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
