914
FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: POTENTIOMETER SIGNAL IS INCONSISTENT WITH SWITCH SIGNAL)…2916
FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER FAILURE 1: INPUT SIGNAL OUT OF RANGE)…2918
FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER FAILURE 2: INCONSISTENT ANALOG SIGNAL)…2920
FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUT OF RANGE)…2922
TROUBLESHOOTING BY FAILURE CODE, PART 4…2925
FAILURE CODE [DKH0KX] (PITCH ANGLE SENSOR: INCLINATION OUT OF RANGE)…2927
FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION)…2929
FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: INCONSISTENT ROTATION SPEED SIGNAL)…2930
FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION)…2931
FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: INCONSISTENT SPEED SIGNAL)…2932
FAILURE CODE [DLF4KA] (DIFFERENTIAL SPEED SENSOR: DISCONNECTION)…2933
FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION)…2934
FAILUTE CODE [DV00KB] (ALARM BUZZER OUTPUT: SHORT CIRCUIT)…2935
FAILURE CODE [DW72KZ] (KICK-OUT SOLENOID OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)…2936
FAILURE CODE [DW73KZ] (HOIST SELECTOR VALVE OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)…2938
FAILURE CODE [DW78KZ] (REAR BRAKE BCV COMMAND OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)…2940
FAILURE CODE [DW79KZ] (FRONT BRAKE BCV COMMAND OUTPUT SYSTEM: DISCONNECTION OF SHORT CIRCUIT)…2942
FAILURE CODE [DX11K4] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL)…2944
FAILURE CODE [DX11KA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT: DISCONNECTION)…2946
FAILURE CODE [DX11KB] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT)…2947
FAILURE CODE [DX11KY] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)…2948
FAILURE CODE [DX11MA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: MALFUNCTION)…2949
FAILURE CODE [DX12K4] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL)…2951
FAILURE CODE [DX12KA] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT: DISCONNECTION)…2953
FAILURE CODE [DX12KB] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT)…2954
FAILURE CODE [DX12KY] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)…2955
FAILURE CODE [DX12MA] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: MALFUNCTION)…2956
FAILURE CODE [DX13KA] (HOIST EPC VALVE OUTPUT CIRCUIT: DISCONNECTION)…2958
FAILURE CODE [DX13KB] (HOIST EPC VALVE OUTPUT CIRCUIT: SHORT CIRCUIT)…2959
FAILURE CODE [DX13KY] (HOIST EPC VALVE OUTPUT CIRCUIT: SHORT CIRCUIT IN POWER SOURCE LINE)…2960
FAILURE CODE [DXH0KA] (INTER-AXLE DIFFERENTIAL LOCK PRESSURE CONTROL VALVE: DISCONNECTION)…2961
FAILURE CODE [DXH0KB] (INTER-AXLE DIFFERENTIAL LOCK PRESSURE CONTROL VALVE: SHORT CIRCUIT)…2962
FAILURE CODE [DXH0KY] (INTER-AXLE DIFFERENTIAL LOCKUP PRESSURE CONTROL VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)…2963
FAILURE CODE [DXH1KA] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2964
FAILURE CODE [DXH1KB] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2965
FAILURE CODE [DXH1KY] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2966
FAILURE CODE [DXH2KA] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2967
FAILURE CODE [DXH2KB] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2969
FAILURE CODE [DXH2KY] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2971
FAILURE CODE [DXH3KA] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2974
FAILURE CODE [DXH3KB] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2976
FAILURE CODE [DXH3KY] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2978
FAILURE CODE [DXH4KA] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2981
FAILURE CODE [DXH4KB] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2983
FAILURE CODE [DXH4KY] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2985
FAILURE CODE [DXH5KA] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2988
FAILURE CODE [DXH5KB] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2990
FAILURE CODE [DXH5KY] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2992
FAILURE CODE [DXH6KA] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…2995
FAILURE CODE [DXH6KB] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…2997
FAILURE CODE [DXH6KY] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…2999
FAILURE CODE [DXH7KA] (R CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)…3002
FAILURE CODE [DXH7KB] (R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)…3004
FAILURE CODE [DXH7KY] (R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)…3006
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…3010
BEFORE TROUBLESHOOTING OF ELECTRIC SYSTEM…3012
CONTENTS OF TROUBLESHOOTING TABLE…3015
E-1 ENGINE DOES NOT SHART…3016
E-2 AUTOMATIC PREHEATING DOES NOT OPERATE…3019
E-3 MACHINE MONITOR DOES NOT DISPLAY ALL, WHEN STARTING SWITCH IS TURNED ON…3023
E-4 MACHINE MONITOR DOES NOT OPERATE WHEN STARTING SWITCH IS OFF…3025
E-5 ALARM BUZZER DOES NOT SOUND…3027
E-6 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLY…3028
E-7 SELECTION OF DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGED…3029
E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLY…3033
E-9 ALSS FUNCTION DOES NOT OPERATE PROPERLY…3034
E-10 SEAT BELT CAUTION LAMP DOES DISPLAY PROPERLY…3035
E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZARD LAMP) DO NOT WORK PROPERLY…3036
E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLY…3039
E-13 EMERGENCY STEERING DOES NOT OPERATE…3046
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…3052
CONTENTS OF TROUBLESHOOTING TABLE…3054
H-1 MACHINE DOES NOT START…3055
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)…3057
H-3 LOCKUP CANNOT BE CANCELLED…3057
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING…3058
H-5 TRANSMISSION DOES NOT SHIFT UP…3059
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING…3060
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR…3062
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH…3063
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW…3064
H-10 FRONT BRAKE IS INEFFECTIVE…3065
H-11 CENTER BRAKE IS INEFFECTIVE…3066
H-12 STEERING WHEEL IS HEAVY…3067
H-13 STEERING WHEEL DOES NOT WORK…3068
H-14 STEERING WHEEL VIBRATES…3069
H-15 DUMP BODY LIFTING SPEED IS SLOW…3070
H-16 DUMP BODY DOES NOT WORK…3071
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY…3072
TROUBLESHOOTING OF ENGINE (S-MODE)…3074
HOW TO USR A TROUBLESHOOTING CHART…3076
S-1 ENGINE IS HARD TO START…3079
S-2 ENGINE DOES NOT START…3081
S-3 ENGINE DOES NOT PICK UP SMOOTHLY…3085
S-4 ENGINE STOPS DURING OPERATIONS…3086
S-5 ENGINE DOES NOT ROTATE SMOOTHLY…3087
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…3088
S-7 EXHAUST GAS COLOR IS BLACK (INCOMPLETE COMBUSTION)…3089
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS COLOR IS BLUE)…3091
S-9 OIL GETS CONTAMINATED PREMATURELY…3092
S-10 FUEL CONSUMPTION IS EXCESSIVE…3093
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…3094
S-12 OIL PRESSURE DROPS…3095
S-13 OIL LEVEL RISES (COOLANT OR FUEL MIXES)…3096
S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)…3098
S-15 ABNORMAL NOISE COMES OUT…3099
S-16 VIBRATION IS EXCESSIVE…3100
50 DISASSEMBLY AND ASSEMBLY…0
GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY…3102
HOW TO READ THIS MANUAL…3103
COATING MATERIALS LIST…3105
SPECIAL TOOL LIST…3108
SKETCHES OF SPECIAL TOOLS…3113
ENGINE (SAA6D125E-5)…3128
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY…3129
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY…3134
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY…3139
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL…3152
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL…3154
ENGINE AND COOLING SYSTEM (SAA6D125E-5)…3160
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY…3161
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY…3169
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY…3171
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY…3174
DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY…3179
POWER TRAIN, PART 1…3184
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…3185
DISCONNECTION AND CONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY…3191
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY…3193
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY…3208
POWER TRAIN, PART 2…3216
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY…3217
POWER TRAIN, PART 3…3260
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY…3261
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY…3265
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY…3282
DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY…3284
POWER TRAIN, PART 4…3300
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…3301
DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY…3304
REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…3314
DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY…3316
POWER TRAIN, PART 5…3326
DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY…3327
REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY…3334
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY…3337
UNDERCARRIAGE AND FRAME…3340
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY…3341
REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY…3343
REMOVAL AND INSTALLATION OF EQUALIZER BAR…3344
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY…3346
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY…3356
HYDRAULIC SYSTEM…3364
REMOVAL AND INSTALLATION OF FLOW AMP VALVE…3365
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY…3367
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY…3370
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY…3374
BODY…3380
REMOVAL AND INSTALLATION OF BODY ASSEMBLY…3381
CAB AND ITS ATTACHMENTS…3384
REMOVAL AND INSTALLATION OF OPERATOR'S CAB…3385
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)…3390
DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY (IF EQUIPPED)…3397
ELECTRICAL SYSTEM…3408
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY…3409
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER…3414
REMOVAL AND INSTALLATION OF RETARDER CONTROLLER…3416
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY…3418
90 DIAGRAMS AND DRAWINGS…0
HYDRAULIC DIAGRAMS AND DRAWINGS…3420
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…3422
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM…3424
BRAKE HYDRAULIC CIRCUIT DIAGRAM…3426
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM…3428
ELECTRICAL DIAGRAMS AND DRAWINGS…3430
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/4)…3432
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4) (SERIAL NO.: 2001 – 2241)…3433
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4) (SERIAL NO.: 2242 AND UP)…3434
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: 2001 – 2241)…3435
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: 2242 AND UP)…3436
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (4/4)…3437
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3)…3438
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3)…3439
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3)…3440
CONNECTORS TABLE AND ARRANGEMENT DRAWING…3441
SEN00237-13 – Articulated Dump Truck HM300-2 Shop Manual…3444
COVER …3444
00 Index and foreword…0
Index…3446
Composition of shop manual…3447
Table of contents…3449
Foreword and general information…3460
Safety notice…3461
How to read the shop manual…3466
Explanation of terms for maintenance standard…3468
Handling of electric equipment and hydraulic component…3470
Handling of connectors newly used for engines…3479
How to read electric wire code…3482
Precautions when carrying out operation…3485
Method of disassembling and connecting push-pull type coupler…3488
Standard tightening torque table…3491
Conversion table…3495
01 Specification…0
Specification and technical data…3502
Specification drawings…3503
Specifications…3504
Weight table…3507
Fuel, coolant and lubricants…3508
10 Structure, function and maintenance standard…0
Engine and cooling system…3512
Radiator, oil cooler, aftercooler…3513
Output shaft…3514
Power train, Part 1…3518
Power train skeleton…3519
Torque converter and transmission hydraulic piping…3521
Brake cooling oil control valve (BCV)…3523
Power train pump…3524
Torque converter…3527
Transmission…3533
Transmission control valve…3561
ECMV…3562
Main relief, torque converter relief valve…3569
Power train, Part 2…3572
Drive shaft…3573
Axle…3574
Differential…3577
Limited slip differential…3583
Final drive…3587
Steering system…3594
Steering column…3595
Brake system…3598
Brake piping…3599
Brake valve…3601
Accumulator charge valve…3604
Accumulator…3608
Slack adjuster…3609
Brake…3611
Proportional reducing valve…3616
Brake system tank…3617
Parking brake…3619
Parking brake solenoid…3623
Undercarriage and frame…3626
Suspension…3627
Suspension cylinder…3633
Oscillation hitch…3635
Hydraulic system…3640
Steering, hoist oil pressure piping diagram…3641
Dump body control…3642
Hydraulic tank and filter…3643
Flow amp valve…3644
Steering valve…3647
Steering cylinder…3651
Hoist valve…3653
Dump control valve (EPC valve)…3659
Hoist cylinder…3663
Hydraulic pump…3664
Cab and its attachments…3668
ROPS cab…3669
Cab tilt…3670
Air conditioner…3671
Rear view monitor…3679
Controller related…3682
Electrical system, Part 1…3684
Machine monitor system…3685
Electrical system, Part 2…3706
Automatic shift control system…3707
Retarder control system…3739
Auto emergency steering system…3751
Battery disconnector switch…3753
Dump control lever…3755
Electrical system, Part 3…3760
Payload meter (Card type)…3761
Electrical system, Part 4…3794
Sensors, switches…3795
KOMTRAX terminal system (If equipped)…3803
20 Standard value table…0
Standard service value table…3806
Standard value table for engine…3807
Standard value table for chassis…3808
30 Testing and adjusting…0
Testing and adjusting, Part 1…3814
Tools for testing, adjusting, and troubleshooting…3816
Sketches of special tools…3820
Testing engine speed…3821
Testing intake air pressure (boostpressure)…3822
Testing exhaust temperature…3823
Testing exhaust gas color…3825
Adjusting valve clearance…3826
Testing compression pressure…3828
Testing blow-by pressure…3830
Testing engine oil pressure…3831
Testing EGR valve and bypass valve drive oil pressure…3832
Handling of fuel system devices…3833
Releasing residual pressure from fuel system…3833
Testing fuel pressure…3834
Handling during cylinder cut-out operation…3835
Handling during no injection cranking operation…3835
Testing fuel return and leak amount…3836
Bleeding air from fuel circuit…3839
Testing fuel circuit for leakage…3840
Testing and adjusting alternator belt tension…3841
Testing and adjusting air conditioner compressor belt tension…3841
Adjusting the body mount…3841
Testing and adjusting, Part 2…3844
Testing torque converter stallspeed…3845
Testing power train oil pressure…3846
Adjusting transmission speed sensor…3854
Testing and adjusting brake oilpressure…3856
Testing of accumulator nitrogengas pressure and procedure forcharging accumulator withnitrogen gas…3860
Testing brake performance…3864
Bleeding air from brake circuit…3865
Testing wear of wheel brake disc…3866
Testing wear of parking brake pad…3867
Method for emergency release ofparking brake…3869
Testing and adjusting steeringcircuit oil pressure…3870
Testing and adjusting suspensioncylinder…3872
Method of tilting cab up…3876
Testing and adjusting dumpcircuit oil pressure…3878
Adjusting body positioner sensor…3881
Procedure for adjusting length ofspring in body heating sphericaljoint…3882
Handling engine controller highvoltage circuit…3882
Adjusting transmission controller…3883
Method for emergency escape at electrical system failure…3884
Testing and adjusting, Part 3…3890
Setting and adjusting various equipments…3891
Special function of machine monitor (EMMS)…3903
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal…4231
Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)…4233
Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection )…4235
Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)…4237
Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)…4238
Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)…4239
Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)…4240
Failure code [DF10KA] (Gear shift lever: Disconnection)…4241
Failure code [DF10KB] (Gear shift lever: Short circuit)…4244
Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)…4247
Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit)…4249
Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)…4251
Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)…4253
Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)…4255
Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)…4257
Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)…4259
Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)…4261
Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop)…4263
Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)…4265
Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range)…4267
Failure code [DJF1KA] (Fuel level sensor: Disconnection)…4269
Failure code [DK51L5] (Retarder lever potentiometer : Potentiometer signal is inconsistent with switch signal)…4271
Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range)…4273
Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)…4275
Failure code [DK54KX] (Body positioner sensor: Input signal out of range)…4277
Troubleshooting by failure code, Part 4…4280
Failure code [DKH0KX] (Inclination sensor: Inclination out of range)…4283
Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)…4285
Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)…4286
Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)…4287
Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal)…4288
Failure code [DLF4KA] (Differential speed sensor: Disconnection)…4289
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)…4290
Failure code [DV00KB] (Alarm buzzer output: Short circuit)…4291
Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit)…4293
Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)…4295
Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)…4297
Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)…4299
Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)…4301
Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)…4303
Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)…4304
Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)…4305
Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)…4307
Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)…4309
Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection)…4311
Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)…4312
Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line)…4313
Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)…4315
Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)…4317
Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)…4318
Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)…4319
Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)…4320
Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)…4321
Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)…4322
Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)…4323
Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)…4324
Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)…4325
Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)…4327
Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)…4329
Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)…4331
Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)…4335
Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)…4337
Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)…4339
Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)…4343
Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)…4345
Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)…4347
Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)…4351
Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)…4353
Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)…4355
Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)…4359
Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)…4361
Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)…4363
Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)…4367
Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)…4369
Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)…4371
Troubleshooting of electrical system (E-mode)…4376
Information in troubleshooting table…4377
E-1 Engine does not start…4378
E-2 Automatic preheating does not operate…4381
E-3 Machine monitor does not display all, when starting switch is turned ON…4384
E-4 Machine monitor does not operate when starting switch is OFF…4386
E-5 Alarm buzzer does not stop sounding…4388
E-6 Gauges of machine monitor, caution lamps or character display section do not display properly…4389
E-7 Selection of display in character display section cannot be changed…4390
E-8 Power mode selecting function does not operate properly…4394
E-9 AISS function does not operate properly…4395
E-10 Seat belt caution lamp does not display properly…4396
E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly…4397
E-12 Night illumination (lighting) does not work properly…4400
E-13 Emergency steering does not operate…4407
E-14 Air conditioner does not operate normally…4411
Troubleshooting of hydraulic and mechanical system (H-mode)…4418
Contents of troubleshooting table…4420
H-1 Machine does not start…4421
H-2 Machine does not travel smoothly (machine jerks)…4423
H-3 Lockup cannot be cancelled…4423
H-4 Excessive shock when starting or shifting…4424
H-5 Transmission does not shift up…4425
H-6 Machine lacks power or speed when traveling…4426
H-7 Time lag is excessive when starting or shifting gear…4428
H-8 Torque converter oil temperature is high…4429
H-9 Torque converter oil pressure is low…4430
H-10 Front brake is ineffective…4431
H-11 Center brake is ineffective…4432
H-12 Steering wheel is heavy…4433
H-13 Steering wheel does not work…4434
H-14 Steering wheel vibrates…4435
H-15 Dump body lifting speed is slow…4436
H-16 Dump body does not work…4437
H-17 Excessive hydraulic drift of dump body…4438
Troubleshooting of engine (S-mode)…4440
How to use a troubleshooting chart…4442
S-1 Engine is hard to start…4445
S-2 Engine does not start…4447
S-3 Engine does not pick up smoothly…4451
S-4 Engine stops during operations…4452
S-5 Engine does not rotate smoothly…4453
S-6 Engine lacks output (or lacks power)…4454
S-7 Exhaust gas color is black (incomplete combustion)…4455
S-8 Oil consumption is excessive (or exhaust gas color is blue)…4457
S-9 Oil gets contaminated prematurely…4458
S-10 Fuel consumption is excessive…4459
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…4460
S-12 Oil pressure drops…4461
S-13 Oil level rises (coolant or fuel mixes)…4463
S-14 Coolant temperature rises too high (overheat)…4465
S-15 Abnormal noise comes out…4466
S-16 Vibration is excessive…4467
50 Disassembly and assembly…0
General information on disassembly and assembly…4470
How to read this manual…4471
Coating materials list…4473
Special tool list…4476
Sketches of special tools…4480
Engine and cooling system, Part 1…4494
Removal and installation of fuel supply pump assembly…4495
Removal and installation of fuel injector assembly…4500
Removal and installation of cylinder head assembly…4505
Removal and installation of engine front seal…4518
Removal and installation of engine rear seal…4520
Engine and cooling system, Part 2…4526
Removal and installation of engine assembly…4527
Removal and installation of radiator assembly…4535
Removal and installation of cooling assembly…4537
Removal and installation of output shaft assembly…4540
Disassembly and assembly of output shaft assembly…4545
Power train, Part 1…4550
Removal and installation of transmission and front differential assembly…4551
Disconnection and connection of front differential assembly and transmission assembly…4557
Disassembly and assembly of front differential assembly…4559
Disassembly and assembly of torque converter assembly…4574
Power train, Part 2…4582
Disassembly and assembly of transmission assembly…4583
Power train, Part 3…4626
Removal and installation of center differential assembly…4627
Disassembly and assembly of center differential assembly…4631
Removal and installation of rear differential assembly…4648
Disassembly and assembly of rear differential assembly…4650
Power train, Part 4…4666
Removal and installation of front final drive and brake assembly…4667
Disassembly and assembly of front final drive and brake assembly…4670
Removal and installation of center final drive and brake assembly…4680
Disassembly and assembly of center final drive and brake assembly…4682
Power train, Part 5…4692
Disassembly and assembly of rear final drive assembly…4693
Removal and installation of center axle assembly…4700
Removal and installation of rear axle assembly…4703
Undercarriage and frame…4706
Removal and installation of front suspension cylinder assembly…4707
Removal and installation of rear suspension cylinder assembly…4709
Disassembly and assembly of front and rear suspension cylinder assembly…4710
Removal and installation of equalizer bar…4712
Removal and installation of hitch frame assembly…4714
Disassembly and assembly of hitch frame assembly…4724
Hydraulic system…4732
Removal and installation of flow amp valve…4733
Removal and installation of hoist valve assembly…4735
Disassembly and assembly of steering cylinder assembly…4738
Disassembly and assembly of hoist cylinder assembly…4742
Body…4748
Removal and installation of body assembly…4749
Cab and its attachments…4752
Removal and installation of operator’s cab…4753
Removal and installation of operator’s cab glass (Stuck glass)…4758
Disassembly and assembly of operator’s seat assembly (If equipped)…4765
Electrical system…4776
Removal and installation of air conditioner unit assembly…4777
Removal and installation of engine controller…4782
Removal and installation of retarder controller…4784
Removal and installation of transmission controller assembly…4786
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…4788
Power train hydraulic circuit diagram…4790
Steering and hoist hydraulic circuit diagram…4791
Brake hydraulic circuit diagram…4793
Brake cooling hydraulic circuit diagram…4794
Electrical diagrams and drawings…4796
Electrical circuit diagram for inside cab (1/4)…4798
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 – 2241)…4799
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)…4800
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 – 2241)…4801
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)…4802
Electrical circuit diagram for inside cab (4/4)…4803
Electrical circuit diagram for outside cab (1/3)…4804
Electrical circuit diagram for outside cab (2/3)…4805
Electrical circuit diagram for outside cab (3/3)…4806
Electrical circuit diagram for payload meter…4807
Connectors table and arrangement drawing…4808
SEN00237-14 – Articulated Dump Truck HM300-2 Shop Manual…4811
COVER …4811
00 Index and foreword…0
Index…4813
Composition of shop manual…4814
Table of contents…4816
Foreword and general information…4827
Safety notice…4828
How to read the shop manual…4833
Explanation of terms for maintenance standard…4835
Handling of electric equipment and hydraulic component…4837
Handling of connectors newly used for engines…4846
How to read electric wire code…4849
Precautions when carrying out operation…4852
Method of disassembling and connecting push-pull type coupler…4855
Standard tightening torque table…4858
Conversion table…4862
01 Specification…0
Specification and technical data…4869
Specification drawings…4870
Specifications…4871
Weight table…4874
Fuel, coolant and lubricants…4875
10 Structure, function and maintenance standard…0
Engine and cooling system…4879
Radiator, oil cooler, aftercooler…4880
Output shaft…4881
Power train, Part 1…4885
Power train skeleton…4886
Torque converter and transmission hydraulic piping…4888
Brake cooling oil control valve (BCV)…4890
Power train pump…4891
Torque converter…4894
Transmission…4900
Transmission control valve…4928
ECMV…4929
Main relief, torque converter relief valve…4936
Power train, Part 2…4939
Drive shaft…4940
Axle…4941
Differential…4944
Limited slip differential…4950
Final drive…4954
Steering system…4961
Steering column…4962
Brake system…4965
Brake piping…4966
Brake valve…4968
Accumulator charge valve…4971
Accumulator…4975
Slack adjuster…4976
Brake…4978
Proportional reducing valve…4983
Brake system tank…4984
Parking brake…4986
Parking brake solenoid…4990
Undercarriage and frame…4993
Suspension…4994
Suspension cylinder…5000
Oscillation hitch…5002
Hydraulic system…5007
Steering, hoist oil pressure piping diagram…5008
Dump body control…5009
Hydraulic tank and filter…5010
Flow amp valve…5011
Steering valve…5014
Steering cylinder…5018
Hoist valve…5020
Dump control valve (EPC valve)…5026
Hoist cylinder…5030
Hydraulic pump…5031
Cab and its attachments…5035
ROPS cab…5036
Cab tilt…5037
Air conditioner…5038
Rear view monitor…5046
Controller related…5049
Electrical system, Part 1…5051
Machine monitor system…5052
Electrical system, Part 2…5073
Automatic shift control system…5074
Retarder control system…5106
Auto emergency steering system…5118
Battery disconnector switch…5120
Dump control lever…5122
Electrical system, Part 3…5127
Payload meter (Card type)…5128
Electrical system, Part 4…5161
Sensors, switches…5162
KOMTRAX terminal system (If equipped)…5170
20 Standard value table…0
Standard service value table…5173
Standard value table for engine…5174
Standard value table for chassis…5175
30 Testing and adjusting…0
Testing and adjusting, Part 1…5181
Tools for testing, adjusting, and troubleshooting…5183
Sketches of special tools…5187
Testing engine speed…5188
Testing intake air pressure (boostpressure)…5189
Testing exhaust temperature…5190
Testing exhaust gas color…5192
Adjusting valve clearance…5193
Testing compression pressure…5195
Testing blow-by pressure…5197
Testing engine oil pressure…5198
Testing EGR valve and bypass valve drive oil pressure…5199
Handling of fuel system devices…5200
Releasing residual pressure from fuel system…5200
Testing fuel pressure…5201
Handling during cylinder cut-out operation…5202
Handling during no injection cranking operation…5202
Testing fuel return and leak amount…5203
Bleeding air from fuel circuit…5206
Testing fuel circuit for leakage…5207
Testing and adjusting alternator belt tension…5208
Testing and adjusting air conditioner compressor belt tension…5208
Adjusting the body mount…5208
Testing and adjusting, Part 2…5211
Testing torque converter stallspeed…5212
Testing power train oil pressure…5213
Adjusting transmission speed sensor…5221
Testing and adjusting brake oilpressure…5223
Testing of accumulator nitrogengas pressure and procedure forcharging accumulator withnitrogen gas…5227
Testing brake performance…5231
Bleeding air from brake circuit…5232
Testing wear of wheel brake disc…5233
Testing wear of parking brake pad…5234
Method for emergency release ofparking brake…5236
Testing and adjusting steeringcircuit oil pressure…5237
Testing and adjusting suspensioncylinder…5239
Method of tilting cab up…5243
Testing and adjusting dumpcircuit oil pressure…5245
Adjusting body positioner sensor…5248
Procedure for adjusting length ofspring in body heating sphericaljoint…5249
Handling engine controller highvoltage circuit…5249
Adjusting transmission controller…5250
S-1 Engine is hard to start…5812
S-2 Engine does not start…5814
S-3 Engine does not pick up smoothly…5818
S-4 Engine stops during operations…5819
S-5 Engine does not rotate smoothly…5820
S-6 Engine lacks output (or lacks power)…5821
S-7 Exhaust gas color is black (incomplete combustion)…5822
S-8 Oil consumption is excessive (or exhaust gas color is blue)…5824
S-9 Oil gets contaminated prematurely…5825
S-10 Fuel consumption is excessive…5826
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…5827
S-12 Oil pressure drops…5828
S-13 Oil level rises (coolant or fuel mixes)…5830
S-14 Coolant temperature rises too high (overheat)…5832
S-15 Abnormal noise comes out…5833
S-16 Vibration is excessive…5834
50 Disassembly and assembly…0
General information on disassembly and assembly…5837
How to read this manual…5838
Coating materials list…5840
Special tool list…5843
Sketches of special tools…5847
Engine and cooling system, Part 1…5861
Removal and installation of fuel supply pump assembly…5862
Removal and installation of fuel injector assembly…5867
Removal and installation of cylinder head assembly…5872
Removal and installation of engine front seal…5885
Removal and installation of engine rear seal…5887
Engine and cooling system, Part 2…5893
Removal and installation of engine assembly…5894
Removal and installation of radiator assembly…5902
Removal and installation of cooling assembly…5904
Removal and installation of output shaft assembly…5907
Disassembly and assembly of output shaft assembly…5912
Power train, Part 1…5917
Removal and installation of transmission and front differential assembly…5918
Disconnection and connection of front differential assembly and transmission assembly…5924
Disassembly and assembly of front differential assembly…5926
Disassembly and assembly of torque converter assembly…5941
Power train, Part 2…5949
Disassembly and assembly of transmission assembly…5950
Power train, Part 3…5993
Removal and installation of center differential assembly…5994
Disassembly and assembly of center differential assembly…5998
Removal and installation of rear differential assembly…6015
Disassembly and assembly of rear differential assembly…6017
Power train, Part 4…6033
Removal and installation of front final drive and brake assembly…6034
Disassembly and assembly of front final drive and brake assembly…6037
Removal and installation of center final drive and brake assembly…6047
Disassembly and assembly of center final drive and brake assembly…6049
Power train, Part 5…6059
Disassembly and assembly of rear final drive assembly…6060
Removal and installation of center axle assembly…6067
Removal and installation of rear axle assembly…6070
Undercarriage and frame…6073
Removal and installation of front suspension cylinder assembly…6074
Removal and installation of rear suspension cylinder assembly…6076
Disassembly and assembly of front and rear suspension cylinder assembly…6077
Removal and installation of equalizer bar…6079
Removal and installation of hitch frame assembly…6081
Disassembly and assembly of hitch frame assembly…6091
Hydraulic system…6099
Removal and installation of flow amp valve…6100
Removal and installation of hoist valve assembly…6102
Disassembly and assembly of steering cylinder assembly…6105
Disassembly and assembly of hoist cylinder assembly…6109
Body…6115
Removal and installation of body assembly…6116
Cab and its attachments…6119
Removal and installation of operator’s cab…6120
Removal and installation of operator’s cab glass (Stuck glass)…6125
Disassembly and assembly of operator’s seat assembly (If equipped)…6132
Electrical system…6143
Removal and installation of air conditioner unit assembly…6144
Removal and installation of engine controller…6149
Removal and installation of retarder controller…6151
Removal and installation of transmission controller assembly…6153
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…6155
Power train hydraulic circuit diagram…6157
Steering and hoist hydraulic circuit diagram…6158
Brake hydraulic circuit diagram…6160
Brake cooling hydraulic circuit diagram…6161
Electrical diagrams and drawings…6163
Electrical circuit diagram for inside cab (1/4)…6165
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 – 2241)…6166
Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)…6167
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 – 2241)…6168
Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)…6169
Electrical circuit diagram for inside cab (4/4)…6170
Electrical circuit diagram for outside cab (1/3)…6171
Electrical circuit diagram for outside cab (2/3)…6172
Electrical circuit diagram for outside cab (3/3)…6173
Electrical circuit diagram for payload meter…6174
Connectors table and arrangement drawing…6175
SEN05629-04 – Articulated Dump Truck HM300-3 Shop Manual…6178
Cover…6178
00 Index and foreword …6180
Index …6181
Foreword, safety and general information …6196
Important safety notice …6196
How to read the shop manual …6203
Explanation of terms for maintenance standard …6205
Handling equipment of fuel system devices …6207
Handling of intake system parts …6208
Handling of hydraulic equipment …6209
Method of disconnecting and connecting of push-pull type coupler …6211
Handling of electrical equipment …6214
How to read electric wire code …6222
Precautions when performing operation …6225
Practical use of KOMTRAX …6230
Standard tightening torque table …6231
List of abbreviation …6237
Conversion table …6242
01 Specification …6248
Table of contents …6249
Specifications …6250
Specification drawing …6250
Specifications …6252
Weight table …6258
Table of fuel, coolant, and lubricants …6259
10 Structure and function …6262
Table of contents …6263
Engine and cooling system …6265
Engine related parts …6265
Output shaft …6267
KVGT …6268
EGR system piping drawing …6274
EGR system circuit diagram …6276
EGR valve …6278
EGR cooler …6280
KCCV layout drawing …6282
KCCV ventilator …6284
KDPF …6286
Cooling system …6292
Radiator fan pump …6294
Aftercooler fan motor …6304
Radiator fan motor …6315
Oil cooler bypass valve …6321
Power train …6322
Power train system …6322
Drive shaft …6324
Torque converter and transmission hydraulic piping …6325
Torque converter …6327
Transmission …6333
Transmission control valve …6357
Forward and reverse clutch ECMV and gear speed clutch ECMV …6360
Lockup clutch ECMV …6367
Differential lock clutch ECMV …6371
Main relief valve, torque converter relief valve, and main flow selector valve …6375
Axle …6381
Differential …6384
Final drive …6388
Steering system …6391
Layout of steering devices …6391
Steering column …6392
Flow amplifier valve …6393
Steering valve …6397
Emergency steering pump …6402
Brake system …6404
Layout of brake parts …6404
Parking brake solenoid and accumulator charge valve …6406
Accumulator …6412
Shut off solenoid valve …6413
Brake valve …6414
Proportional pressure reducing valve …6419
Slack adjuster …6421
Brake …6425
Brake system tank …6428
Parking brake …6429
Undercarriage and frame …6432
Suspension …6432
Suspension cylinder …6438
Oscillation hitch …6440
Hydraulic system …6442
Hydraulic component layout …6442
Dump body control …6443
Hydraulic tank …6444
Steering and hoist control pump …6445
Hoist valve …6457
Steering pump selector solenoid valve …6463
Hoist and radiator fan direction selector solenoid valve …6464
Dump EPC valve …6465
Brake cooling oil control valve …6467
Front brake cooling relief valve …6468
Cab and its attachments …6469
ROPS cab …6469
Cab tilt …6470
Electrical system …6471
Electrical control system …6471
Machine monitor system …6497
Rear view monitor system …6521
KOMTRAX system …6525
System component parts …6529
Sensor …6549
20 Standard value tables …6586
Table of contents …6587
Standard service value table …6588
Standard value table for engine …6588
Standard value table for machine …6590
30 Testing and adjusting …6598
Table of contents …6599
Related information on testing and adjusting …6601
Tools for testing and adjusting …6601
Sketch of tools for testing and adjusting …6607
Engine and cooling system …6610
Testing engine speed …6610
Testing boost pressure …6611
Testing exhaust gas temperature …6613
Testing exhaust gas color …6615
Testing and adjusting valve clearance …6617
Testing compression pressure …6619
Testing blowby pressure …6622
Testing engine oil pressure …6624
Testing EGR valve and KVGT driving oil pressure …6625
Testing fuel pressure …6626
Handling cylinder cutout mode operation …6627
Handling no‐injection cranking operation …6628
Testing fuel return rate and leakage …6629
Bleeding air from fuel system …6632
Testing fuel circuit for leakage …6634
Checking and adjusting air conditioner compressor belt tension …6635
Replacing alternator belt …6636
Procedures for cleaning fuel doser …6637
Writing compensation values at replacement of injector and engine controller …6640
Power train …6644
Testing torque converter stall speed …6644
Testing power train oil pressure …6646
Adjusting transmission speed sensor …6656
Adjusting transmission controller …6659
Retrieval of disabled machine that resulted from a trouble in electrical system …6660
Retrieval of disabled machine due to traction control system (KTCS) failure …6664
Steering system …6666
Testing and adjusting steering circuit oil pressure …6666
Brake system …6668
Testing and adjusting brake oil pressure …6668
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas …6671
Testing braking performance …6675
Bleeding air from brake circuit …6676
Testing wear of wheel brake disc …6677
Parking brake emergency releasing procedure …6678
Testing wear of parking brake pad and adjusting clearance …6679
Hydraulic system …6681
Testing and adjusting suspension cylinder …6681
Testing and adjusting dump circuit oil pressure …6687
Work equipment …6690
Adjusting dump body positioner sensor …6690
Testing and adjusting body mount …6691
Cab and its attachments …6693
Cab tilt-up procedure …6693
Electrical system …6696
Setting and adjusting each equipment …6696
Special functions of machine monitor …6706
KOMTRAX terminal start-up procedure …6771
Handling voltage circuit of engine controller …6775
Handling battery disconnect switch …6776
Pm clinic …6777
Pm Clinic service …6777
40 Troubleshooting …6784
Table of contents …6785
Related information on troubleshooting …6794
Troubleshooting points …6794
Sequence of events in troubleshooting …6796
Check before troubleshooting …6798
Inspection procedure before troubleshooting …6800
Preparation for troubleshooting of electrical system …6818
Classification and procedures for troubleshooting …6824
Symptom and troubleshooting numbers …6827
Information in troubleshooting table …6830
Connector list and layout …6832
Connector contact identification …6848
T-branch box and T-branch adapter table …6886
Table of fuse locations …6891
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement …6895
Precautions on troubleshooting of machine monitor …6898
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit …6900
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) …6905
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) …6906
Failure codes table …6907
E-1 Engine does not start (Engine does not rotate) …7654
E-2 Manual preheating system does not work …7660
E-3 Automatic preheating system does not work …7663
E-4 While preheating is working, preheating monitor does not light up …7665
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing …7667
E-6 LCD unit on machine monitor displays nothing …7670
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) …7672
E-8 LCD on machine monitor does not display properly …7674
E-9 Meter unit display on machine monitor is abnormal …7676
E-10 Night lighting lamp of meter unit on machine monitor is abnormal …7679
E-11 LED unit lamp on machine monitor is abnormal …7682
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly …7684
E-13 2 switches operation of switch panel on machine monitor does not function …7686
E-14 Switch panel buzzer of machine monitor is abnormal …7688
E-15 Rear view monitor does not light up or backlight flickers …7690
E-16 Rear view monitor images are not displayed clearly …7692
E-17 Rear view monitor brightness cannot be adjusted …7695
E-18 Night lighting lamp of rear view monitor is abnormal …7698
E-19 Rearview monitor does not display images while reverse linked display function is enabled …7700
E-20 Guide line on rear view monitor is not displayed while guide line is set …7703
E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly …7705
E-22 Fuel level gauge does not indicate correct level …7706
E-23 Seat belt caution lamp indication is abnormal …7708
E-24 Machine monitor cannot be operated when starting switch is in OFF position …7709
E-25 Alarm buzzer does not sound …7710
E-26 Alarm buzzer does not stop sounding …7712
E-27 Engine mode selector function does not operate properly …7714
E-28 AISS function does not operate properly …7715
E-29 Hoist lever does not operate properly …7716
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly …7718
E-31 None of headlamp, clearance lamp, and tail lamp lights …7722
E-32 Clearance lamp does not light up …7724
E-33 Tail lamp does not light up …7726
E-34 Low beam of headlamp does not light up …7728
E-35 High beam of headlamp does not light up …7730
E-36 Neither Low beam nor High beam of headlamp lights up …7732
E-37 High beams do not light up while passing switch is operated …7734
E-38 KOMTRAX does not operate properly …7736
Troubleshooting of hydraulic and mechanical system (H-mode) …7737
Information described in troubleshooting table (H-mode) …7737
System diagram of hydraulic and mechanical systems …7738
Failure mode and cause table …7740
H-1 Machine does not start …7744
H-2 Machine does not travel smoothly (machine hunts) …7746
H-3 Lockup is not released …7747
H-4 Abnormally large shocks result from starting of machine and gear shifting …7748
H-5 Gear is not shifted up …7749
H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds …7751
H-7 Machine lacks travel speed or power when traveling in torque converter drive mode …7752
H-8 Machine lacks travel speed or power when traveling at some gear speed …7753
H-9 Large time lag is observed when machine starts and gear is shifted …7754
H-10 Oil temperature of torque converter is high …7756
H-11 Oil pressure of torque converter is low …7757
H-12 Front brake does not work enough …7758
H-13 Center brake does not work enough …7759
H-14 Steering wheel is heavy …7760
H-15 Steering wheel does not turn …7761
H-16 Steering wheel waggles …7762
H-17 Dump body rising speed is low …7763
H-18 Dump body does not move …7764
H-19 Hydraulic drift of dump body is large …7765
H-20 Radiator fan speed is unusual (excessively high or low, or fan stops) …7766
H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) …7767
H-22 Unusual noise is heard from around radiator fan …7768
H-23 Unusual noise is heard from around aftercooler fan …7769
Troubleshooting of engine (S-mode) …7770
Information mentioned in troubleshooting table (S mode) …7770
S-1 When starting switch is turned to START position, engine is not cranked …7771
S-2 The engine cranks but exhaust smoke does not come out …7772
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) …7773
S-4 Engine startability is poor …7774
S-5 Engine does not pick-up smoothly …7776
S-6 Engine stops during operation …7778
S-7 Engine runs rough or is unstable …7780
S-8 Engine lacks power …7781
S-9 KDPF gets clogged in a short time …7783
S-10 Engine oil consumption is excessive …7785
S-11 Engine oil becomes contaminated early …7786
S-12 Fuel consumption is excessive …7787
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …7788
S-14 Oil pressure drops …7789
S-15 Fuel mixes into engine oil …7790
S-16 Water mixes into engine oil (milky) …7791
S-17 Coolant temperature rises too high (overheating) …7792
S-18 Unusual noise is heard …7793
S-19 Vibration is excessive …7794
S-20 Air cannot be bled from fuel circuit …7795
S-21 Active regeneration is executed frequently …7796
S-22 Active regeneration takes a long time …7797
S-23 White smoke is exhausted during active regeneration …7798
50 Disassembly and assembly …7800
Table of contents …7801
Related information on disassembly and assembly …7803
How to read this manual …7803
Coating materials list …7805
Special tools list …7809
Sketches of special tools …7814
Engine and cooling system …7832
Removal and installation of supply pump assembly …7832
Removal and installation of injector assembly …7839
Removal and installation of cylinder head assembly …7851
Removal and installation of radiator assembly …7863
Removal and installation of radiator fan and fan motor …7866
Removal and installation of aftercooler assembly …7869
Removal and installation of aftercooler fan and fan motor assembly …7873
Removal and installation of engine assembly …7876
Removal and installation of engine front oil seal …7883
Removal and installation of engine rear oil seal …7888
Removal and installation of output shaft assembly …7894
Disassembly and assembly of output shaft assembly …7898
Removal and installation of KDPF assembly …7901
Disassembly and assembly of KDPF assembly …7905
Removal and installation of KCCV assembly …7914
Removal and installation of air cleaner assembly …7915
Power train …7917
Removal and installation of transmission and front differential assembly …7917
Disconnection and connection of front differential assembly and transmission assembly …7929
Disassembly and assembly of front differential assembly …7930
Disassembly and assembly of torque converter assembly …7941
Disassembly and assembly of transmission assembly …7948
Removal and installation of center differential assembly …7984
Disassembly and assembly of center differential assembly …7988
Removal and installation of rear differential assembly …8000
Disassembly and assembly of rear differential assembly …8002
Removal and installation of front final drive and brake assembly …8012
Disassembly and assembly of front final drive and brake assembly …8018
Removal and installation of center final drive and brake assembly …8028
Disassembly and assembly of center final drive and brake assembly …8030
Disassembly and assembly of rear final drive assembly …8037
Removal and installation of center axle assembly …8043
Removal and installation of rear axle assembly …8046
Steering system …8048
Disassembly and assembly of steering cylinder assembly …8048
Undercarriage and frame …8054
Removal and installation of front suspension cylinder assembly …8054
Removal and installation of rear suspension assembly …8060
Disassembly and assembly of suspension cylinder assembly …8062
Removal and installation of equalizer bar assembly …8064
Removal and installation of hitch frame assembly …8067
Disassembly and assembly of hitch frame assembly …8076
Hydraulic system …8081
Removal and installation of flow amplifier valve assembly …8081
Removal and installation of hoist valve assembly …8084
Disassembly and assembly of hoist cylinder assembly …8087
Body …8093
Removal and installation of dump body assembly …8093
Cab and its attachments …8095
Removal and installation of operator's cab assembly …8095
Removal and installation of operator's cab glass (adhered glass) …8099
Removal and installation of operator's seat assembly …8105
Electrical system …8107
Removal and installation of machine monitor assembly …8107
Removal and installation of engine controller assembly …8109
Removal and installation of retarder and hoist controller assembly …8111
Removal and installation of transmission controller assembly …8112
Removal and installation of mass air flow and temperature sensor …8113
Removal and installation of KOMTRAX terminal assembly …8114
Air conditioner unit …8115
Removal and installation of air conditioner unit assembly …8115
Removal and installation of air conditioner compressor assembly …8120
60 Maintenance standard …8122
Table of contents …8123
Engine and cooling system …8124
Engine mount …8124
Output shaft …8125
Radiator fan pump …8126
Radiator fan motor …8128
Aftercooler fan motor …8130
Power train …8132
Drive shaft …8132
Torque converter and transmission mount …8133
Torque converter …8134
Transmission …8137
Transmission control valve …8146
Forward and reverse clutch ECMV and gear speed clutch ECMV …8147
Lockup clutch ECMV …8148
Differential lock clutch ECMV …8149
Main relief valve, torque converter relief valve, and main flow selector valve …8150
Axle …8152
Differential …8155
Final drive …8158
Steering system …8162
Steering column …8162
Steering cylinder …8163
Brake system …8164
Slack adjuster …8164
Brake …8166
Parking brake …8168
Undercarriage and frame …8170
Suspension …8170
Suspension cylinder …8174
Oscillation hitch …8175
Hydraulic system …8177
Steering and hoist control pump …8177
Front brake cooling duplex pump and aftercooler fan pump …8180
Center brake cooling pump …8181
Brake charge pump …8182
Hoist valve …8183
Hoist cylinder …8185
80 Appendix …8186
Table of contents …8187
Air conditioner components …8188
Precautions for refrigerant …8188
Air conditioner component …8189
Configuration and function of refrigeration cycle …8192
Outline of refrigeration cycle …8193
Air conditioner unit …8195
Dual pressure switch …8200
Air conditioner controller …8201
Compressor …8202
Condenser …8203
Receiver drier …8204
Outer temperature sensor (outside air temperature sensor) …8205
Procedure for testing and troubleshooting …8206
Circuit diagram and arrangement of connector pins …8208
System diagram …8210
Input and output signals of the air conditioner controller …8211
Parts and connectors layout …8213
Details …8214
Testing air leakage (duct) …8218
Testing with self-diagnosis function …8221
How to open the electrical system abnormality record screen in service mode of the machine monitor …8222
Testing vent (mode) changeover …8224
Testing FRESH/RECIRC air changeover …8225
Testing (dual) pressure switch for refrigerant …8226
Testing relays …8228
Troubleshooting chart 1 …8230
Troubleshooting chart 2 …8231
Information in troubleshooting table …8234
Failure code list related to air conditioner …8235
Failure code [879AKA] A/C Inner Sensor Open Circuit …8236
Failure code [879AKB] A/C Inner Sensor Short Circuit …8237
Failure code [879BKA] A/C Outer sensor Open Circuit …8238
Failure code [879BKB] A/C Outer sensor Short Circuit …8240
Failure code [879CKA] Ventilating Sensor Open Circuit …8242
Failure code [879CKB] Ventilating Sensor Short Circuit …8243
Failure code [879EMC] Ventilation Damper Abnormality …8244
Failure code [879FMC] Air Mix Damper Abnormality …8245
Failure code [879GKX] Refrigerant Abnormality …8246
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …8248
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …8250
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …8253
A-4 Troubleshooting for FRESH/RECIRC air changeover …8255
Troubleshooting with gauge pressure …8257
Connection of service tool …8260
Precautions for disconnecting and connecting air conditioner piping …8262
Handling of compressor oil …8264
90 Diagrams and drawings …8266
Table of contents …8267
Hydraulic circuit diagram …8268
Symbols in hydraulic circuit diagram …8268
Power train hydraulic circuit diagram…8272
Steering and hoist hydraulic circuit diagram …8273
Brake hydraulic circuit diagram …8274
Brake cooling system hydraulic circuit diagram …8275
Electric circuit diagram …8277
Symbols in electric circuit diagram …8277
Inside cab electric circuit diagram…8281
Outside cab electrical circuit diagram…8288
INDEX…8295
SEN05629-05 – Articulated Dump Truck HM300-3 Shop Manual…8309
Cover…8309
00 Index and foreword …8311
Index …8312
Foreword, safety and general information …8327
Important safety notice …8327
How to read the shop manual …8334
Explanation of terms for maintenance standard …8336
Handling equipment of fuel system devices …8338
Handling of intake system parts …8339
Handling of hydraulic equipment …8340
Method of disconnecting and connecting of push-pull type coupler …8342
Handling of electrical equipment …8345
How to read electric wire code …8353
Precautions when performing operation …8356
Practical use of KOMTRAX …8361
Standard tightening torque table …8362
List of abbreviation …8368
Conversion table …8373
01 Specification …8379
Table of contents …8380
Specifications …8381
Specification drawing …8381
Specifications …8383
Weight table …8389
Table of fuel, coolant, and lubricants …8390
10 Structure and function …8393
Table of contents …8394
Engine and cooling system …8396
Engine related parts …8396
Output shaft …8398
KVGT …8399
EGR system piping drawing …8405
EGR system circuit diagram …8407
EGR valve …8409
EGR cooler …8411
KCCV layout drawing …8413
KCCV ventilator …8415
KDPF …8417
Cooling system …8423
Radiator fan pump …8425
Aftercooler fan motor …8435
Radiator fan motor …8446
Oil cooler bypass valve …8452
Power train …8453
Power train system …8453
Drive shaft …8455
Torque converter and transmission hydraulic piping …8456
Torque converter …8458
Transmission …8464
Transmission control valve …8488
Forward and reverse clutch ECMV and gear speed clutch ECMV …8491
Lockup clutch ECMV …8498
Differential lock clutch ECMV …8502
Main relief valve, torque converter relief valve, and main flow selector valve …8506
Axle …8512
Differential …8515
Final drive …8519
Steering system …8522
Layout of steering devices …8522
Steering column …8523
Flow amplifier valve …8524
Steering valve …8528
Emergency steering pump …8533
Brake system …8535
Layout of brake parts …8535
Parking brake solenoid and accumulator charge valve …8537
Accumulator …8543
Shut off solenoid valve …8544
Brake valve …8545
Proportional pressure reducing valve …8550
Slack adjuster …8552
Brake …8556
Brake system tank …8559
Parking brake …8560
Undercarriage and frame …8563
Suspension …8563
Suspension cylinder …8569
Oscillation hitch …8571
Hydraulic system …8573
Hydraulic component layout …8573
Dump body control …8574
Hydraulic tank …8575
Steering and hoist control pump …8576
Hoist valve …8588
Steering pump selector solenoid valve …8594
Hoist and radiator fan direction selector solenoid valve …8595
Dump EPC valve …8596
Brake cooling oil control valve …8598
Front brake cooling relief valve …8599
Cab and its attachments …8600
ROPS cab …8600
Cab tilt …8601
Electrical system …8602
Electrical control system …8602
Machine monitor system …8632
Rear view monitor system …8656
KOMTRAX system …8660
System component parts …8664
Sensor …8689
20 Standard value tables …8735
Table of contents …8736
Standard service value table …8737
Standard value table for engine …8737
Standard value table for machine …8739
30 Testing and adjusting …8747
Table of contents …8748
Related information on testing and adjusting …8750
Tools for testing and adjusting …8750
Sketch of tools for testing and adjusting …8756
Engine and cooling system …8759
Testing engine speed …8759
Testing boost pressure …8760
Testing exhaust gas temperature …8762
Testing exhaust gas color …8764
Testing and adjusting valve clearance …8766
Testing compression pressure …8768
Testing blowby pressure …8771
Testing engine oil pressure …8773
Testing EGR valve and KVGT driving oil pressure …8774
Testing fuel pressure …8775
Handling cylinder cutout mode operation …8776
Handling no‐injection cranking operation …8777
Testing fuel return rate and leakage …8778
Bleeding air from fuel system …8781
Testing fuel circuit for leakage …8783
Checking and adjusting air conditioner compressor belt tension …8784
Replacing alternator belt …8785
Procedures for cleaning fuel doser …8786
Writing compensation values at replacement of injector and engine controller …8789
Power train …8793
Testing torque converter stall speed …8793
Testing power train oil pressure …8795
Adjusting transmission speed sensor …8805
Adjusting transmission controller …8808
Retrieval of disabled machine that resulted from a trouble in electrical system …8809
Retrieval of disabled machine due to traction control system (KTCS) failure …8813
Steering system …8815
Testing and adjusting steering circuit oil pressure …8815
Brake system …8817
Testing and adjusting brake oil pressure …8817
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas …8820
Testing braking performance …8824
Bleeding air from brake circuit …8825
Testing wear of wheel brake disc …8826
Parking brake emergency releasing procedure …8827
Testing wear of parking brake pad and adjusting clearance …8828
Hydraulic system …8830
Testing and adjusting suspension cylinder …8830
Testing and adjusting dump circuit oil pressure …8836
Work equipment …8839
Adjusting dump body positioner sensor …8839
Testing and adjusting body mount …8840
Cab and its attachments …8842
Cab tilt-up procedure …8842
Electrical system …8846
Setting and adjusting each equipment …8846
Special functions of machine monitor …8857
KOMTRAX terminal start-up procedure …8931
Handling voltage circuit of engine controller …8935
Handling battery disconnect switch …8936
Pm clinic …8937
Pm Clinic service …8937
40 Troubleshooting …8945
Table of contents …8946
Related information on troubleshooting …8955
Troubleshooting points …8955
Sequence of events in troubleshooting …8957
Check before troubleshooting …8959
Inspection procedure before troubleshooting …8961
Preparation for troubleshooting of electrical system …8979
Classification and procedures for troubleshooting …8985
Symptom and troubleshooting numbers …8988
Information in troubleshooting table …8991
Connector list and layout …8993
Connector contact identification …9009
T-branch box and T-branch adapter table …9048
Table of fuse locations …9053
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement …9057
Precautions on troubleshooting of machine monitor …9060
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit …9062
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) …9067
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) …9068
E-2 Manual preheating system does not work …9823
E-3 Automatic preheating system does not work …9826
E-4 While preheating is working, preheating monitor does not light up …9828
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing …9830
E-6 LCD unit on machine monitor displays nothing …9833
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) …9835
E-8 LCD on machine monitor does not display properly …9837
E-9 Meter unit display on machine monitor is abnormal …9839
E-10 Night lighting lamp of meter unit on machine monitor is abnormal …9842
E-11 LED unit lamp on machine monitor is abnormal …9845
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly …9847
E-13 2 switches operation of switch panel on machine monitor does not function …9849
E-14 Switch panel buzzer of machine monitor is abnormal …9851
E-15 Rear view monitor does not light up or backlight flickers …9853
E-16 Rear view monitor images are not displayed clearly …9855
E-17 Rear view monitor brightness cannot be adjusted …9858
E-18 Night lighting lamp of rear view monitor is abnormal …9861
E-19 Rearview monitor does not display images while reverse linked display function is enabled …9863
E-20 Guide line on rear view monitor is not displayed while guide line is set …9866
E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly …9868
E-22 Fuel level gauge does not indicate correct level …9869
E-23 Seat belt caution lamp indication is abnormal …9871
E-24 Machine monitor cannot be operated when starting switch is in OFF position …9872
E-25 Alarm buzzer does not sound …9873
E-26 Alarm buzzer does not stop sounding …9875
E-27 Engine mode selector function does not operate properly …9877
E-28 AISS function does not operate properly …9878
E-29 Hoist lever does not operate properly …9879
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly …9881
E-31 None of headlamp, clearance lamp, and tail lamp lights …9885
E-32 Clearance lamp does not light up …9887
E-33 Tail lamp does not light up …9889
E-34 Low beam of headlamp does not light up …9891
E-35 High beam of headlamp does not light up …9893
E-36 Neither Low beam nor High beam of headlamp lights up …9895
E-37 High beams do not light up while passing switch is operated …9897
E-38 KOMTRAX does not operate properly …9899
Troubleshooting of hydraulic and mechanical system (H-mode) …9900
Information described in troubleshooting table (H-mode) …9900
System diagram of hydraulic and mechanical systems …9901
Failure mode and cause table …9903
H-1 Machine does not start …9907
H-2 Machine does not travel smoothly (machine hunts) …9909
H-3 Lockup is not released …9910
H-4 Abnormally large shocks result from starting of machine and gear shifting …9911
H-5 Gear is not shifted up …9912
H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds …9914
H-7 Machine lacks travel speed or power when traveling in torque converter drive mode …9915
H-8 Machine lacks travel speed or power when traveling at some gear speed …9916
H-9 Large time lag is observed when machine starts and gear is shifted …9917
H-10 Oil temperature of torque converter is high …9919
H-11 Oil pressure of torque converter is low …9920
H-12 Front brake does not work enough …9921
H-13 Center brake does not work enough …9922
H-14 Steering wheel is heavy …9923
H-15 Steering wheel does not turn …9924
H-16 Steering wheel waggles …9925
H-17 Dump body rising speed is low …9926
H-18 Dump body does not move …9927
H-19 Hydraulic drift of dump body is large …9928
H-20 Radiator fan speed is unusual (excessively high or low, or fan stops) …9929
H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) …9930
H-22 Unusual noise is heard from around radiator fan …9931
H-23 Unusual noise is heard from around aftercooler fan …9932
Troubleshooting of engine (S-mode) …9933
Information mentioned in troubleshooting table (S mode) …9933
S-1 When starting switch is turned to START position, engine is not cranked …9934
S-2 The engine cranks but exhaust smoke does not come out …9935
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) …9936
S-4 Engine startability is poor …9937
S-5 Engine does not pick-up smoothly …9939
S-6 Engine stops during operation …9941
S-7 Engine runs rough or is unstable …9943
S-8 Engine lacks power …9944
S-9 KDPF gets clogged in a short time …9946
S-10 Engine oil consumption is excessive …9948
S-11 Engine oil becomes contaminated early …9949
S-12 Fuel consumption is excessive …9950
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) …9951
S-14 Oil pressure drops …9952
S-15 Fuel mixes into engine oil …9953
S-16 Water mixes into engine oil (milky) …9954
S-17 Coolant temperature rises too high (overheating) …9955
S-18 Unusual noise is heard …9956
S-19 Vibration is excessive …9957
S-20 Air cannot be bled from fuel circuit …9958
S-21 Active regeneration is executed frequently …9959
S-22 Active regeneration takes a long time …9960
S-23 White smoke is exhausted during active regeneration …9961
50 Disassembly and assembly …9963
Table of contents …9964
Related information on disassembly and assembly …9966
How to read this manual …9966
Coating materials list …9968
Special tools list …9972
Sketches of special tools …9977
Engine and cooling system …9995
Removal and installation of supply pump assembly …9995
Removal and installation of injector assembly …10002
Removal and installation of cylinder head assembly …10014
Removal and installation of radiator assembly …10026
Removal and installation of radiator fan and fan motor …10029
Removal and installation of aftercooler assembly …10032
Removal and installation of aftercooler fan and fan motor assembly …10036
Removal and installation of engine assembly …10039
Removal and installation of engine front oil seal …10046
Removal and installation of engine rear oil seal …10051
Removal and installation of output shaft assembly …10057
Disassembly and assembly of output shaft assembly …10061
Removal and installation of KDPF assembly …10064
Disassembly and assembly of KDPF assembly …10068
Removal and installation of KCCV assembly …10077
Removal and installation of air cleaner assembly …10078
Power train …10080
Removal and installation of transmission and front differential assembly …10080
Disconnection and connection of front differential assembly and transmission assembly …10092
Disassembly and assembly of front differential assembly …10093
Disassembly and assembly of torque converter assembly …10104
Disassembly and assembly of transmission assembly …10111
Removal and installation of center differential assembly …10147
Disassembly and assembly of center differential assembly …10151
Removal and installation of rear differential assembly …10163
Disassembly and assembly of rear differential assembly …10165
Removal and installation of front final drive and brake assembly …10175
Disassembly and assembly of front final drive and brake assembly …10181
Removal and installation of center final drive and brake assembly …10191
Disassembly and assembly of center final drive and brake assembly …10193
Disassembly and assembly of rear final drive assembly …10200
Removal and installation of center axle assembly …10206
Removal and installation of rear axle assembly …10209
Steering system …10211
Disassembly and assembly of steering cylinder assembly …10211
Undercarriage and frame …10217
Removal and installation of front suspension cylinder assembly …10217
Removal and installation of rear suspension assembly …10223
Disassembly and assembly of suspension cylinder assembly …10225
Removal and installation of equalizer bar assembly …10227
Removal and installation of hitch frame assembly …10230
Disassembly and assembly of hitch frame assembly …10239
Hydraulic system …10244
Removal and installation of flow amplifier valve assembly …10244
Removal and installation of hoist valve assembly …10247
Disassembly and assembly of hoist cylinder assembly …10250
Body …10256
Removal and installation of dump body assembly …10256
Cab and its attachments …10258
Removal and installation of operator's cab assembly …10258
Removal and installation of operator's cab glass (adhered glass) …10262
Removal and installation of operator's seat assembly (GRAMMER) …10268
Removal and installation of operator's seat assembly (SEARS) …10270
Electrical system …10272
Removal and installation of machine monitor assembly …10272
Removal and installation of engine controller assembly …10274
Removal and installation of retarder and hoist controller assembly …10276
Removal and installation of transmission controller assembly …10277
Removal and installation of mass air flow and temperature sensor …10278
Removal and installation of KOMTRAX terminal assembly …10279
Air conditioner unit …10280
Removal and installation of air conditioner unit assembly …10280
Removal and installation of air conditioner compressor assembly …10285
60 Maintenance standard …10287
Table of contents …10288
Engine and cooling system …10289
Engine mount …10289
Output shaft …10290
Radiator fan pump …10291
Radiator fan motor …10293
Aftercooler fan motor …10295
Power train …10297
Drive shaft …10297
Torque converter and transmission mount …10298
Torque converter …10299
Transmission …10302
Transmission control valve …10311
Forward and reverse clutch ECMV and gear speed clutch ECMV …10312
Lockup clutch ECMV …10313
Differential lock clutch ECMV …10314
Main relief valve, torque converter relief valve, and main flow selector valve …10315
Axle …10317
Differential …10320
Final drive …10323
Steering system …10327
Steering column …10327
Steering cylinder …10328
Brake system …10329
Slack adjuster …10329
Brake …10331
Parking brake …10333
Undercarriage and frame …10335
Suspension …10335
Suspension cylinder …10339
Oscillation hitch …10340
Hydraulic system …10342
Steering and hoist control pump …10342
Front brake cooling duplex pump and aftercooler fan pump …10345
Center brake cooling pump …10346
Brake charge pump …10347
Hoist valve …10348
Hoist cylinder …10350
80 Appendix …10351
Table of contents …10352
Air conditioner components …10353
Precautions for refrigerant …10353
Air conditioner component …10354
Configuration and function of refrigeration cycle …10357
Outline of refrigeration cycle …10358
Air conditioner unit …10360
Dual pressure switch …10365
Air conditioner controller …10366
Compressor …10367
Condenser …10368
Receiver drier …10369
Outer temperature sensor (outside air temperature sensor) …10370
Procedure for testing and troubleshooting …10371
Circuit diagram and arrangement of connector pins …10373
System diagram …10375
Input and output signals of the air conditioner controller …10376
Parts and connectors layout …10378
Details …10379
Testing air leakage (duct) …10383
Testing with self-diagnosis function …10386
How to open the electrical system abnormality record screen in service mode of the machine monitor …10387
Testing vent (mode) changeover …10389
Testing FRESH/RECIRC air changeover …10390
Testing (dual) pressure switch for refrigerant …10391
Testing relays …10393
Troubleshooting chart 1 …10395
Troubleshooting chart 2 …10396
Information in troubleshooting table …10399
Failure code list related to air conditioner …10400
Failure code [879AKA] A/C Inner Sensor Open Circuit …10401
Failure code [879AKB] A/C Inner Sensor Short Circuit …10402
Failure code [879BKA] A/C Outer sensor Open Circuit …10403
Failure code [879BKB] A/C Outer sensor Short Circuit …10405
Failure code [879CKA] Ventilating Sensor Open Circuit …10407
Failure code [879CKB] Ventilating Sensor Short Circuit …10408
Failure code [879EMC] Ventilation Damper Abnormality …10409
Failure code [879FMC] Air Mix Damper Abnormality …10410
Failure code [879GKX] Refrigerant Abnormality …10411
A-1 Troubleshooting for power supply system (Air conditioner does not operate) …10413
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) …10415
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) …10418
A-4 Troubleshooting for FRESH/RECIRC air changeover …10420
Troubleshooting with gauge pressure …10422
Connection of service tool …10425
Precautions for disconnecting and connecting air conditioner piping …10427
Handling of compressor oil …10429
90 Diagrams and drawings …10431
Table of contents …10432
Hydraulic circuit diagram …10433
Symbols in hydraulic circuit diagram …10433
Power train hydraulic circuit diagram …10437
Steering and hoist hydraulic circuit diagram …10438
Brake hydraulic circuit diagram …10439
Brake cooling system hydraulic circuit diagram …10440
Electric circuit diagram …10442
Symbols in electric circuit diagram …10442
Inside cab electric circuit diagram …10446
Outside cab electric circuit diagram …10453
Circuit diagram related to payload meter …10460
INDEX…10461
SEN06511-05 – Articulated Dump Truck HM300-5 Shop Manual…10475
COVER…10475
00 INDEX AND FOREWORD…10477
INDEX…10478
ABBREVIATION LIST…10497
FOREWORD, SAFETY, BASIC INFORMATION…10502
HOW TO READ THE SHOP MANUAL…10502
SAFETY NOTICE FOR OPERATION…10504
PRECAUTIONS TO PREVENT FIRE…10512
ACTIONS IF FIRE OCCURS…10514
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…10515
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…10516
PRECAUTIONS FOR DEF…10517
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…10517
PRECAUTIONS FOR ADDING…10517
PRECAUTIONS FOR STORING…10517
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…10517
THE OTHER PRECAUTIONS…10517
STORE AdBlue/DEF…10518
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…10519
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…10522
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…10528
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…10530
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…10531
PRACTICAL USE OF KOMTRAX…10532
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…10533
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…10533
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…10534
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…10535
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…10537
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…10541
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…10542
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…10544
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…10545
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…10547
HOW TO READ ELECTRICAL WIRE CODE…10548
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…10552
STANDARD TIGHTENING TORQUE TABLE…10555
CONVERSION TABLE…10562
01 SPECIFICATIONS…10567
CONTENTS…10568
ABBREVIATION LIST…10569
SPECIFICATIONS…10574
SPECIFICATION DRAWING…10574
SPECIFICATION DRAWING: HM300-5…10574
SPECIFICATIONS…10576
SPECIFICATIONS: HM300-5…10576
WEIGHT TABLE…10582
WEIGHT TABLE: HM300-5…10582
TABLE OF FUEL, COOLANT, AND LUBRICANTS…10584
10 STRUCTURE AND FUNCTION…10587
CONTENTS…10588
ABBREVIATION LIST…10592
UREA SCR SYSTEM…10597
LAYOUT DRAWING OF UREA SCR SYSTEM…10597
UREA SCR SYSTEM DIAGRAM…10600
FUNCTION OF UREA SCR SYSTEM…10601
FUNCTION OF AdBlue/DEF SYSTEM…10601
INDUCEMENT STRATEGY…10603
COMPONENT PARTS OF UREA SCR SYSTEM…10618
AdBlue/DEF MIXING TUBE…10618
SCR ASSEMBLY…10618
AdBlue/DEF TANK…10621
AdBlue/DEF PUMP…10623
AdBlue/DEF INJECTOR…10624
AdBlue/DEF HOSE…10625
AdBlue/DEF TANK HEATING VALVE…10626
BOOT-UP SYSTEM…10627
LAYOUT DRAWING OF BOOT-UP SYSTEM…10627
SYSTEM OPERATING LAMP SYSTEM…10629
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…10629
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…10629
BATTERY DISCONNECT SWITCH…10630
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH…10630
FUNCTION OF BATTERY DISCONNECT SWITCH…10630
ENGINE SYSTEM…10632
LAYOUT DRAWING OF ENGINE SYSTEM…10632
FUNCTION OF ENGINE SYSTEM…10634
AUTOMATIC IDLE STOP SYSTEM…10635
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…10635
COMPONENT PARTS OF ENGINE SYSTEM…10637
OUTPUT SHAFT…10637
VGT…10638
EGR SYSTEM…10641
EGR VALVE…10643
EGR COOLER…10645
KCCV SYSTEM…10646
KCCV VENTILATOR…10648
KDPF…10650
COOLING SYSTEM…10655
LAYOUT DRAWING OF COOLING SYSTEM…10655
SPECIFICATIONS OF COOLING SYSTEM…10656
RADIATOR FAN CONTROL SYSTEM…10658
RADIATOR FAN CONTROL SYSTEM DIAGRAM…10658
FUNCTION OF RADIATOR FAN CONTROL SYSTEM…10658
AFTERCOOLER FAN CONTROL SYSTEM…10660
AFTERCOOLER FAN CONTROL SYSTEM DIAGRAM…10660
FUNCTION OF AFTERCOOLER FAN CONTROL SYSTEM…10660
COMPONENT PARTS OF COOLING SYSTEM…10662
RADIATOR FAN PUMP…10662
RADIATOR FAN MOTOR…10669
AFTERCOOLER FAN MOTOR…10674
HYDRAULIC OIL COOLER BYPASS VALVE…10684
CONTROL SYSTEM…10686
LAYOUT DRAWING OF CONTROL SYSTEM…10686
RETARDER AND HOIST CONTROL SYSTEM…10688
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM…10688
MACHINE MONITOR SYSTEM…10689
MACHINE MONITOR SYSTEM DIAGRAM…10689
FUNCTION OF MACHINE MONITOR SYSTEM…10690
REARVIEW MONITOR SYSTEM…10691
REARVIEW MONITOR SYSTEM DIAGRAM…10691
FUNCTION OF REARVIEW MONITOR SYSTEM…10691
KOMTRAX SYSTEM…10692
KOMTRAX SYSTEM DIAGRAM…10692
FUNCTION OF KOMTRAX SYSTEM…10692
COMPONENT PARTS OF CONTROL SYSTEM…10693
MACHINE MONITOR…10693
SWITCH PANEL…10713
REARVIEW MONITOR…10714
REARVIEW CAMERA…10715
KOMTRAX TERMINAL…10716
TRANSMISSION CONTROLLER…10718
RETARDER AND HOIST CONTROLLER…10722
MONITOR CONTROLLER…10726
ENGINE CONTROLLER…10730
ACCELERATOR PEDAL…10737
SHIFT LEVER…10738
RETARDER CONTROL LEVER…10739
HYDRAULIC SYSTEM…10740
LAYOUT DRAWING OF HYDRAULIC SYSTEM…10740
COMPONENT PARTS OF HYDRAULIC SYSTEM…10742
HYDRAULIC TANK…10742
STEERING AND HOIST PUMP…10743
LS VALVE…10749
PC VALVE…10751
POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP…10755
HOIST VALVE…10757
POWER TRAIN SYSTEM…10763
LAYOUT DRAWING OF POWER TRAIN SYSTEM…10763
TRANSMISSION CONTROL SYSTEM…10766
TRANSMISSION CONTROL SYSTEM DIAGRAM…10766
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE…10767
GEAR SHIFT CONTROL SYSTEM…10771
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM…10771
SHIFT HOLD SYSTEM…10774
FUNCTION OF SHIFT HOLD SYSTEM…10774
DIRECTION CONTROL SYSTEM…10775
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM…10775
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM…10775
KOMATSU TRACTION CONTROL SYSTEM (KTCS)…10776
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM…10776
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)…10776
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC…10777
COMPONENT PARTS OF POWER TRAIN SYSTEM…10779
DRIVE SHAFT…10779
TORQUE CONVERTER AND PTO…10780
LOCKUP CLUTCH ECMV…10784
TRANSMISSION…10788
TRANSMISSION CONTROL VALVE…10810
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV…10811
DIFFERENTIAL LOCK CLUTCH ECMV…10816
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE…10820
AXLE…10824
DIFFERENTIAL…10827
FINAL DRIVE…10831
WORK EQUIPMENT SYSTEM…10835
WORK EQUIPMENT CONTROL…10835
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM…10835
FUNCTION OF WORK EQUIPMENT CONTROL…10836
HOIST CONTROL…10837
HOIST CONTROL SYSTEM DIAGRAM…10837
FUNCTION OF HOIST CONTROL…10837
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…10839
HOIST AND RADIATOR FAN DIRECTION SELECTOR SOLENOID VALVE…10839
DUMP LEVER…10841
DUMP EPC VALVE…10845
STEERING SYSTEM…10847
LAYOUT DRAWING OF STEERING SYSTEM…10847
FUNCTION OF STEERING SYSTEM…10848
STEERING COLUMN…10849
STRUCTURE OF STEERING COLUMN…10849
COMPONENT PARTS OF STEERING SYSTEM…10850
FLOW AMPLIFIER VALVE…10850
STEERING VALVE…10854
STEERING PUMP SELECTOR SOLENOID VALVE…10859
SECONDARY STEERING PUMP…10860
SECONDARY STEERING MOTOR…10861
BRAKE SYSTEM…10862
LAYOUT DRAWING OF BRAKE SYSTEM…10862
RETARDER CONTROL…10863
RETARDER CONTROL SYSTEM DIAGRAM…10863
FUNCTION OF RETARDER CONTROL…10864
PARKING BRAKE INTERLOCK FUNCTION…10866
FUNCTION OF PARKING BRAKE INTERLOCK FUNCTION…10866
OPERATION OF PARKING BRAKE INTERLOCK FUNCTION…10866
ARAC SYSTEM…10867
ARAC SYSTEM DIAGRAM…10867
FUNCTION OF ARAC SYSTEM…10867
COMPONENT PARTS OF BRAKE SYSTEM…10868
BRAKE CHARGE PUMP…10868
PARKING BRAKE SOLENOID VALVE AND ACCUMULATOR CHARGE VALVE…10868
PARKING BRAKE SOLENOID VALVE…10870
ACCUMULATOR CHARGE VALVE…10870
BRAKE CIRCUIT ACCUMULATOR…10873
SHUT OFF SOLENOID VALVE…10875
BRAKE VALVE…10876
PROPORTIONAL PRESSURE REDUCING VALVE…10879
SLACK ADJUSTER…10880
BRAKE…10883
BRAKE COOLING OIL CONTROL VALVE…10885
FRONT BRAKE COOLING RELIEF VALVE…10887
BRAKE SYSTEM TANK…10888
PARKING BRAKE…10889
SPRING CYLINDER…10890
PARKING BRAKE CALIPER…10892
UNDERCARRIAGE AND FRAME…10894
FRONT SUSPENSION…10894
STRUCTURE OF FRONT SUSPENSION…10894
FUNCTION OF FRONT SUSPENSION…10895
CENTER AND REAR SUSPENSIONS…10896
STRUCTURE OF CENTER AND REAR SUSPENSIONS…10896
FUNCTION OF CENTER SUSPENSION…10897
FUNCTION OF REAR SUSPENSION…10898
SUSPENSION CYLINDER…10899
STRUCTURE OF SUSPENSION CYLINDER…10899
FUNCTION OF SUSPENSION CYLINDER…10900
OPERATION OF SUSPENSION CYLINDER…10900
OSCILLATION HITCH…10902
STRUCTURE OF OSCILLATION HITCH…10902
FUNCTION OF OSCILLATION HITCH…10903
WORK EQUIPMENT…10904
STRUCTURE OF WORK EQUIPMENT…10904
FUNCTION OF WORK EQUIPMENT…10905
CAB AND ITS ATTACHMENTS…10906
ROPS CAB…10906
STRUCTURE OF ROPS CAB…10906
FUNCTION OF ROPS CAB…10906
CAB TILT…10907
STRUCTURE OF CAB TILT…10907
20 STANDARD VALUE TABLE…10909
CONTENTS…10910
ABBREVIATION LIST…10911
STANDARD VALUE TABLE FOR ENGINE…10916
STANDARD VALUE TABLE FOR ENGINE: HM300-5…10916
STANDARD VALUE TABLE FOR MACHINE…10920
STANDARD VALUE TABLE FOR MACHINE: HM300-5…10920
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…10934
STANDARD VALUE TABLE FOR ELECTRICAL…10935
STANDARD VALUE TABLE FOR ELECTRICITY…10935
30 TESTING AND ADJUSTING…10951
CONTENTS…10952
ABBREVIATION LIST…10955
RELATED INFORMATION ON TESTING AND ADJUSTING…10960
TOOLS FOR TESTING AND ADJUSTING…10960
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…10967
ENGINE AND COOLING SYSTEM…10968
TEST ENGINE SPEED…10968
METHOD FOR TESTING ENGINE SPEED…10968
TEST BOOST PRESSURE…10971
METHOD FOR TESTING BOOST PRESSURE…10971
TEST EXHAUST GAS TEMPERATURE…10973
METHOD FOR TESTING EXHAUST GAS TEMPERATURE…10973
TEST EXHAUST GAS COLOR…10976
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…10976
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…10977
TEST AND ADJUST VALVE CLEARANCE…10979
METHOD FOR TESTING VALVE CLEARANCE…10979
METHOD FOR ADJUSTING VALVE CLEARANCE…10980
TEST COMPRESSION PRESSURE…10982
METHOD FOR TESTING COMPRESSION PRESSURE…10982
TEST BLOWBY PRESSURE…10985
METHOD FOR TESTING BLOWBY PRESSURE…10985
TEST ENGINE OIL PRESSURE…10988
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR…10988
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL…10988
TEST EGR VALVE AND VGT OIL PRESSURE…10990
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE…10990
TEST FUEL PRESSURE…10992
METHOD FOR TESTING FUEL PRESSURE…10992
TEST FUEL RETURN RATE AND LEAKAGE…10994
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE…10995
BLEED AIR FROM FUEL SYSTEM…11000
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…11000
TEST FUEL CIRCUIT FOR LEAKAGE…11002
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…11002
HANDLE CYLINDER CUT-OUT MODE OPERATION…11004
HANDLE NO-INJECTION CRANKING OPERATION…11005
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION…11006
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION…11006
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…11006
CLEAN FUEL DOSER…11007
METHOD FOR CLEANING FUEL DOSER…11007
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER…11010
METHOD FOR WRITING INJECTOR COMPENSATION VALUE…11010
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…11017
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…11017
TEST SCR RELATED FUNCTIONS…11018
TEST AdBlue/DEF PUMP RAISED PRESSURE…11022
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…11025
TEST AdBlue/DEF LINE HEATER RELAY 1…11029
TEST AdBlue/DEF LINE HEATER RELAY 2…11033
TEST AdBlue/DEF PUMP HEATER RELAY…11037
TEST AdBlue/DEF TANK HEATER VALVE…11041
TEST DENITRATION EFFICIENCY OF SCR…11045
CLEAN AdBlue/DEF TANK…11049
METHOD FOR CLEANING AdBlue/DEF TANK…11049
TEST TORQUE CONVERTER STALL SPEED…11054
METHOD FOR TESTING TORQUE CONVERTER STALL SPEED…11054
TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED…11059
METHOD FOR TESTING RADIATOR FAN AND AFTERCOOLER FAN SPEED…11059
POWER TRAIN…11061
TEST POWER TRAIN OIL PRESSURE…11061
METHOD FOR TESTING POWER TRAIN OIL PRESSURE…11064
ADJUST TRANSMISSION SPEED SENSOR…11079
METHOD FOR ADJUSTING TRANSMISSION SPEED SENSOR…11079
ADJUST TRANSMISSION CONTROLLER…11082
METHOD FOR ADJUSTING TRANSMISSION CONTROLLER…11082
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM…11083
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN ENGINE CONTROL SYSTEM…11083
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN TRANSMISSION CONTROL SYSTEM…11084
MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS)…11090
METHOD FOR MOVING MACHINE WITH SECONDARY KTCS OPERATION CONNECTOR…11092
STEERING SYSTEM…11093
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE…11093
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE…11093
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE…11094
BRAKE SYSTEM…11095
TEST AND ADJUST BRAKE OIL PRESSURE…11095
METHOD FOR TESTING BRAKE OIL PRESSURE…11095
METHOD FOR ADJUSTING BRAKE OIL PRESSURE…11099
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE…11100
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE…11100
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE…11102
TEST BRAKE PERFORMANCE…11105
METHOD FOR TESTING BRAKE PERFORMANCE…11105
BLEED AIR FROM BRAKE CIRCUIT…11109
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT…11109
TEST WEAR OF WHEEL BRAKE DISC…11111
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC…11111
RELEASE PARKING BRAKE MANUALLY…11112
METHOD FOR RELEASING PARKING BRAKE MANUALLY…11112
TEST AND ADJUST WEAR OF PARKING BRAKE PAD…11113
METHOD FOR TESTING WEAR OF PARKING BRAKE PAD…11113
METHOD FOR ADJUSTING CLEARANCE OF PARKING BRAKE PAD…11114
HYDRAULIC SYSTEM…11116
TEST AND ADJUST SUSPENSION CYLINDER…11116
METHOD FOR TESTING SUSPENSION CYLINDER…11117
METHOD FOR ADJUSTING SUSPENSION CYLINDER…11117
TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE…11122
METHOD FOR TESTING DUMP CIRCUIT OIL PRESSURE…11122
METHOD FOR ADJUSTING DUMP CIRCUIT OIL PRESSURE…11123
WORK EQUIPMENT…11125
TEST AND ADJUST DUMP BODY POSITIONER SENSOR…11125
METHOD FOR TESTING BODY POSITIONER SENSOR…11125
METHOD FOR ADJUSTING DUMP BODY POSITIONER SENSOR…11125
TEST AND ADJUST DUMP BODY MOUNT…11127
METHOD FOR TESTING DUMP BODY MOUNT…11127
METHOD FOR ADJUSTING DUMP BODY MOUNT…11128
CAB AND ITS ATTACHMENTS…11129
CAB TILT UP…11129
METHOD FOR TILTING UP CAB…11130
ELECTRICAL SYSTEM…11136
SET AND ADJUST EACH EQUIPMENT…11136
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT…11138
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT…11139
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING…11142
METHOD FOR SETTING CHARACTERISTIC VALUE OF ARAC (Automatic Retarder Accelerator Control)…11147
METHOD FOR PERFORMING SYSTEM CHECK OF KTCS (Komatsu Traction Control System)…11150
SET AND OPERATE MACHINE MONITOR…11152
OPERATOR MODE…11156
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…11156
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…11156
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…11157
CHECKING FUNCTION OF SERVICE METER AND ODOMETER…11158
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD…11158
SERVICE MODE…11162
METHOD FOR OPERATING SERVICE MODE…11162
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…11165
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…11173
ABNORMALITY RECORD MENU…11189
METHOD FOR CONFIRMING MAINTENANCE RECORD…11194
METHOD FOR OPERATING MAINTENANCE MODE SETTING…11196
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…11200
DEFAULT MENU…11202
DIAGNOSTIC TESTS MENU…11217
ADJUSTMENT MENU…11229
METHOD FOR PERFORMING NO-INJECTION CRANKING…11238
PAYLOAD METER SETTING…11240
KOMTRAX SETTINGS MENU…11263
METHOD FOR DISPLAYING SERVICE MESSAGE…11265
METHOD FOR STARTING UP KOMTRAX TERMINAL…11267
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…11272
HANDLE BATTERY DISCONNECT SWITCH…11273
TEST DIODES…11274
METHOD FOR TESTING DIODE USING DIGITAL TESTER…11274
METHOD FOR TESTING DIODE USING ANALOG TESTER…11274
Pm CLINIC…11275
Pm CLINIC SERVICE…11275
Pm CLINIC CHECK SHEET…11278
40 TROUBLESHOOTING…11287
CONTENTS…11288
ABBREVIATION LIST…11300
RELATED INFORMATION ON TROUBLESHOOTING…11305
GENERAL TROUBLESHOOTING POINTS…11305
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…11306
SEQUENCE OF EVENTS IN TROUBLESHOOTING…11318
CHECKS BEFORE TROUBLESHOOTING…11320
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…11322
WALK-AROUND CHECK…11322
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…11324
CHECK FUEL LEVEL AND TYPE…11324
CHECK IMPURE INGREDIENT IN FUEL…11324
CHECK AdBule/DEF LEVEL AND TYPE…11325
CHECK FUEL PREFILTER…11325
CHECK MAIN FILTER…11327
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE…11328
CHECK COOLANT LEVEL (RESERVOIR TANK)…11329
CHECK CLOGGING OF AIR CLEANER…11330
OUTER ELEMENT – CLEAN…11330
REPLACE ELEMENT…11332
CHECK HYDRAULIC OIL LEVEL…11334
CHECK HYDRAULIC OIL STRAINER…11334
CHECK HYDRAULIC FILTER…11335
CHECK OIL LEVEL IN TRANSMISSION CASE…11336
CHECK OIL LEVEL IN DIFFERENTIAL CASE…11336
CHECK OIL LEVEL IN FINAL DRIVE CASE…11337
BLEED AIR FROM FUEL SYSTEM…11338
BLEED AIR FROM HYDRAULIC SYSTEM…11338
METHOD FOR CHECKING ELECTRIC EQUIPMENTMETHOD…11338
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION…11347
PROCEDURE FOR TESTING AND TROUBLESHOOTING…11356
SYMPTOM AND TROUBLESHOOTING NUMBERS…11358
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…11361
CONNECTORS LIST AND LAYOUT…11363
CONNECTOR CONTACT IDENTIFICATION…11382
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…11422
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…12525
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…12525
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…12531
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…12534
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…12536
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING…12538
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING…12541
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)…12544
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY…12547
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL…12550
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL…12553
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL…12557
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY…12559
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION…12562
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL…12565
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY…12568
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS…12569
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY…12571
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED…12574
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL…12577
E-20 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED…12579
E-21 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET…12582
E-22 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL…12584
E-23 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL…12586
E-24 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION…12587
E-25 ALARM BUZZER DOES NOT SOUND…12588
E-26 ALARM BUZZER DOES NOT STOP SOUNDING…12589
E-27 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY…12591
E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY…12593
E-29 HOIST LEVER DOES NOT OPERATE PROPERLY…12595
E-30 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY…12597
E-31 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS…12601
E-32 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP…12603
E-33 TAIL LAMP DOES NOT LIGHT UP…12605
E-34 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP…12607
E-35 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP…12609
E-36 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP…12611
E-37 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED…12613
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…12615
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…12616
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…12616
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS…12617
FAILURE MODE AND CAUSE TABLE…12619
H-1 MACHINE DOES NOT START…12629
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)…12631
H-3 LOCKUP IS NOT RELEASED…12632
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING…12633
H-5 GEAR IS NOT SHIFTED UP…12634
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS…12636
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE…12637
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED…12638
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED…12640
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH…12643
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW…12644
H-12 STEERING WHEEL IS HEAVY TO OPERATE…12645
H-13 STEERING WHEEL CANNOT BE OPERATED…12646
H-14 STEERING WHEEL WAGGLES…12647
H-15 FRONT BRAKE DOES NOT WORK ENOUGH…12648
H-16 CENTER BRAKE DOES NOT WORK ENOUGH…12649
H-17 DUMP BODY RISING SPEED IS LOW…12650
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE…12652
H-19 DUMP BODY DOES NOT MOVE…12653
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)…12655
H-21 AFTERCOOLER FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)…12656
H-22 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN…12657
H-23 UNUSUAL NOISE IS HEARD FROM AROUND AFTERCOOLER FAN…12658
TROUBLESHOOTING OF ENGINE (S-MODE)…12659
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…12659
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…12660
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…12661
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…12662
S-4 ENGINE STARTABILITY IS POOR…12663
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…12665
S-6 ENGINE STOPS DURING OPERATION…12667
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…12669
S-8 ENGINE LACKS POWER…12670
S-9 KDPF GETS CLOGGED IN A SHORT TIME…12672
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…12674
S-11 OIL BECOMES CONTAMINATED QUICKLY…12675
S-12 FUEL CONSUMPTION IS EXCESSIVE…12676
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…12677
S-14 OIL PRESSURE DROPS…12678
S-15 FUEL MIXES INTO ENGINE OIL…12680
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…12681
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…12682
S-18 UNUSUAL NOISE IS HEARD…12683
S-19 VIBRATION IS EXCESSIVE…12684
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…12685
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…12686
S-22 ACTIVE REGENERATION TAKES TIME…12688
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…12690
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…12691
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…12693
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…12694
50 DISASSEMBLY AND ASSEMBLY…12695
CONTENTS…12696
ABBREVIATION LIST…12701
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…12706
HOW TO READ THIS MANUAL…12706
COATING MATERIALS LIST…12708
SPECIAL TOOLS LIST…12713
SKETCHES OF SPECIAL TOOLS…12731
ENGINE AND COOLING SYSTEM…12749
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…12749
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…12750
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…12755
REMOVE AND INSTALL INJECTOR ASSEMBLY…12761
METHOD FOR REMOVING INJECTOR ASSEMBLY…12761
METHOD FOR INSTALLING INJECTOR ASSEMBLY…12772
REMOVE AND INSTALL FUEL DOSER ASSEMBLY…12786
METHOD FOR REMOVING FUEL DOSER ASSEMBLY…12786
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY…12787
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…12789
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…12790
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…12801
REMOVE AND INSTALL EGR VALVE ASSEMBLY…12816
METHOD FOR REMOVING EGR VALVE ASSEMBLY…12816
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…12817
REMOVE AND INSTALL EGR COOLER ASSEMBLY…12819
METHOD FOR REMOVING EGR COOLER ASSEMBLY…12819
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…12823
REMOVE AND INSTALL STARTER ASSEMBLY…12827
METHOD FOR REMOVING STARTER ASSEMBLY…12827
METHOD FOR INSTALLING STARTER ASSEMBLY…12829
REMOVE AND INSTALL ALTERNATOR BELT…12831
METHOD FOR REMOVING ALTERNATOR BELT…12831
METHOD FOR INSTALLING ALTERNATOR BELT…12833
REMOVE AND INSTALL RADIATOR ASSEMBLY…12835
METHOD FOR REMOVING RADIATOR ASSEMBLY…12835
METHOD FOR INSTALLING RADIATOR ASSEMBLY…12837
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY…12841
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY…12841
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY…12844
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…12849
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…12850
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…12853
REMOVE AND INSTALL AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY…12857
METHOD FOR REMOVING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY…12857
METHOD FOR INSTALLING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY…12858
REMOVE AND INSTALL ENGINE ASSEMBLY…12862
METHOD FOR REMOVING ENGINE ASSEMBLY…12864
METHOD FOR INSTALLING ENGINE ASSEMBLY…12869
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…12876
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…12876
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…12880
REMOVE AND INSTALL ENGINE REAR OIL SEAL…12886
METHOD FOR REMOVING ENGINE REAR OIL SEAL…12886
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…12888
REMOVE AND INSTALL OUTPUT SHAFT…12894
METHOD FOR REMOVING OUTPUT SHAFT…12895
METHOD FOR INSTALLING OUTPUT SHAFT…12897
DISASSEMBLE AND ASSEMBLE OUTPUT SHAFT…12902
METHOD FOR DISASSEMBLING OUTPUT SHAFT…12902
METHOD FOR ASSEMBLING OUTPUT SHAFT…12904
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…12907
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…12907
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…12911
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12915
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12915
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…12920
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…12924
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…12924
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…12924
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…12926
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…12926
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…12926
REMOVE AND INSTALL KDPF ASSEMBLY…12927
METHOD FOR REMOVING KDPF ASSEMBLY…12927
METHOD FOR INSTALLING KDPF ASSEMBLY…12931
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY…12935
METHOD FOR DISASSEMBLING KDPF ASSEMBLY…12935
METHOD FOR ASSEMBLING KDPF ASSEMBLY…12939
REMOVE AND INSTALL SCR ASSEMBLY…12944
METHOD FOR REMOVING SCR ASSEMBLY…12944
METHOD FOR INSTALLING SCR ASSEMBLY…12948
REMOVE AND INSTALL KCCV ASSEMBLY…12953
METHOD FOR REMOVING KCCV ASSEMBLY…12953
METHOD FOR INSTALLING KCCV ASSEMBLY…12954
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…12955
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…12955
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…12961
REMOVE AND INSTALL AdBlue/DEF INJECTOR…12968
METHOD FOR REMOVING AdBlue/DEF INJECTOR…12968
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…12971
REMOVE AND INSTALL AdBlue/DEF PUMP…12974
METHOD FOR REMOVING AdBlue/DEF PUMP…12974
METHOD FOR INSTALLING AdBlue/DEF PUMP…12977
REMOVE AND INSTALL AdBlue/DEF HOSE…12982
METHOD FOR REMOVING AdBlue/DEF HOSE…12982
METHOD FOR INSTALLING AdBlue/DEF HOSE…12986
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…12990
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…12990
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…12993
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…12996
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…12996
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…12998
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY…13000
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY…13000
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY…13001
POWER TRAIN…13002
REMOVE AND INSTALL TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13002
METHOD FOR REMOVING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13003
METHOD FOR INSTALLING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13015
DISCONNECT AND CONNECT TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13029
METHOD FOR DISCONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13029
METHOD FOR CONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY…13030
DISASSEMBLE AND ASSEMBLE FRONT DIFFERENTIAL ASSEMBLY…13032
METHOD FOR DISASSEMBLING FRONT DIFFERENTIAL ASSEMBLY…13032
METHOD FOR ASSEMBLING FRONT DIFFERENTIAL ASSEMBLY…13037
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY…13048
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY…13048
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY…13053
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY…13058
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY…13059
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY…13084
REMOVE AND INSTALL CENTER DIFFERENTIAL ASSEMBLY…13111
METHOD FOR REMOVING CENTER DIFFERENTIAL ASSEMBLY…13111
METHOD FOR INSTALLING CENTER DIFFERENTIAL ASSEMBLY…13114
DISASSEMBLE AND ASSEMBLE CENTER DIFFERENTIAL ASSEMBLY…13118
METHOD FOR DISASSEMBLING CENTER DIFFERENTIAL ASSEMBLY…13119
METHOD FOR ASSEMBLING CENTER DIFFERENTIAL ASSEMBLY…13124
REMOVE AND INSTALL REAR DIFFERENTIAL ASSEMBLY…13135
METHOD FOR REMOVING REAR DIFFERENTIAL ASSEMBLY…13135
METHOD FOR INSTALLING REAR DIFFERENTIAL ASSEMBLY…13137
DISASSEMBLE AND ASSEMBLE REAR DIFFERENTIAL ASSEMBLY…13139
METHOD FOR DISASSEMBLING REAR DIFFERENTIAL ASSEMBLY…13139
METHOD FOR ASSEMBLING REAR DIFFERENTIAL ASSEMBLY…13143
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13152
METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13152
METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13157
DISASSEMBLE AND ASSEMBLE FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13162
METHOD FOR DISASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13163
METHOD FOR ASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY…13169
REMOVE AND INSTALL CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13178
METHOD FOR REMOVING CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13178
METHOD FOR INSTALLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13180
DISASSEMBLE AND ASSEMBLE CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13182
METHOD FOR DISASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13183
METHOD FOR ASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY…13186
DISASSEMBLE AND ASSEMBLE REAR FINAL DRIVE ASSEMBLY…13193
METHOD FOR DISASSEMBLING REAR FINAL DRIVE ASSEMBLY…13193
METHOD FOR ASSEMBLING REAR FINAL DRIVE ASSEMBLY…13197
REMOVE AND INSTALL CENTER AXLE ASSEMBLY…13202
METHOD FOR REMOVING CENTER AXLE ASSEMBLY…13202
METHOD FOR INSTALLING CENTER AXLE ASSEMBLY…13205
REMOVE AND INSTALL REAR AXLE ASSEMBLY…13208
METHOD FOR REMOVING REAR AXLE ASSEMBLY…13208
METHOD FOR INSTALLING REAR AXLE ASSEMBLY…13210
STEERING SYSTEM…13213
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY…13213
METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY…13214
METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY…13217
UNDERCARRIAGE AND FRAME…13222
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY…13222
METHOD FOR REMOVING FRONT SUSPENSION CYLINDER ASSEMBLY…13223
METHOD FOR INSTALLING FRONT SUSPENSION CYLINDER ASSEMBLY…13226
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY…13231
METHOD FOR REMOVING REAR SUSPENSION CYLINDER ASSEMBLY…13231
METHOD FOR INSTALLING REAR SUSPENSION CYLINDER ASSEMBLY…13232
DISASSEMBLE AND ASSEMBLE SUSPENSION CYLINDER ASSEMBLY…13234
METHOD FOR DISASSEMBLING SUSPENSION CYLINDER ASSEMBLY…13234
METHOD FOR ASSEMBLING SUSPENSION CYLINDER ASSEMBLY…13234
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY…13236
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY…13236
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY…13238
REMOVE AND INSTALL HITCH FRAME ASSEMBLY…13240
METHOD FOR REMOVING HITCH FRAME ASSEMBLY…13241
METHOD FOR INSTALLING HITCH FRAME ASSEMBLY…13250
DISASSEMBLE AND ASSEMBLE HITCH FRAME ASSEMBLY…13261
METHOD FOR DISASSEMBLING HITCH FRAME ASSEMBLY…13261
METHOD FOR ASSEMBLING HITCH FRAME ASSEMBLY…13263
HYDRAULIC SYSTEM…13268
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…13268
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…13268
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…13273
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY…13277
METHOD FOR REMOVING FLOW AMPLIFIER VALVE ASSEMBLY…13277
METHOD FOR INSTALLING FLOW AMPLIFIER VALVE ASSEMBLY…13279
REMOVE AND INSTALL HOIST VALVE ASSEMBLY…13282
METHOD FOR REMOVING HOIST VALVE ASSEMBLY…13282
METHOD FOR INSTALLING HOIST VALVE ASSEMBLY…13285
DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY…13287
METHOD FOR DISASSEMBLING HOIST CYLINDER ASSEMBLY…13287
METHOD FOR ASSEMBLING HOIST CYLINDER ASSEMBLY…13290
WORK EQUIPMENT…13296
REMOVE AND INSTALL DUMP BODY ASSEMBLY…13296
METHOD FOR REMOVING DUMP BODY ASSEMBLY…13296
METHOD FOR INSTALLING DUMP BODY ASSEMBLY…13298
CAB AND ITS ATTACHMENTS…13300
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…13300
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY…13301
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY…13303
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)…13307
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)…13308
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)…13308
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…13313
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…13314
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…13320
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY (MANUFACTURED BY GRAMMER)…13327
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY…13327
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY…13328
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY (MANUFACTURED BY SEARS)…13330
METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY…13330
METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY…13332
REMOVE AND INSTALL SEAT BELT…13335
METHOD FOR REMOVING SEAT BELT…13335
METHOD FOR INSTALLING SEAT BELT…13336
ELECTRICAL SYSTEM…13337
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…13337
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…13337
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…13339
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY…13342
METHOD FOR REMOVING RETARDER AND HOIST CONTROLLER ASSEMBLY…13342
METHOD FOR INSTALLING RETARDER AND HOIST CONTROLLER ASSEMBLY…13343
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY…13344
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY…13344
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY…13345
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…13346
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…13346
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…13348
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…13351
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…13351
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…13353
REMOVE AND INSTALL SCR TEMPERATURE SENSOR…13355
METHOD FOR REMOVING SCR TEMPERATURE SENSOR…13355
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR…13357
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY…13359
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY…13359
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY…13360
60 MAINTENANCE STANDARD…13361
CONTENTS…13362
ABBREVIATION LIST…13364
ENGINE AND COOLING SYSTEM…13369
MAINTENANCE STANDARD OF ENGINE MOUNT…13369
MAINTENANCE STANDARD OF OUTPUT SHAFT…13370
MAINTENANCE STANDARD OF RADIATOR FAN PUMP…13371
MAINTENANCE STANDARD OF SERVO VALVE OF RADIATOR FAN PUMP…13372
MAINTENANCE STANDARD OF RADIATOR FAN MOTOR…13373
MAINTENANCE STANDARD OF AFTERCOOLER FAN MOTOR…13375
POWER TRAIN…13378
MAINTENANCE STANDARD OF DRIVE SHAFT…13378
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT…13379
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO…13380
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV…13383
MAINTENANCE STANDARD OF TRANSMISSION…13384
MAINTENANCE STANDARD OF FL, R CLUTCH…13388
MAINTENANCE STANDARD OF FH, 1ST CLUTCH…13389
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH…13390
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH…13392
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE…13394
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV…13395
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH ECMV…13396
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE…13397
MAINTENANCE STANDARD OF FRONT AXLE…13399
MAINTENANCE STANDARD OF CENTER AXLE…13400
MAINTENANCE STANDARD OF REAR AXLE…13401
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL…13402
MAINTENANCE STANDARD OF CENTER DIFFERENTIAL…13403
MAINTENANCE STANDARD OF REAR DIFFERENTIAL…13404
MAINTENANCE STANDARD OF FRONT FINAL DRIVE…13405
MAINTENANCE STANDARD OF CENTER FINAL DRIVE…13407
MAINTENANCE STANDARD OF REAR FINAL DRIVE…13408
STEERING SYSTEM…13409
MAINTENANCE STANDARD OF STEERING COLUMN…13409
MAINTENANCE STANDARD OF STEERING CYLINDER…13410
BRAKE SYSTEM…13411
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER…13411
MAINTENANCE STANDARD OF CENTER SLACK ADJUSTER…13412
MAINTENANCE STANDARD OF FRONT BRAKE…13413
MAINTENANCE STANDARD OF CENTER BRAKE…13415
MAINTENANCE STANDARD OF PARKING BRAKE…13417
UNDERCARRIAGE AND FRAME…13419
MAINTENANCE STANDARD OF FRONT SUSPENSION…13419
MAINTENANCE STANDARD OF CENTER AND REAR SUSPENSIONS…13421
MAINTENANCE STANDARD OF SUSPENSION CYLINDER…13424
MAINTENANCE STANDARD OF OSCILLATION HITCH…13426
HYDRAULIC SYSTEM…13428
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP…13428
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP…13429
MAINTENANCE STANDARD OF POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP…13431
MAINTENANCE STANDARD OF CENTER BRAKE COOLING PUMP…13433
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP…13434
MAINTENANCE STANDARD OF HOIST VALVE…13435
WORK EQUIPMENT…13437
MAINTENANCE STANDARD OF HOIST CYLINDER…13437
80 APPENDIX…13439
CONTENTS…13440
ABBREVIATION LIST…13442
AIR CONDITIONER SYSTEM…13447
PRECAUTIONS FOR REFRIGERANT…13447
AIR CONDITIONER COMPONENT…13448
SPECIFICATIONS OF AIR CONDITIONER…13450
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…13451
OUTLINE OF REFRIGERATION CYCLE…13452
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…13454
AIR CONDITIONER UNIT…13454
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…13454
FUNCTION OF AIR CONDITIONER UNIT…13456
COMPONENT PARTS OF AIR CONDITIONER UNIT…13458
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…13459
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…13459
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…13459
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…13459
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…13460
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…13460
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…13460
FUNCTION OF DUAL PRESSURE SWITCH…13461
AIR CONDITIONER CONTROLLER…13462
STRUCTURE OF AIR CONDITIONER CONTROLLER…13462
COMPRESSOR…13463
STRUCTURE OF COMPRESSOR…13463
SPECIFICATIONS OF COMPRESSOR…13463
FUNCTION OF COMPRESSOR…13463
CONDENSER…13464
STRUCTURE OF CONDENSER…13464
SPECIFICATIONS OF CONDENSER…13464
FUNCTION OF CONDENSER…13464
RECEIVER DRIER…13465
STRUCTURE OF RECEIVER DRIER…13465
SPECIFICATIONS OF RECEIVER DRIER…13465
FUNCTION OF RECEIVER DRIER…13465
SENSORS FOR AIR CONDITIONER SYSTEM…13466
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…13466
FUNCTION OF AMBIENT TEMPERATURE SENSOR…13466
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…13467
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER…13469
AIR CONDITIONER SYSTEM DIAGRAM…13471
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER…13472
FUNCTION OF AIR CONDITIONER CONTROLLER…13473
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…13474
TESTING AIR LEAKAGE (DUCT)…13477
METHOD FOR TESTING AIR LEAKAGE (DUCT)…13477
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION…13481
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR…13482
TEST VENT (MODE) CHANGEOVER…13484
METHOD FOR TESTING VENT (MODE) CHANGEOVER…13484
TESTING FRESH/RECIRC AIR CHANGEOVER…13485
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER…13485
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…13486
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…13486
TEST RELAYS…13487
METHOD FOR TESTING RELAYS…13487
AIR CONDITIONER TROUBLESHOOTING CHART 1…13489
AIR CONDITIONER TROUBLESHOOTING CHART 2…13490
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…13493
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)…13507
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)…13509
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…13512
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER…13514
TROUBLESHOOTING USING GAUGE PRESSURE…13516
CONNECTION OF SERVICE TOOL…13519
METHOD FOR CONNECTING SERVICE TOOL…13519
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…13521
HANDLE COMPRESSOR OIL…13523
90 CIRCUIT DIAGRAMS…13525
CONTENTS…13526
ABBREVIATION LIST…13527
HYDRAULIC CIRCUIT DIAGRAM…13532
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…13532
HYDRAULIC CIRCUIT DIAGRAM…13537
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…13538
ELECTRICAL CIRCUIT DIAGRAM…13539
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…13539
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/8)…13543
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/8)…13544
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/8)…13545
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/8)…13546
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/8)…13547
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/8)…13548
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/8)…13549
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/8)…13550
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/7)…13551
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/7)…13552
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/7)…13553
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/7)…13554
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/7)…13555
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/7)…13556
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/7)…13557
INDEX…13558

Komatsu Articulated Dump Truck HM300 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD785-5LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Dump Truck HD785-5LC workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM006103 – Dump Truck HD785-5LC Shop Manual.pdf
CEBM013801 – Dump Truck HD785-5LC Shop Manual.pdf
CEAM006003 – Dump Truck HD785-5LC Operation & Maintenance Manual.pdf
CEAM014100 – Dump Truck HD785-5LC Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,663 pages
File Format: PDF
Language: English

MAIN SECTIONS
CEAM006003 – Dump Truck HD785-5LC Operation & Maintenance Manual…2
  OM6005.pdf…0
    PAYLOAD METER II™…133
    PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)…136
      GENERAL INFORMATION…136
        Haul Cycles…136
      LIGHTS, SWITCHES, and COMPONENTS…137
      TIPS FOR OPERATION…138
      EXTERNAL DISPLAY LIGHTS…138
      THEORY OF OPERATION…139
        Basic Description…139
        Inclinometer…139
        Linkage Factor…139
        Gain Factor…140
        Brake Lock…140
        Sources of Error…140
        Typical Data From Service Check Mode…140
        Example Calculation of Payload…141
        Viewing Payload Calculation Inputs…141
        Checking the Gain…142
        Adjusting the Gain…142
      TYPES OF DATA STORED…143
        Cycle Data…143
        Engine ON/OFF Data…144
        Fault Codes and Warning Data…144
        Engine Operation…145
        Total Payload and Total Number of Cycles…145
        Other Data…145
      OPERATOR FUNCTIONS…146
        Using the Operator Load Counter…146
        Viewing the Operator Load Counter…146
        Clearing the Operator Load Counter…146
        Dimming the Lights on the Display…146
      INITIAL SETUP OF PAYLOAD METER…147
        Switch Settings…147
        Checking the Operator Check Mode…148
        Checking the Service Check Mode…148
        Checking the Gt setting:…149
        Checking the Inclinometer Settings…149
        Calibrating a Truck…149
        DISPLAYS AT START-UP…150
        NORMAL OPERATION…150
      SETUP AND MAINTENANCE…151
        Setting The Speed Limit…151
        Setting the Option Code…151
        Setting The Machine I.D. Code…152
        Setting The Operator I.D. Code…152
        Setting The Time and Date…152
      DOWNLOAD OF INFORMATION…153
      DISPLAY OF FAULT CODES…153
        Monitoring Input Signals…157
        Service Check Mode…157
      UP Factor – Payload Calculation Gain…158
      PL Mode – Load Calculation Timing…158
      FINAL GEAR RATIO SELECTION…159
      BATTERY REPLACEMENT PROCEDURE…160
        Replacing the Battery…160
        After Replacing the Battery…161
      SUSPENSION PRESSURE SENSOR…161
        Removal…161
        Installation…162
      INCLINOMETER…162
        Removal…162
        Installation…162
        Adjustment…162
      PAYLOAD METER BACK PANEL…163
      CONNECTIONS…164
      PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE…165
    PAYLOAD CIRCUIT NUMBERS…166
CEAM014100 – Dump Truck HD785-5LC Operation & Maintenance Manual…169
  COVER…169
  INTRODUCTION…175
    FOREWORD…175
    ALERTS PAGE…176
    TABLE OF CONTENTS…177
    TRUCK MODEL ILLUSTRATION…185
    ABOUT THIS MANUAL…186
    STANDARD CHARTS AND TABLES…187
      INDEX OF TABLES…187
  GENERAL SAFETY…193
    Safety Rules…193
    Safety Features…193
    Clothing And Personal Protective Items…193
    Unauthorized Modification…193
    Leaving The Operator's Seat…194
    Mounting And Dismounting…194
    Fire Prevention For Fuel And Oil…194
    Precautions When Handling At High Temperatures…195
    Asbestos Dust Hazard Prevention…195
    Prevention Of Injury By Work Equipment…195
    Fire Extinguisher And First Aid Kit…195
    Precautions When Using ROPS…196
    Precautions For Attachments…196
    PRECAUTIONS DURING OPERATION…197
      BEFORE STARTING ENGINE…197
        Safety At Worksite…197
        Fire Prevention…197
        In Operator's Cab…197
        Ventilation For Enclosed Areas…197
        In Operator's Cab – Before Starting Engine…198
        Keep Mirrors, Windows, And Lights Clean…198
      OPERATING THE MACHINE…198
        When Starting Engine…198
        Truck Operation – General…198
        Check When Traveling In Reverse…199
        Traveling…199
        Traveling On Slopes…200
        Ensure Good Visibility…200
        Operate Carefully On Snow…200
        Avoid Damage To Dump Body…200
        Do Not Go Close To High-voltage Cables…200
        When Dumping…201
        Working On Loose Ground…201
        When Loading…201
        Parking The Machine…201
      TOWING…201
        When Towing, Attach Cable To Hook…201
      BATTERY…202
        Battery Hazard Prevention…202
        Starting With Booster Cables…202
    PRECAUTIONS FOR MAINTENANCE…203
      BEFORE CARRYING OUT MAINTENANCE…203
        Warning Tag…203
        Proper Tools…203
        Periodic Replacement Of Critical Parts…203
        Stopping The Engine Before Service…203
        Securing The Dump Body…204
      DURING MAINTENANCE…204
        Personnel…204
        Attachments…204
        Work Under The Machine…204
        Keep The Machine Clean…204
        Rules To Follow When Adding Fuel Or Oil…205
        Radiator Water Level…205
        Use Of Lighting…205
        Precautions With Battery…205
        Handling High-Pressure Hoses…205
        Precautions With High Pressure Oil…206
        Precautions When Carrying Out Maintenance At High Temperature Or High Pressure…206
        Rotating Fan And Belt…206
        Waste Materials…206
      TIRES…207
        Handling Tires…207
        Storing Tires After Removal…207
    WARNINGS AND CAUTIONS…209
  OPERATION…219
    OPERATING INSTRUCTIONS…219
      PREPARING FOR OPERATION…219
        SAFETY IS THINKING AHEAD…219
        At The Truck – Ground Level Walk Around Inspection…219
      ENGINE START-UP SAFETY PRACTICES…223
        Before Starting The Engine…223
        Starting The Engine…224
        Starting The Engine In Cold Weather…224
      AFTER ENGINE HAS STARTED…225
      MACHINE OPERATION SAFETY PRECAUTIONS…226
      LOADING…226
      HAULING…227
      RETARDER OPERATION…227
        Engine Overspeed…228
      PASSING…229
      DUMPING…229
        To Raise dump body:…229
        To Lower Body:…230
      SAFE PARKING PROCEDURES…230
      SHUTDOWN PROCEDURE…230
      TOWING…231
      BRAKE RELEASE…232
        Release Of Parking Brake…232
        Release Of Emergency Brake…232
    OPERATOR CAB AND CONTROLS…233
      (1) STEERING WHEEL AND CONTROLS…233
        (2) Tilt Lever…233
        (3) Turn Signal Lever Switch…233
        (4) Horn…233
        (5) Windshield Wiper / Washer Switch…233
        (6) Headlights and Dimmer Switch…234
        (7) Retard Control Lever…234
      (8) BRAKE PEDAL…234
      (9) THROTTLE PEDAL…234
      (10) CENTER CONSOLE AND CONTROLS…234
        Transmission Range Selector (1, Figure 32-2)…234
        Shift Limiter Switch (2, Figure 32-2)…236
        Economy / Power Mode Switch (3, Figure 32-2)…236
        Emergency Steering Switch (4, Figure 32-2)…236
        Emergency Brake Lever (5, Figure 32-2)…237
        Parking Brake Valve Lever (6, Figure 32-2)…237
      ENGINE ELECTRONIC CONTROL SYSTEM…238
        Engine Shutdown Light (Stop Engine)…238
        Engine Maintenance Light (Check Engine)…238
        Engine Maintenance Light…238
        Fault Check Switch (11, Figure 32-2)…239
        Fault Scroll Switch (12, Figure 32-2)…239
        Determining Fault Codes…239
      EXITING THE DIAGNOSTICS MODE…239
      (11) HOIST CONTROL…240
        SAFETY LOCK…240
      ASR (AUTOMATIC SPIN REGULATOR) / ARSC (Automatic Retard Speed Control) (Optional)…241
      ASR SYSTEM CONTROLS…241
        System Switch (1, Figure 32-3)…242
        ASR/ARSC Caution Lamp (6, Figure 32-3)…242
        ASR Operation Lamp (8, Figure 32-3)…242
        Central Warning Lamp (12, Figure 32-3)…242
        Retarder Control Lever (10, Figure 32-3)…242
        Accelerator Pedal (5, Figure 32-3)…242
        Brake Pedal (4, Figure 32-3)…242
      PRECAUTIONS WHEN USING THE ASR SYSTEM…242
      ARSC SYSTEM CONTROLS…243
        System Switch (2, Figure 32-3)…243
        ARSC Set Lever (3, Figure 32-3)…243
        Brake Pedal (4, Figure 32-3)…243
        Accelerator Pedal (5, Figure 32-3)…243
        ASR/ARSC Caution Lamp (6, Figure 32-3)…243
        ARSC Standby Lamp (7, Figure 32-3)…243
        Set Speed Display (9, Figure 32-3)…243
        Retarder Control Lever (10, Figure 32-3)…243
        Central Warning Lamp (12, Figure 32-3)…243
      ARSC SYSTEM ACTUATION…244
        Traveling Again At Set Speed…244
        Relationship With Exhaust Brake…245
        Recommended Set Speed…245
      TROUBLESHOOTING THE ASR/ARSC SYSTEM…246
        When a problem occurs in the system…246
        Model Selection, Tire Selection, And Failure Code Display…246
        Failure Codes…246
        Clearing The Failure Code…248
      OPERATOR SEAT…249
    INSTRUMENT PANEL AND INDICATORS…250
      WARNING & CAUTION LAMPS…251
      GAUGE AND MONITOR PANEL…252
        1. Air Pressure Monitor…252
        2. Air Pressure Gauge…252
        3. Coolant Temperature Monitor…252
        4. Engine Cooling Water Temperature Gauge…252
        5. Torque Converter Oil Temperature Monitor…253
        6. Torque Converter Oil Temperature Gauge…253
        7. Retarder Oil Temperature Monitor…253
        8. Retarder Oil Temperature Gauge…253
        9. High Beam Pilot Lamp…253
        10. Left Turn Signal Pilot Lamp…253
        11. Right Turn Signal Pilot Lamp…253
        12. Speedometer…253
        13. Tachometer…253
        14. Shift Limiter Pilot Lamp…253
        15. Lock-up Pilot Lamp…254
        16. Transmission Shift Position Pilot Lamp…254
        17. Shift Indicator…254
        18. Engine Controller Monitor…254
        19. Automatic Transmission Mechatronics Monitor…254
        20. Other Mechatronics Monitor (OPTIONAL)…254
        21. Fuel Level Monitor…254
        22. Fuel Gauge…254
        26. Service Meter…255
        27. Service Meter Indicator…255
        28. Odometer…255
        29. Power Mode Indicator…255
      INDICATORS AND CONTROLS PANEL…255
        Optional Equipment…255
        30. Coolant Level Monitor…256
        31. Engine Oil Pressure Monitor…256
        32. Charge Monitor…256
        33. Transmission Oil Filter Monitor…256
        34. Hazard Warning Lights…256
        35. Front Brake On/Off Switch…256
        36. Panel Dimmer Switch…256
        37. AISS/Auto Switch…257
        38. Manual Starting Aid Switch…257
        39. Starting Switch…257
        40. Pilot Lamp Bulb Check Switch…257
        41. Rear Brake Pilot Lamp…257
        42. Body Float Caution Monitor…257
        43. Parking Brake Monitor…258
        44. Emergency Steering Monitor…258
        45. Exhaust Brake (Optional)…258
        46. Cold Start…258
        48. Steering Oil Temperature…258
        50. Side Slope Warning (Optional)…258
        51. Rear Brake Caution Lamp…258
        52. Exhaust Brake Switch (Optional)…259
        53. Fog Light Switch (Optional)…259
        54. Central Warning Lamp (Red Convex Lens)…259
      HEATER/AIR CONDITIONER CONTROLS…260
        55. Temperature Adjustment Lever…260
        56. Blower Switch…260
        57. Air Selector Lever…260
        58. Vent Selector Lever…260
        59. Air Vent…261
        60. Glove Box Storage Compartment…261
        61. Air Conditioner Switch…261
        62. Correction Code Display…261
  MAINTENANCE…263
    LUBRICATION AND SERVICE…263
      10 HOUR (DAILY) INSPECTION…265
      FLUID LEVELS & OTHER CHECKS…265
      ENGINE…267
      WHEELS AND TIRES…267
        Tires…267
        WHEELS…268
      OPERATIONAL CHECKS…269
      250 HOURS SERVICE…271
      INITIAL 250 HOURS SERVICE ONLY…271
      EVERY 250 HOURS SERVICE…271
      500 HOUR SERVICE…273
      1000 HOUR SERVICE…274
      EVERY 2000 HOUR SERVICE…275
      EVERY 5000 HOUR SERVICE…276
      HYDRAULIC TANK SERVICE…277
        Filling Instructions (Hoist Oil Supply)…277
        Filling Instructions (Rear Brake Cooling Oil Supply)…277
      HYDRAULIC FILTERS…278
        Filter Replacement…278
      HYDRAULIC TANK BREATHER…278
        Cleaning…278
      HIGH PRESSURE HYDRAULIC FILTERS…279
        Filter Assembly Removal…279
        Filter Assembly Installation…279
        Filter Element Replacement…280
      TRANSMISSION FILTER…281
        Service…281
    PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES…282
    BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…283
      CHECKING FRONT BRAKE PAD WEAR…283
      TESTING BRAKE PRESSURE…283
      CHECKING REAR BRAKE DISC WEAR…284
      BRAKE BLEEDING…285
        Rear brakes…285
        Front brakes…285
    PARKING BRAKE…286
      PARKING BRAKE PAD…286
        Inspection…286
      PARKING BRAKE ADJUSTMENT…286
        Testing…286
        Adjusting…286
    AUTOMATIC LUBRICATION SYSTEM…289
      OPERATION…289
      COMPONENTS…289
      COMPONENT LOCATION…290
      GENERAL INFORMATION…292
        Lubricant Required for System…292
        Air Pressure Regulator…292
        Initial Reservoir Fill…292
        System Priming…292
      SYSTEM CHECKOUT…293
        24 VDC Solid State Timer Check…293
        Timer Adjustment…293
      Injectors (SL-1 Series H)…294
        Injector Specifications…294
        Injector Adjustment…294
      INJECTOR OPERATION…295
        STAGE 3…295
        STAGE 4…295
      TROUBLESHOOTING CHART…296
  MAJOR COMPONENTS AND SPECIFICATIONS…299
  OPTIONAL EQUIPMENT…303
    PAYLOAD METER II™…303
      PAYLOAD METER II ON BOARD WEIGHING SYSTEM (OBWS)…306
        GENERAL INFORMATION…306
          Haul Cycles…306
        LIGHTS, SWITCHES, and COMPONENTS…307
        TIPS FOR OPERATION…308
        EXTERNAL DISPLAY LIGHTS…308
        THEORY OF OPERATION…309
          Basic Description…309
          Inclinometer…309
          Linkage Factor…309
          Gain Factor…310
          Brake Lock…310
          Sources of Error…310
          Typical Data From Service Check Mode…310
          Example Calculation of Payload…311
          Viewing Payload Calculation Inputs…311
          Checking the Gain…312
          Adjusting the Gain…312
        TYPES OF DATA STORED…313
          Cycle Data…313
          Engine ON/OFF Data…314
          Fault Codes and Warning Data…314
          Engine Operation…315
          Total Payload and Total Number of Cycles…315
          Other Data…315
        OPERATOR FUNCTIONS…316
          Using the Operator Load Counter…316
          Viewing the Operator Load Counter…316
          Clearing the Operator Load Counter…316
          Dimming the Lights on the Display…316
        INITIAL SETUP OF PAYLOAD METER…317
          Switch Settings…317
          Checking the Operator Check Mode…318
          Checking the Service Check Mode…318
          Checking the Gt setting:…319
          Checking the Inclinometer Settings…319
          Calibrating a Truck…319
          DISPLAYS AT START-UP…320
          NORMAL OPERATION…320
        SETUP AND MAINTENANCE…321
          Setting The Speed Limit…321
          Setting the Option Code…321
          Setting The Machine I.D. Code…322
          Setting The Operator I.D. Code…322
          Setting The Time and Date…322
        DOWNLOAD OF INFORMATION…323
        DISPLAY OF FAULT CODES…323
          Monitoring Input Signals…327
          Service Check Mode…327
        UP Factor – Payload Calculation Gain…328
        PL Mode – Load Calculation Timing…328
        FINAL GEAR RATIO SELECTION…329
        BATTERY REPLACEMENT PROCEDURE…330
          Replacing the Battery…330
          After Replacing the Battery…331
        SUSPENSION PRESSURE SENSOR…331
          Removal…331
          Installation…332
        INCLINOMETER…332
          Removal…332
          Installation…332
          Adjustment…332
        PAYLOAD METER BACK PANEL…333
        CONNECTIONS…334
        PAYLOAD METER 2 RE-INITIALIZATION PROCEDURE…335
        PAYLOAD CIRCUIT NUMBERS…336
    RADIO, AM/FM STEREO CASSETTE…337
      RECEIVER CONTROLS…337
      BASIC OPERATION…338
        Power ON/OFF and Selecting a Source…338
        To Listen To The Radio…338
        Storing and Recalling Broadcast Frequencies…338
        Tuning Strong Signals…338
        Storing the Strongest Broadcast Frequencies…338
        Playing a Cassette Tape…339
        Radio Intercept…339
      AUDIO ADJUSTMENTS…339
        Accessing Audio Controls…339
        Audio Controls Description and Adjustment…339
        BTB (bass treble booster) Adjustment…339
        Loudness Adjustment…340
        Source Level Adjustment…340
      SETTING THE CLOCK…340
        Turning Clock Display on or off…340
      XM SATELLITE RECEIVER OPERATION…340
        Switching the XM Channel Select Setting…340
      LIGHTER & ASH TRAY…341
        Lighter…341
        Ash Tray…341
CEBM006103 – Dump Truck HD785-5LC Shop Manual…345
CEBM013801 – Dump Truck HD785-5LC Shop Manual…1517
  COVER…1517
  FOREWORD…1521
  TABLE OF CONTENTS…1523
  SECTION A GENERAL INFORMATION…1525
    MAJOR COMPONENTS AND SPECIFICATIONS…1527
      SPECIFICATIONS…1529
    GENERAL SAFETY AND OPERATING INSTRUCTIONS…1531
      GENERAL SAFETY…1533
        Safety Rules…1533
        Safety Features…1533
        Clothing And Personal Protective Items…1533
        Unauthorized Modification…1533
        Leaving The Operator's Seat…1534
        Mounting And Dismounting…1534
        Fire Prevention For Fuel And Oil…1534
        Precautions When Handling At High Temperatures…1535
        Asbestos Dust Hazard Prevention…1535
        Prevention Of Injury By Work Equipment…1535
        Fire Extinguisher And First Aid Kit…1535
        Precautions When Using ROPS…1536
        Precautions For Attachments…1536
      PRECAUTIONS DURING OPERATION…1537
        BEFORE STARTING ENGINE…1537
          Safety At Worksite…1537
          Fire Prevention…1537
          In Operator's Cab…1537
          Ventilation For Enclosed Areas…1537
          In Operator's Cab – Before Starting Engine…1538
        OPERATING THE MACHINE…1538
          When Starting Engine…1538
          Truck Operation – General…1538
          Check When Traveling In Reverse…1539
          Traveling…1539
          Traveling On Slopes…1540
          Ensure Good Visibility…1540
          Operate Carefully On Snow…1540
          Avoid Damage To Dump Body…1540
          Do Not Go Close To High-voltage Cables…1540
          When Dumping…1541
          Working On Loose Ground…1541
          When Loading…1541
          Parking The Machine…1541
        TOWING…1541
        WORKING NEAR BATTERIES…1542
          Battery Hazard Prevention…1542
          Starting With Booster Cables…1542
      PRECAUTIONS FOR MAINTENANCE…1543
        BEFORE PERFORMING MAINTENANCE…1543
          Warning Tag…1543
          Proper Tools…1543
          Stopping The Engine Before Service…1543
          Securing The Dump Body…1544
        DURING MAINTENANCE…1544
          Personnel…1544
          Attachments…1544
          Work Under The Machine…1544
          Keep The Machine Clean…1544
          Rules To Follow When Adding Fuel Or Oil…1544
          Radiator Water Level…1545
          Use Of Lighting…1545
          Precautions With The Battery…1545
          Handling High-Pressure Hoses…1545
          Precautions With High-Pressure Oil…1545
          Precautions When Carrying Out Maintenance At High Temperature Or High Pressure…1546
          Rotating Fan And Belt…1546
          Waste Materials…1546
        TIRES…1547
          Handling Tires…1547
          Storing Tires After Removal…1547
      ADDITIONAL JOB SITE RULES…1548
      OPERATING INSTRUCTIONS…1549
        PREPARING FOR OPERATION…1549
          At The Truck – Ground Level Walk Around Inspection…1549
        ENGINE START-UP SAFETY PRACTICES…1553
          Before Starting The Engine…1553
          Starting The Engine…1554
          Starting The Engine In Cold Weather…1554
        AFTER ENGINE HAS STARTED…1555
        MACHINE OPERATION SAFETY PRECAUTIONS…1556
        LOADING…1556
        HAULING…1557
        RETARDER OPERATION…1557
          Engine Overspeed…1558
        PASSING…1559
        DUMPING…1559
          To Raise dump body:…1559
          To Lower Body:…1560
        SAFE PARKING PROCEDURES…1560
        SHUTDOWN PROCEDURE…1560
        TOWING…1561
        BRAKE RELEASE…1562
          Release Of Parking Brake…1562
          Release Of Emergency Brake…1562
    WARNINGS AND CAUTIONS…1563
    STANDARD CHARTS AND TABLES…1573
      INDEX OF TABLES…1573
        Sealants and Adhesives…1577
    STANDARD VALUE TABLES…1579
  SECTION B STRUCTURES…1591
    STRUCTURAL COMPONENTS…1593
      STRUCTURAL COMPONENTS…1595
        GRILLE AND HOOD…1595
          Removal…1595
          Installation…1595
        DECKS…1595
        LEFT DECK AND CAB…1596
          Removal…1596
          Installation…1596
        RIGHT DECK…1597
          Removal…1597
          Installation…1597
        CENTER DECK…1598
          Removal…1598
          Installation…1598
    DUMP BODY…1599
      DUMP BODY…1601
        Removal…1601
        Installation…1602
        BODY PAD…1603
          Removal…1603
          Installation…1603
        BODY PAD ADJUSTMENT (SIDE)…1603
          (With pads in place)…1603
          (With pads removed)…1603
        BODY PAD ADJUSTMENT (FRONT)…1604
        BODY GUIDE…1604
        BODY PIN…1604
        ROCK EJECTORS…1605
          Inspection…1605
    FUEL TANK…1607
      FUEL TANK…1609
        Removal…1609
        Installation…1610
        Cleaning…1610
        VENT…1610
        QUICK FUEL INSTALLATION (OPTION)…1610
  SECTION C ENGINE…1611
    COOLING SYSTEM…1613
      COOLING SYSTEM…1615
        COOLING SYSTEM COMPONENTS…1615
        RADIATOR…1615
          Removal…1615
          Service…1617
          Installation…1617
        BRAKE OIL COOLER…1618
          Removal…1618
          Installation…1618
        FAN…1618
          Removal…1618
          Installation…1618
        FAN BELT…1619
          Fan Belt Replacement…1619
          Fan Belt Adjustment…1619
    ENGINE…1621
      ENGINE…1623
        GENERAL INSTRUCTIONS…1623
        PREPARATION FOR ENGINE REMOVAL…1623
          Removal…1623
          Installation…1626
        DRIVE LINE ADAPTER…1628
          Drive Line Adapter Removal…1628
          Drive Line Adapter Installation…1629
          Drive Line Adapter Damper Disassembly…1630
          Drive Line Adapter Damper Assembly…1631
        RECOMMENDED LUBRICANTS…1631
    AIR FILTRATION SYSTEM…1633
      AIR FILTRATION SYSTEM…1635
        AIR CLEANER…1635
          Service Checks…1635
          Filter Element Replacement…1635
          Main Filter Element Cleaning…1637
          Air Intake Troubleshooting…1638
  SECTION D ELECTRICAL SYSTEM…1639
    24V ELECTRIC SUPPLY SYSTEM…1641
      24VDC ELECTRIC SUPPLY SYSTEM…1643
        ELECTRICAL SYSTEM DESCRIPTION…1643
        BATTERY…1643
          Service…1643
          Storage…1643
          Maintenance and Troubleshooting…1644
          Spillage…1645
        BATTERY DISCONNECT SWITCH (Optional)…1645
        BATTERY CHARGING CIRCUIT COMPONENTS…1646
          Battery Charging Alternator…1646
          Operation…1647
          Magnetizing The Rotor…1647
      ENGINE PRELUB SYSTEM…1648
        OPERATION…1648
          Pressure Switch…1648
          Check Valve…1648
          Timer Solenoid…1648
        MAINTENANCE…1650
          Prelub™ System Operation…1650
          Starter/Prelub Pump…1650
          Check Valve…1650
          Timer Solenoid…1650
        Troubleshooting Prelub Starter Circuit…1651
    24VDC ELECTRICAL SYSTEM COMPONENTS…1653
      24VDC ELECTRICAL SYSTEM COMPONENTS…1655
        VEHICLE MONITOR SYSTEM…1655
          General Description…1655
          Normal Mode…1655
          Service Mode…1655
        NETWORK SIGNALS…1655
        VEHICLE MONITOR PANEL…1658
        SENSORS, SWITCHES…1658
          Engine Water Temperature Sensor…1658
          Retarder Oil Temperature Sensor…1658
          Torque Converter Oil Temperature Sensor…1658
          Air Pressure Sensor…1658
          Fuel Level Sensor…1659
          Engine Speed Sensor…1659
        MONITOR PANEL DISPLAYS…1660
        INSTRUMENT PANEL INDICATORS, TEST SWITCH…1664
        ELECTRONIC ACCELERATOR PEDAL…1666
          Operation…1666
          AISS (Automatic Idling Setting System)…1667
        TRANSMISSION CONTROLLER…1668
          Outline…1668
        OPERATION:…1669
    INTRODUCTION TO ELECTRICAL TROUBLESHOOTING…1671
      POINTS TO REMEMBER WHEN TROUBLESHOOTING…1673
      POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE…1674
        POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT…1674
          Handling Controller Boxes…1679
      POINTS TO REMEMBER WHEN SERVICING HYDRAULIC EQUIPMENT…1680
      CHECKS BEFORE TROUBLESHOOTING…1682
        CONNECTOR TYPE AND LOCATION…1683
        CONNECTOR LOCATION (Chassis)…1690
        CONNECTOR LOCATION (Instrument Panel, Console)…1692
        CONNECTOR LOCATION (Transmission, Rear Cab Area)…1693
        CONNECTOR LOCATION (General Cab Area)…1694
        CONNECTOR TYPE IDENTIFICATION CHARTS…1695
      EXPLANATIONS OF FUNCTIONS (CONTROL MECHANISM) OF ELECTRICAL SYSTEM…1705
        SYSTEM FUNCTION…1705
        SELF-DIAGNOSTIC DISPLAY FUNCTIONS…1705
        CHECKING OPERATION OF ELECTRICAL SYSTEM (No System Faults)…1707
        LOCK-UP FUNCTION CHECK…1708
        OPTIONAL CONTROLLERS…1708
      MONITOR PANEL ACTION CODES AND SERVICE MODE…1709
        OUTLINE…1709
        ACTION CODE DISPLAY…1709
          Service Mode…1710
        SERVICE MODE OPERATION…1714
          Brake Air Pressure Sensor…1722
      SELF-DIAGNOSTIC DISPLAY METHOD FOR MONITOR PANEL AND CONTROLLERS…1723
        MONITOR PANEL…1723
        TRANSMISSION CONTROLLER…1723
      TABLE OF SERVICE CODES AND ACTION CODES…1728
        1. Table of service codes and action codes related to Monitor Panel…1728
        2. Table of service codes and action codes related to Transmission Controller…1729
        METHOD OF USING TABLE…1732
        METHOD OF USING TROUBLESHOOTING CHARTS…1733
        ADJUSTING ELECTRONIC MONITOR…1735
          Adjustment procedure…1735
        SETTING ROTARY SWITCH…1736
        METHOD OF DELETING DATA FROM TRANSMISSION CONTROLLER MEMORY…1737
    TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING…1741
      POINTS TO REMEMBER WHEN TROUBLESHOOTING TRANSMISSION CONTROLLER…1744
      TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK…1746
      TRANSMISSION CONTROLLER SELF-DIAGNOSTIC DISPLAY CODES AND PROBLEMS ON TRUCK…1747
        TABLE FOR TRANSMISSION CONTROLLER, TRANSMISSION RELATED PARTS…1766
        A-1 FAULTS IN POWER SOURCE SYSTEM…1768
          a) (OFF) Controller self-diagnostic display LED does not light up…1768
          b) Drop in voltage of controller power source is displayed…1769
          c) Drop in voltage of battery direct power source is displayed…1770
          d) Drop in voltage of main power source is displayed…1771
          e) Faults in transmission cut relay power source is displayed…1772
        A-2 FAULT IN NEUTRAL SAFETY SYSTEM DISPLAYED…1773
        A-3 DOUBLE ENGAGEMENT FOR CLUTCH DISPLAYED…1774
        A-4 FAULTS IN TRANSMISSION [CUT RELAY] SYSTEM DISPLAYED…1775
        A-5 FAULTS IN REAR BRAKE SOLENOID CIRCUIT DISPLAYED…1776
        A-6 FAULTS IN EXHAUST BRAKE SOLENOID CIRCUIT IS DISPLAYED…1777
        A-7 FAULTS IN BCV VALVE SYSTEM…1778
          a) Short circuit with ground in BCV rear solenoid is displayed…1778
          b) Short circuit in BCV rear solenoid is displayed…1779
          c) Disconnection in BCV rear solenoid is displayed…1780
        A-8 FAULT IN SPEED SENSOR…1781
          a) Disconnection in engine speed sensor [B] is displayed on truck or Failure of engine speed sensor is displayed on truck…1781
          b) Disconnection in input shaft speed sensor is displayed or Failure of input shaft speed sensor is displayed…1782
          c) Disconnection in intermediate shaft speed sensor is displayed or Failure of intermediate shaft speed sensor is displayed…1783
          d) Disconnection in speed sensor (transmission output shaft speed sensor) is displayed or Failure of output shaft speed sensor is displayed…1784
        A-9 SPEED SENSOR, CLUTCH SLIPPING…1785
          a) Input shaft speed sensor or H,L clutch is displayed…1785
          b) Output shaft speed sensor or speed clutch (1,2,3,4,R) system is displayed…1786
        A-10 FAULT IN MODEL SELECTION (WIRING HARNESS) DISPLAYED…1787
          a) Fault in model selection (wiring harness) is displayed…1787
          b) Fault in model selection (rotary switch) is displayed…1788
        A-11 FAULT IN SHIFT LEVER CIRCUIT…1789
          a) Short circuit in shift lever assembly power source is displayed…1789
          b) Shift lever position signal input for 2 or more circuits is displayed…1790
          c) Shift lever position signal is not inputted…1792
        A-12 FAULT IN ACCELERATOR SIGNAL IS DISPLAYED…1794
        A-13 FAULT IN TRANSMISSION OIL TEMPERATURE SENSOR IS DISPLAYED…1795
        A-14 FAULT IN PRESSURE CONTROL VALVE…1796
          a) Fill switch (clutch ON) is displayed regardless of command…1796
          b) Fill switch signal is not input and clutch slipping is displayed…1798
        A-15 NO FILL SWITCH SIGNAL INPUT (FLOW DETECTOR VALVE)…1800
        A-16 SHORT CIRCUIT IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED or DISCONNECTION IN PRESSURE CONTROL VALVE SOLENOID DISPLAYED…1801
        A-17 FAULT IN SENSOR CIRCUITS…1803
          a) Fault in torque converter oil temperature sensor is displayed…1803
          b) Fault in fuel level sensor is displayed…1804
          c) Fault in cooling water temperature sensor is displayed…1805
          d) Fault in air pressure sensor is displayed…1806
          e) Fault in retarder brake oil temperature sensor is displayed…1807
        A-18 WARNING DISPLAY…1808
          a) Transmission filter restricted warning displayed…1808
          b) Tilt warning is displayed…1809
          c) Drop in radiator water level warning is displayed…1810
          d) Battery charge warning is displayed…1811
          e) Steering oil temperature overheat warning is displayed…1812
          f) Drop in engine oil pressure warning is displayed…1813
          g) Rear brake oil pressure warning is displayed…1814
        A-19 FAULT IN ENGINE OIL PRESSURE SENSOR DISPLAYED…1815
        A-20 FAULT IN CONNECTOR CONNECTION DISPLAYED…1816
        A-21…1817
          a) Torque converter oil temperature overheat warning displayed…1817
          b) Engine water temperature overheat warning displayed…1817
          c) Air pressure drop warning displayed…1817
          d) Retarder brake oil temperature overheat warning displayed…1817
          e) Engine overrun actuated displayed…1818
          f) Engine overshoot actuated displayed…1818
    MONITOR PANEL TROUBLESHOOTING…1819
      MONITOR PANEL AND CONTROLLER SELF-DIAGNOSTIC DISPLAY…1821
      ACTION TAKEN BY SELF-DIAGNOSTIC DEVICE AND PROBLEMS ON TRUCK…1822
      TROUBLESHOOTING…1826
        P-1 Check pattern for wiring harnesses between modules…1826
        P-2 Nothing on Monitor Panel Operates…1829
        P-3 LH, RH Module and fuel gauge do not operate…1830
        P-4 LH, RH Module and fuel gauge do not operate…1831
        P-5 RH Module does not operate…1832
        P-6 LH module does not operate…1833
        P-7 Odometer does not operate…1834
        P-8 Service meter does not operate correctly…1835
        P-9 Central Warning Lamp does not operate, or monitor panel detects fault code (monitor panel display) [A002]…1836
        P-10 Central warning lamp stays ON…1837
        P-11 Alarm buzzer does not operate. or Monitor Panel detects fault code A003:…1838
        P-12 Alarm buzzer continues to sound…1839
        P-13 All data from Shift Controller (speedometer, tachometer, shift indicator, etc.) is faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A013, or service code A0018:…1840
        P-14 Suspension mode, power/economy mode displays are faulty (nothing is displayed, or display does not change), or Monitor Panel detects service code A016:…1841
        P-15 Gauge displays are faulty (nothing is displayed or display does not change)…1842
        P-16 Cooling water level drop caution lamp does not operate, or Monitor Panel detects service code A001:…1843
        P-17 Cooling water level drop caution lamp stays ON…1844
        P-18 Emergency steering pilot lamp does not operate, or monitor panel detects service code A001:…1845
        P-19 Emergency steering pilot lamp stays ON…1846
        P-20 Engine oil pressure drop caution lamp does not operate, or monitor panel detects service code A001:…1847
        P-21 Engine oil pressure drop caution lamp stays ON…1848
        P-22 Exhaust brake (Optional) pilot lamp does not operate, or monitor panel detects service code A001:…1849
        P-23 Exhaust brake pilot lamp stays ON (Optional)…1850
        P-24 Charging circuit fault caution lamp does not operate. or monitor panel detects service code A001:…1851
        P-25 Charging circuit fault caution lamp stays ON…1852
        P-26 Transmission filter clogging caution lamp does not operate, or monitor panel detects service code A001:…1853
        P-27 Transmission filter clogging caution lamp stays ON…1854
        P-28 Brake stroke caution lamp does not operate, or monitor panel detects service code A001:…1855
        P-29 Brake stroke caution lamp stays ON…1856
        P-30 Preheating switch pilot lamp does not work, or monitor panel detects service code A001:…1857
        P-31 Preheating switch pilot lamp stays ON…1858
        P-32 Tilt warning lamp does not operate, or monitor panel detects service code A001:…1859
        P-33 Tilt warning lamp stays ON…1860
        P-34 Body FLOAT (except FLOAT) pilot lamp does not operate, or monitor panel detects service code A001:…1861
        P-35 Body FLOAT (except FLOAT) pilot lamp stays ON…1862
        P-36 Rear brake pilot lamp does not work, or monitor panel detects service code A001:…1863
        P-37 Rear brake pilot lamp stays ON…1864
        P-38 Parking brake pilot lamp does not operate, or monitor panel detects service code A001:…1865
        P-39 Parking brake pilot lamp stays ON…1866
        P-40 Maintenance caution lamp does not operate, or monitor panel detects service code A001:…1867
        P-41 Maintenance caution lamp stays ON…1868
        P-42 Steering oil temperature caution lamp does not operate, or monitor panel detects service code A001:…1869
        P-43 Steering oil temperature caution lamp stays ON…1870
        P-46 High beam display does not light up…1871
        P-47 Turn signal lamp (right) does not light up…1873
        P-48 Turn signal lamp (left) does not light up…1874
        P-49 Lamp check switch does not operate…1875
        P-50 AISS switch does not operate…1876
        P-51 Exhaust brake switch does not operate (Optional)…1877
        P-52 Mode change switch (1) does not operate…1878
        P-53 Mode change switch (2) does not operate…1879
        P-54 KPH/MPH speedometer unit selector does not operate…1880
        P-55 Improper operation of all switch inputs…1881
        P-56 Monitor panel detects service codes A014 or A019:…1882
        P-58 Monitor panel detects service code A011:…1883
        P-59 Monitor panel detects service code A012:…1883
        P-60 Monitor panel detects service code A000:…1883
    ENGINE ELECTRONIC DIAGNOSTIC SYSTEM…1885
      ENGINE ELECTRONIC DIAGNOSTIC SYSTEM…1887
        SYSTEM DESCRIPTION…1887
          Engine Shutdown Light (Stop Engine)…1888
          Engine Maintenance Light (Check Engine)…1888
          Engine Maintenance Light (Protect Engine)…1888
          Fault Check Switch…1888
          Fault Scroll Switch…1888
          Determining Fault Codes…1889
        EXITING THE DIAGNOSTICS MODE…1889
      FAULT CODE INFORMATION (T01-001)…1890
        ELECTRICAL SPECIFICATIONS…1893
        SENSOR SPECIFICATIONS…1893
    HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING…1895
      HYDRAULIC AND MECHANICAL SYSTEMS TROUBLESHOOTING…1897
        H-1 Truck does not move…1897
        H-2 Truck does not travel smoothly (truck jerks)…1899
        H-3 Lock-up clutch cannot be disengaged (engine stalls)…1899
        H-4 Excessive shock when starting to move or shifting…1899
        H-5 Transmission does not shift up…1900
        H-6 Truck lacks power or speed when moving…1901
        H-7 Time lag is excessive when starting to move, or shifting gear…1905
        H-8 Torque converter oil temperature is high…1907
        H-9 Torque converter oil pressure is low…1908
        H-10 Front brakes are ineffective, or effective only on one side…1909
        H-11 Rear brakes are ineffective, or effective on one side only…1910
        H-12 Steering wheel is difficult to turn…1911
        H-13 Steering wheel is inoperative…1912
        H-14 Steering wheel vibrates…1912
        H-15 Hoist cylinder lacks lifting force (lifting speed)…1913
        H-16 Hoist cylinders do not operate…1915
        H-17 Excessive dump body hydraulic drift…1917
        H-18 Air pressure does not increase (low-pressure buzzer does not turn off. Air pressure does not increase to green range.)…1918
  SECTION F TRANSMISSION…1919
    TRANSMISSION…1921
      TRANSMISSION…1923
        TORQUE CONVERTER…1924
        TORQUE CONVERTER VALVE…1926
        TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING…1927
        HYDRAULIC PUMP…1928
        MAIN RELIEF VALVE…1929
          Function…1929
          Operation…1929
          Actuating Pressure:…1929
        TORQUE CONVERTER RELIEF VALVE…1929
          Function…1929
          Operation…1929
          Actuating Pressure:…1929
        LOCKUP SOLENOID VALVE…1930
        LOCKUP VALVE…1931
          Function…1931
          Operation…1931
        TESTING HYDRAULIC PRESSURE OF TORQUE CONVERTER VALVE…1934
          Testing Main Relief Pressure…1934
          Testing Hydraulic Pressure At Torque Converter Inlet Port (Relief)…1934
          Testing Hydraulic Pressure At Torque Converter Outlet Port (Regulator)…1934
        TORQUE CONVERTER STALL SPEED CHECK…1935
          Preparing For Stall Speed Check…1935
      TRANSMISSION…1937
        TRANSMISSION SHIFT VALVES…1938
        ECMV (Electronic Control Modulation Valve)…1941
          Pressure Control Valve…1941
          Flow Sensor Valve…1941
          ECMV and Proportional Solenoid…1941
          ECMV and Fill Switch…1941
        ECMV REPAIR PROCEDURE…1945
          Filter Cleaning Procedure…1945
          ECMV Removal…1946
          Disassembly…1946
          Reassembly…1947
        CLUTCH PRESSURE CHECK & ADJUSTMENT…1949
        LUBRICATION RELIEF VALVE…1951
          Function…1951
          Specifications…1951
        TRANSMISSION…1952
          Transmission Removal…1952
          Transmission Installation…1954
        TRANSMISSION FILTER…1956
          Service…1956
    TRANSMISSION OIL COOLER…1957
      TRANSMISSION OIL COOLER…1959
        Removal And Installation…1959
        Repair…1959
        TRANSMISSION STRAINER…1959
          Removal…1959
          Installation…1959
        TORQUE CONVERTER CONTROL VALVE…1960
          Removal…1960
          Installation…1960
          Disassembly…1960
          Assembly…1961
    DRIVELINES…1963
      DRIVELINES…1965
        FRONT DRIVELINE…1965
          Removal…1965
          Installation…1965
          Disassembly…1965
          Assembly…1965
        REAR DRIVELINE…1966
          Removal…1966
          Installation…1966
          Disassembly…1966
          Assembly…1966
        LUBRICATION…1966
    AUTOMATIC SHIFT CONTROL SYSTEM…1967
      AUTOMATIC SHIFT CONTROL SYSTEM…1969
        GENERAL INFORMATION…1969
        TRANSMISSION SHIFT CONTROLLER…1969
          Power Mode…1969
          Braking Mode…1969
          Lock-up And Engine Overspeed…1969
          Transmission Speeds Monitoring…1969
          Self Diagnostics…1970
        RANGE SELECTOR POSITIONS AND AUTOMATIC GEAR SHIFTING RANGES…1972
        TRANSMISSION OPERATION MODES…1972
          Braking Mode:…1972
          Power Mode:…1972
          Economy Mode:…1973
        AUTOMATIC GEAR SHIFTING…1973
          Automatic Shifting Sequence…1973
          Gear shifting time lag…1974
          Safety Functions…1975
        TRANSMISSION RANGE SELECTOR…1976
        SENSORS, SWITCHES…1977
          Transmission Speed Sensors…1977
          Adjustment Procedure…1977
          Transmission and Torque Converter Oil Temperature Sensors…1978
          Oil Temperature Sensor Tests…1978
          Insulation Resistance Test:…1978
          Thermistor Resistance Calibration Test:…1978
          Fill Switch…1980
          Shift Limit Switch…1981
          Power Mode Switch…1981
        TRANSMISSION TROUBLESHOOTING PROCEDURES…1982
          Clutch Combinations…1982
          Solenoid Valves…1982
        HARNESS CONNECTORS AND SIGNALS…1983
  SECTION G DRIVE AXLE, SPINDLES AND WHEELS…1987
    TIRES AND RIMS…1989
      TIRES AND RIMS…1991
        GENERAL INFORMATION AND RECOMMENDATIONS…1991
        FRONT TIRES AND RIMS…1992
          Removal…1992
          Installation…1993
        REAR TIRE AND RIM…1993
          Removal…1993
          Installation Of Rear Wheel Assembly…1994
        TIRE MATCHING…1996
    FRONT WHEEL HUB AND SPINDLE…1997
      FRONT WHEEL HUB AND SPINDLES…1999
        FRONT WHEEL HUB…1999
          Removal…1999
        DISASSEMBLY OF FRONT WHEEL HUB ASSEMBLY…2000
          Inspection…2001
        ASSEMBLY OF FRONT WHEEL HUB ASSEMBLY…2001
          Front Wheel Hub Bearing Adjustment…2001
        FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION…2002
        SUSPENSION A-FRAME…2002
          Removal…2002
          Installation…2002
        CENTER TIE ROD PIVOT…2003
          Removal…2003
          Inspection…2003
          Installation…2003
    FINAL DRIVE ATTACHMENTS…2005
      FINAL DRIVE ATTACHMENTS…2007
        FINAL DRIVE ANCHOR…2007
          Lower Link Removal…2007
          Inspection…2008
          Installation…2008
        DIAGONAL PANHARD ROD…2008
          Removal…2008
          Inspection…2009
          Installation…2009
    FINAL DRIVE CENTER CASE ASSEMBLY…2011
      FINAL DRIVE CENTER CASE ASSEMBLY…2013
        Specifications:…2013
        OPERATION…2014
          Straight-away-travel…2014
          Turning…2015
          To Check Oil Level…2015
          Specifications:…2015
        REAR AXLE…2015
          Removal…2015
          Installation…2016
        DIFFERENTIAL ASSEMBLY…2017
          Removal…2017
          Installation…2018
        DIFFERENTIAL ASSEMBLY…2018
          Disassembly…2018
          Disassembly of Pinion Carrier Assembly…2019
          Differential Gear Unit…2020
          Disassembly Of Differential Gear Unit…2020
        ASSEMBLY of DIFFERENTIAL…2023
          Differential Bearing…2023
          Assembly Of Differential Gear Assembly…2023
          Installation Of Differential Assembly…2025
          Input Pinion and Carrier Assembly…2026
          Adjusting Tooth Contact, Backlash…2029
    FINAL DRIVE PLANETARIES AND WHEEL HUBS…2033
      FINAL DRIVE PLANETARIES AND WHEEL HUBS…2035
        FINAL DRIVE…2035
        CARRIER ASSEMBLY…2036
          Removal…2036
          Installation…2037
        FINAL DRIVE CARRIER…2037
          Disassembly…2037
          Assembly…2038
        FINAL DRIVE ASSEMBLY…2038
          Disassembly…2038
          Assembly…2041
  SECTION H SUSPENSIONS…2043
    FRONT SUSPENSIONS…2045
      SUSPENSION SYSTEM…2047
        SUSPENSION SYSTEM OPERATION…2047
        FRONT SUSPENSION…2048
          Removal…2049
          Installation…2051
        SUSPENSION REBUILD…2052
          Disassembly…2052
          Inspection…2053
          Assembly…2053
        ATTENUATION VALVE (FIXED RATE)…2055
          Disassembly…2055
          Assembly…2055
    REAR SUSPENSIONS…2057
      REAR SUSPENSIONS…2059
        SUSPENSION OPERATION…2059
          Removal…2060
          Installation…2060
        SUSPENSION REBUILD…2061
          Disassembly…2061
          Cleaning and Inspection…2061
          Assembly…2062
        REAR SUSPENSION SPHERICAL BEARING REPAIR…2063
          Disassembly…2063
          Inspection…2063
          Assembly…2063
    OILING AND CHARGING PROCEDURES…2065
      OILING AND CHARGING PROCEDURES…2067
        GENERAL…2067
          Equipment List…2067
        FRONT SUSPENSION…2067
          Front Suspension Oiling…2068
          Front Suspension Nitrogen Charging…2069
        REAR SUSPENSION…2071
          Rear Suspension Oiling…2071
          Rear Suspension Nitrogen Charging…2072
  SECTION J BRAKE SYSTEM…2075
    BRAKE CIRCUIT OPERATION…2077
      BRAKE CIRCUIT OPERATION…2079
        COMPONENT DESCRIPTION…2079
        AIR TREADLE VALVE…2079
        EMERGENCY RELAY (RE-6) VALVE…2080
        HAND BRAKE VALVE (Retarder control valve)…2083
          Function…2084
        PARKING BRAKE PILOT VALVE…2085
          Function…2085
          Operation…2085
        PARKING BRAKE RELAY VALVE…2086
          Function…2086
        BRAKE CHAMBER…2087
        SLACK ADJUSTER…2088
          Specifications…2088
          Function…2089
        PRESSURE SWITCH…2090
          Function…2090
        STOP LIGHT SWITCH…2090
          Function…2090
        PARKING BRAKE SWITCH…2091
          Function…2091
        AUTOMATIC RETARDER VALVE…2091
          Function…2091
        FRONT BRAKE CUT-OFF VALVE…2092
          Function…2092
        BRAKE COOLING VALVE (BCV)…2093
        2-WAY AIR CONTROL VALVE…2094
          Function…2094
        EMERGENCY BRAKE CONTROL VALVE…2095
          Function…2095
          Operation…2096
        BRAKE VALVE…2099
          Function…2100
    BRAKE CIRCUIT COMPONENT SERVICE…2103
      BRAKE CIRCUIT COMPONENT SERVICE…2105
        BRAKE TREADLE ASSEMBLY…2105
          Removal…2105
          Installation…2105
          Disassembly…2106
          Assembly…2107
        FRONT BRAKE CHAMBER ASSEMBLY…2108
          Removal…2108
          Installation…2108
          Disassembly…2108
          Assembly…2111
        REAR BRAKE CHAMBER ASSEMBLY…2112
          Removal…2112
          Installation…2112
          Disassembly…2113
          Assembly…2115
        SLACK ADJUSTER…2116
          Removal…2116
        EMERGENCY BRAKE CONTROL VALVE…2119
          Removal…2119
          Installation…2119
          Disassembly…2120
          Inspection…2120
          Assembly…2120
    BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…2123
      BRAKE CIRCUIT CHECKOUT AND ADJUSTMENT…2125
        CHECKING FRONT BRAKE PAD WEAR…2125
        TESTING BRAKE PRESSURE…2125
        CHECKING WEAR OF REAR BRAKE DISCS…2126
        BRAKE BLEEDING…2127
          Rear Brakes…2127
          Front Brakes…2127
      TROUBLESHOOTING…2128
    FRONT BRAKES…2131
      FRONT BRAKES…2133
        FRONT BRAKE CALIPER PAD…2133
          Removal…2133
          Installation…2133
        BRAKE CALIPER ASSEMBLY…2133
          Removal…2133
          Installation…2134
          Disassembly…2134
          Assembly…2135
    REAR WET DISC BRAKE ASSEMBLY…2137
      REAR WET DISC BRAKE ASSEMBLY…2139
        WET DISC BRAKE ASSEMBLY…2139
          Removal…2139
          Installation…2140
        WET DISC BRAKE…2141
          Disassembly…2141
          Inspection…2142
          Assembly…2142
    PARKING BRAKE…2145
      PARKING BRAKE…2147
        Inspection…2147
        Pad Removal…2147
        Pad Installation…2147
        PARKING BRAKE CALIPER…2147
          Caliper Removal…2147
          Caliper Installation…2148
          Caliper Disassembly…2148
          Caliper Assembly…2149
        PARKING BRAKE SPRING CYLINDER…2149
          Removal…2149
          Installation…2149
          Disassembly…2149
          Assembly…2150
        PARKING BRAKE ADJUSTMENT…2151
          Testing…2151
          Adjusting…2151
        PARKING BRAKE DISC…2152
          Driveshaft Removal…2152
          Parking Brake Disc Removal…2152
          Parking Brake Disc Installation…2153
          Driveshaft Installation…2153
        BRAKE RELEASE…2153
          Release Of Parking Brake…2153
          Release Of Emergency Brake…2154
  SECTION K AIR SYSTEM…2155
    AIR SYSTEM…2157
      AIR SYSTEM…2159
        GENERAL DESCRIPTION…2159
        AIR DRYER…2160
          Operation…2160
        SAFETY VALVE…2163
        AIR GOVERNORS…2163
        AUTOMATIC DRAIN VALVE (HEATED)…2164
          Function…2164
          Operation…2164
        HORN SOLENOID…2164
          Function…2164
    AIR SYSTEM COMPONENT REPAIR…2165
      AIR SYSTEM COMPONENT REPAIR…2167
        GENERAL PRECAUTIONS…2167
        AIR DRYER…2167
          Removal…2167
          Installation…2167
          Desiccant Cartridge Service…2168
          Desiccant Cartridge Replacement…2168
          Unloader Valve Service…2169
          Unloader Valve Replacement…2169
          Bleed Valve Service…2170
          Bleed Valve Replacement…2170
          Check Valve Service…2170
          Operational Check…2170
          Check Valve Replacement…2170
          Turbo Valve Service…2171
          Operational Check:…2171
          Turbo Valve Replacement…2171
          Heater Assembly Service…2171
          Operational Checks…2171
          Heater Assembly Replacement…2171
      AIR DRYER TROUBLESHOOTING…2172
      AIR DRYER TROUBLESHOOTING (Continued)…2173
        AIR COMPRESSOR…2174
        AIR GOVERNORS…2174
          Removal…2174
          Installation…2174
          Disassembly…2175
          Cleaning and Inspection…2175
          Assembly…2175
          Adjustment…2176
          Primary Governor…2176
          Secondary Governor…2176
     RETARDER VALVE…2177
      RETARDER VALVE…2179
        RETARDER FUNCTION…2179
          Removal…2179
          Installation…2179
          Disassembly…2181
          Assembly…2181
  SECTION L HYDRAULIC SYSTEM…2183
    HYDRAULIC SYSTEM…2185
      HYDRAULIC SYSTEM…2187
        HYDRAULIC SYSTEM OPERATION…2187
        COMPONENT DESCRIPTION…2187
          Pump…2187
          Tank…2188
    HYDRAULIC SYSTEM COMPONENT REPAIR…2191
      HYDRAULIC SYSTEM COMPONENT REPAIR…2193
        HYDRAULIC PUMP…2193
          Removal…2193
          Installation…2194
        HYDRAULIC TANK…2194
        HYDRAULIC TANK FILTERS…2195
          Filter Replacement…2195
        HYDRAULIC TANK BREATHER…2195
          Cleaning…2195
        BRAKE COOLING OIL STRAINER…2196
          Cleaning…2196
        HIGH PRESSURE HYDRAULIC FILTERS…2196
          Filter Assembly Removal…2196
          Filter Assembly Installation…2197
          Filter Element Replacement…2197
    STEERING CIRCUIT…2199
      STEERING CIRCUIT…2201
        STEERING CIRCUIT OPERATION…2201
        DEMAND VALVE…2202
        STEERING CONTROL VALVE…2202
        CROSSOVER RELIEF VALVE…2203
        OPERATION OF DEMAND AND STEERING CONTROL VALVE…2204
        EMERGENCY STEERING SYSTEM…2212
          Flow Switch…2213
          Operation…2213
          Relay Timer…2213
    STEERING VALVE ASSEMBLY…2215
      STEERING VALVE ASSEMBLY…2217
        Removal…2217
        Installation…2217
        Disassembly…2218
        Preparation…2218
        Assembly…2223
    STEERING CIRCUIT COMPONENT REPAIR…2231
      STEERING CIRCUIT COMPONENT REPAIR…2233
        EMERGENCY STEERING MOTOR PUMP ASSEMBLY…2233
          Removal…2233
          Installation…2233
        STEERING CYLINDER ASSEMBLY…2234
          Removal…2234
          Installation…2234
          Disassembly…2235
          Assembly…2237
        DEMAND VALVE ASSEMBLY…2239
          Removal…2239
          Installation…2239
          Disassembly…2240
          Assembly…2240
        RELIEF VALVE ASSEMBLY…2241
          Disassembly…2241
          Assembly…2241
    HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION…2243
      HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION…2245
        HOIST CIRCUIT OPERATION…2245
        HOIST CIRCUIT COMPONENT DESCRIPTION…2245
          Hoist Cylinders…2245
          Hydraulic Filter…2245
          Hoist Valve…2245
          RAISE…2246
          HOLD…2247
          POWER DOWN…2248
          FLOAT…2249
    HOIST CIRCUIT COMPONENT REPAIR…2251
      HOIST CIRCUIT COMPONENT REPAIR…2253
        HOIST VALVE ASSEMBLY…2253
          Removal…2253
          Installation…2253
          Disassembly…2254
          Assembly…2254
        HOIST CYLINDER…2256
          Removal…2256
          Installation…2257
          Disassembly…2258
          Assembly…2258
    HYDRAULIC CHECKOUT…2261
      HYDRAULIC CHECKOUT…2263
        DUMP BODY CONTROL…2263
        ADJUSTING HOIST LEVER LINKAGE…2264
        ADJUSTING HOIST LIMITER…2265
        TESTING AND ADJUSTING HYDRAULIC PRESSURE IN STEERING, HOIST CIRCUIT…2266
          Steering Circuit…2266
          Hoist Circuit…2267
  SECTION M OPTIONS AND SPECIAL TOOLS…2275
    WIGGINS QUICK FILL FUEL SYSTEM…2277
      WIGGINS QUICK FILL FUEL SYSTEM…2279
        FUEL TANK BREATHER VALVE…2279
          Removal…2279
          Installation…2279
          Disassembly…2279
          Assembly…2279
        FUEL RECEIVER…2279
      FAN DRIVE CLUTCH…2281
      FAN DRIVE CLUTCH…2283
        GENERAL DESCRIPTION…2283
        MAJOR COMPONENTS…2283
          Input…2283
          Output…2284
          Stationary Components…2284
        OPERATION MODES…2284
          Fully Engaged…2284
          Modulated Variable Speed…2285
          Fully Released…2285
          Lubricating & Cooling Oil…2286
        MAINTENANCE…2287
        TROUBLESHOOTING…2288
          Basic Preliminary Checks…2288
        FIELD CHECK DIAGNOSIS…2289
          Preliminary Checks With Engine Off…2289
          Off Truck Test…2292
        TROUBLESHOOTING CHART…2293
      FAN CLUTCH REBUILD…2295
        DISASSEMBLY…2296
          Preparation…2296
          Cleaning And Inspection…2303
        ASSEMBLY INSTRUCTIONS…2306
          General Instructions…2306
          Assembly…2306
        FAN CLUTCH TEST…2316
          Operational Test…2316
    COOLANT AND OIL HEATERS…2321
      COOLANT AND OIL HEATERS…2323
        SYSTEM OPERATION…2323
        ENGINE COOLANT HEATERS…2325
          Troubleshooting…2325
        OIL HEATERS…2326
          Troubleshooting…2326
    SPECIAL TOOLS…2329
    PAYLOAD METER II – ON BOARD WEIGHING SYSTEM…2339
      GENERAL INFORMATION…2341
        Haul Cycles…2341
      LIGHTS, SWITCHES AND COMPONENTS…2342
      TIPS FOR OPERATION…2343
      EXTERNAL DISPLAY LIGHTS…2343
      THEORY OF OPERATION…2344
        Basic Description…2344
        Inclinometer…2344
        Linkage Factor…2344
        Gain Factor…2345
        Brake Lock…2345
        Sources of Error…2345
        Typical Data From Service Check Mode…2345
        Example Calculation of Payload…2346
        Viewing Payload Calculation Inputs…2346
        Checking the Gain…2347
        Adjusting the Gain…2347
      TYPES OF DATA STORED…2348
        Cycle Data…2348
        Engine ON/OFF Data…2349
        Fault Codes and Warning Data…2349
        Engine Operation…2350
        Total Payload and Total Number of Cycles…2350
        Other Data…2350
      OPERATOR FUNCTIONS…2351
        Using the Operator Load Counter…2351
        Viewing the Operator Load Counter…2351
        Clearing the Operator Load Counter…2351
        Dimming the Lights on the Display…2351
      INITIAL SETUP OF PAYLOAD METER…2352
        Switch Settings…2352
        Checking the Operator Check Mode…2353
        Checking the Service Check Mode…2353
        Checking the Gt setting:…2354
        Checking the Inclinometer Settings…2354
        Calibrating a Truck…2354
      DISPLAYS AT START-UP…2355
        Normal Operation…2355
      SETUP AND MAINTENANCE…2356
        Setting The Speed Limit…2356
        Setting the Option Code…2356
        Setting The Machine I.D. Code…2357
        Setting The Operator I.D. Code…2357
        Setting The Time and Date…2357
      DOWNLOAD OF INFORMATION…2358
      DISPLAY OF FAULT CODES…2358
        Monitoring Input Signals…2362
        Service Check Mode…2362
      UP FACTOR – PAYLOAD CALCULATION GAIN…2363
      PL MODE -LOAD CALCULATION TIMING…2363
      FINAL GEAR RATIO SELECTION…2364
      BATTERY REPLACEMENT PROCEDURE…2365
        Replacing the Battery…2365
        After Replacing the Battery…2366
      SUSPENSION PRESSURE SENSOR…2366
        Removal…2366
        Installation…2367
      INCLINOMETER…2367
        Removal…2367
        Installation…2367
        Adjustment…2367
      PAYLOAD METER BACK PANEL…2368
      CONNECTIONS…2369
      PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE…2370
      PAYLOAD CIRCUIT NUMBERS…2371
      TROUBLESHOOTING…2372
        COMMON PROBLEMS…2372
          Suspension Charging…2372
          Symptom Table…2373
          Missing Body-Up Signal…2373
          Missing Speed Signal…2374
          F-18: Alternator R-Terminal, Oil Pressure Signals…2374
          Shorted 18v Sensor Power Supply (930E)…2374
        FAULT TREE DIAGNOSIS…2375
          Payload Lights Won't Illuminate…2375
          Red, Amber or Green Payload Light Does Not Illuminate…2376
          Cannot Download – PC Communications…2377
          PC Communications Configuration…2378
          F.CAL: Payload Meter Won't Calibrate…2379
          F-20: Sensor Power Fault…2380
          F-21, F-25: Left Front Pressure Sensor…2382
          F-22, F-26: Right Front Pressure Sensor…2382
          F-23, F-27: Left Rear Pressure Sensor…2382
          F-24, F-28: Right Rear Pressure Sensor…2382
          F-31, F-32: Inclinometer…2384
          Body Up Input…2386
          Brake Lock Input…2387
          Speed Signal…2388
          Adjusting the Speed Sensor…2388
        CONNECTORS AND PRESSURE SENSORS…2390
      REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM…2393
        Menu Functions…2396
        Using Scope…2396
        Log File Information…2396
        Connections to Payload Meter II™…2397
      USING SCOPE…2398
        Monitoring Inputs Using Scope…2398
        Monitoring Suspension Charging Using Scope…2398
        Pressure Sensor Dummy Loads…2401
      GAIN ADJUSTMENT WORKSHEET…2402
    EXHAUST BRAKE…2403
      EXHAUST BRAKE…2405
        FUNCTION…2405
        SYSTEM OPERATION…2406
        SYSTEM COMPONENTS…2407
          Exhaust Brake Pressure Switch…2407
          Exhaust Brake Solenoid Valve…2407
          Exhaust Brake Assembly…2408
        MAINTENANCE…2409
          1000 Hour Maintenance…2409
          Gate Adjustment…2409
        TROUBLESHOOTING…2410
          Operational Characteristics…2410
          System Component Checks…2411
    AUTOMATIC SPIN REGULATOR (ASR) SYSTEM…2413
      AUTOMATIC SPIN REGULATOR (ASR) SYSTEM…2415
        ASR SYSTEM…2415
        ASR SYSTEM DESCRIPTION…2416
          Torque Control…2416
          Compensation for Steering…2416
          System Diagnostics…2416
          System Components…2416
        OPERATION…2418
      ASR SYSTEM TROUBLESHOOTING…2420
        GENERAL TROUBLESHOOTING INFORMATION…2420
          Preliminary Troubleshooting Procedures…2420
          Troubleshooting Specific Problems…2420
        NORMAL SYSTEM OPERATION…2421
          Clearing Fault Codes…2421
      TROUBLESHOOTING SYSTEM COMPONENTS…2424
          Stabilizing the AC System…2559
        SYSTEM PERFORMANCE TEST…2559
        SYSTEM LEAK TESTING…2560
          Electronic leak detector…2560
          Tracer dyes…2560
          Soap and water…2560
        SYSTEM REPAIR…2561
          System Cleaning…2561
          Hoses and Fittings…2561
          Lines…2561
          Expansion Valve…2561
          Receiver-Drier…2562
          Thermostat…2562
          Compressor…2562
          Clutch…2562
          Servicing the Compressor Clutch…2563
          Pulley Removal…2565
          Clutch Coil Check…2565
          Pulley Installation…2565
          Clutch Assembly Installation…2566
        RECOVERING AND RECYCLING THE REFRIGERANT…2567
          Performing the Recovery Cycle…2567
          Performing the Recycling Procedure…2567
          Evacuating and Charging the AC System…2567
        EVACUATING THE SYSTEM…2568
        CHARGING THE AC SYSTEM…2569
        TROUBLESHOOTING…2570
          Pre-Diagnosis Checks…2570
          Preparing For Diagnosis…2570
          Preliminary Steps…2570
          System Performance Test…2570
          Diagnosis Of Gauge Readings And System Performance…2571
      PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM…2578
    OPERATOR CAB AND CONTROLS…2579
      OPERATOR CAB AND CONTROLS…2583
        STEERING WHEEL AND CONTROLS…2583
          Tilt Lever…2583
          Turn Signal Lever Switch…2583
          Horn…2583
          Windshield Wiper / Washer Switch…2583
          Headlights and Dimmer Switch…2584
          Retard Control Lever…2584
        BRAKE PEDAL…2584
        THROTTLE PEDAL…2584
        CENTER CONSOLE AND CONTROLS…2584
          Transmission Range Selector…2584
          Shift Limiter Switch…2586
          Economy / Power Mode Switch…2586
          Emergency Steering Switch…2586
          Emergency Brake Lever…2587
          Parking Brake Valve Lever…2587
        ENGINE ELECTRONIC CONTROL SYSTEM…2588
          Engine Shutdown Light (Stop Engine)…2588
          Engine Maintenance Light (Check Engine)…2588
          Engine Maintenance Light…2588
        ENGINE DIAGNOSTICS…2589
          Fault Check Switch…2589
          Fault Scroll Switch…2589
          Determining Fault Codes…2589
          Exiting The Diagnostics Mode…2589
        HOIST CONTROL…2590
          Safety Lock…2590
        ASR / ARSC (OPTIONAL)…2591
        ASR SYSTEM CONTROLS…2591
          System Switch…2592
          ASR/ARSC Caution Lamp…2592
          ASR Operation Lamp…2592
          Central Warning Lamp…2592
          Retarder Control Lever…2592
          Accelerator Pedal…2592
          Brake Pedal…2592
        PRECAUTIONS WHEN USING THE ASR SYSTEM…2592
        ARSC SYSTEM CONTROLS…2593
          System Switch…2593
          ARSC Set Lever…2593
          Brake Pedal…2593
          Accelerator Pedal…2593
          ASR/ARSC Caution Lamp…2593
          ARSC Standby Lamp…2593
          Set Speed Display…2593
          Retarder Control Lever…2593
          Central Warning Lamp…2593
        ARSC SYSTEM ACTUATION…2594
          Traveling Again At Set Speed…2594
          Relationship With Exhaust Brake…2595
          Recommended Set Speed…2595
        TROUBLESHOOTING THE ASR/ARSC SYSTEMS…2596
          When a problem occurs in the system…2596
          Model Selection, Tire Selection, And Failure Code Display…2596
          Failure Codes…2596
      INSTRUMENT PANEL AND INDICATORS…2599
        WARNING & CAUTION LAMPS…2600
        GAUGE AND MONITOR PANEL…2601
          Air Pressure Monitor…2601
          Air Pressure Gauge…2601
          Coolant Temperature Monitor…2601
          Engine Cooling Water Temperature Gauge…2601
          Torque Converter Oil Temperature Monitor…2602
          Torque Converter Oil Temperature Gauge…2602
          Retarder Oil Temperature Monitor…2602
          Retarder Oil Temperature Gauge…2602
          High Beam Pilot Lamp…2602
          Left Turn Signal Pilot Lamp…2602
          Right Turn Signal Pilot Lamp…2602
          Speedometer…2602
          Tachometer…2602
          Shift Limiter Pilot Lamp…2602
          Lock-up Pilot Lamp…2603
          Transmission Shift Position Pilot Lamp…2603
          Shift Indicator…2603
          Engine Controller Monitor…2603
          Automatic Transmission Mechatronics Monitor…2603
          Other Mechatronics Monitor (OPTIONAL)…2603
          Fuel Level Monitor…2603
          Fuel Gauge…2603
          Service Meter…2604
          Service Meter Indicator…2604
          Odometer…2604
          Power Mode Indicator…2604
        INDICATORS AND CONTROLS PANEL…2604
          Optional Equipment…2604
          Coolant Level Monitor…2605
          Engine Oil Pressure Monitor…2605
          Charge Monitor…2605
          Transmission Oil Filter Monitor…2605
          Hazard Warning Lights…2605
          Front Brake On/Off Switch…2605
          Panel Dimmer Switch…2605
          AISS/Auto Switch…2606
          Manual Starting Aid Switch…2606
          Starting Switch…2606
          Pilot Lamp Bulb Check Switch…2606
          Rear Brake Pilot Lamp…2606
          Body Float Caution Monitor…2606
          Parking Brake Monitor…2607
          Emergency Steering Monitor…2607
          Exhaust Brake (Optional)…2607
          Cold Start…2607
          Steering Oil Temperature…2607
          Side Slope Warning (Optional)…2607
          Rear Brake Caution Lamp…2607
          Exhaust Brake Switch (Optional)…2608
          Fog Light Switch (Optional)…2608
          Central Warning Lamp (Red Convex Lens)…2608
        HEATER/AIR CONDITIONER CONTROLS…2609
          Temperature Adjustment Lever…2609
          Blower Switch…2609
          Air Selector Lever…2609
          Vent Selector Lever…2609
          Air Vent…2610
          Glove Box Storage Compartment…2610
          Air Conditioner Switch…2610
          Correction Code Display…2610
  SECTION P LUBRICATION AND SERVICE…2611
    LUBRICATION AND SERVICE…2613
      LUBRICATION AND SERVICE…2615
        10 HOUR (DAILY) INSPECTION…2617
        FLUID LEVELS & OTHER CHECKS…2617
        10 HOUR (DAILY) INSPECTION (continued)…2619
          ENGINE…2619
          WHEELS AND TIRES…2619
            Tires…2619
        10 HOUR (DAILY) INSPECTION (continued)…2620
          Wheels…2620
          OPERATIONAL CHECKS…2621
        250 HOUR SERVICE…2623
          INITIAL 250 HOUR SERVICE…2623
          EVERY 250 HOUR SERVICE…2623
          500 HOUR SERVICE…2625
          1000 HOUR SERVICE…2626
          EVERY 2000 HOUR SERVICE…2627
          EVERY 5000 HOUR SERVICE…2628
          HYDRAULIC TANK SERVICE…2629
            Filling Instructions (Hoist Oil Supply)…2629
            Filling Instructions (Rear Brake Cooling Oil Supply)…2629
          HYDRAULIC FILTERS…2630
            Filter Replacement…2630
          HYDRAULIC TANK BREATHER…2630
            Cleaning…2630
          HIGH PRESSURE HYDRAULIC FILTERS…2631
            Filter Assembly Removal…2631
            Filter Assembly Installation…2631
            Filter Element Replacement…2632
          TRANSMISSION FILTER…2633
            Service…2633
        PERIODIC REPLACEMENT OF COMPONENT PARTS FOR SAFETY DEVICES…2634
    AUTOMATIC LUBRICATION SYSTEM…2635
      AUTOMATIC LUBRICATION SYSTEM…2637
        OPERATION…2637
        COMPONENTS…2637
          Component Location…2638
        GENERAL INFORMATION…2640
          Lubricant Required for System…2640
          Air Pressure Regulator…2640
          Initial Reservoir Fill…2640
          System Priming…2640
        SYSTEM CHECKOUT…2641
          Lubrication Cycle Timer Check…2641
          Timer Adjustment…2641
        INJECTORS (SL-1 Series “H”)…2642
          Injector Specifications…2642
          Injector Adjustment…2642
          Injector Operation…2643
        TROUBLESHOOTING CHART…2644
  ALPHABETICAL INDEX…2647
  SECTION R SYSTEM SCHEMATICS…2651
    HA207 AIR CIRCUIT DIAGRAM…2653
    HA208 AIR SCHEMATIC…2654
    HH345 HYDRAULIC SCHEMATIC…2655
    HH346 HYDRAULIC PIPING…2656
    KT-T01 TRANSMISSION…2657
    HE482 ELECTRICAL SCHEMATIC…2658

Komatsu Dump Truck HD785-5LC Repair Service Manuals

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