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Komatsu Articulated Dump Truck HM350-2 Shop Manual SEN00238-15 – PDF DOWNLOAD
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Komatsu Articulated Dump Truck HM350-2 Shop Manual
SERIAL NUMBERS : 2001 and up
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Description
Komatsu Articulated Dump Truck HM350-2 Shop Manual SEN00238-15
FILE DETAILS:
Komatsu Articulated Dump Truck HM350-2 Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HM350-2
Serial Number: 2001 and up
Book Code: SEN00238-15
Language: English
Pages: 1446
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu Articulated Dump Truck HM350-2 Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu Articulated Dump Truck HM350-2 Shop Manual
COVER ........................................................................................................................ 1 00 Index and foreword......................................................................................................... 0 Index..................................................................................................................... 3 Composition of shop manual............................................................................................ 4 Table of contents..................................................................................................... 6 Foreword and general information.......................................................................................... 17 Safety notice......................................................................................................... 18 How to read the shop manual........................................................................................... 23 Explanation of terms for maintenance standard......................................................................... 25 Handling of electric equipment and hydraulic component................................................................ 27 Handling of connectors newly used for engines......................................................................... 36 How to read electric wire code........................................................................................ 39 Precautions when carrying out operation............................................................................... 42 Method of disassembling and connecting push-pull type coupler......................................................... 45 Standard tightening torque table...................................................................................... 48 Conversion table...................................................................................................... 52 01 Specification.............................................................................................................. 0 Specification and technical data.......................................................................................... 59 Specification drawings................................................................................................ 60 Specifications........................................................................................................ 61 Weight table.......................................................................................................... 64 Fuel, coolant and lubricants.......................................................................................... 65 10 Structure, function and maintenance standard............................................................................... 0 Engine and cooling system................................................................................................. 69 Radiator, oil cooler, aftercooler..................................................................................... 70 Output shaft.......................................................................................................... 71 Power train, Part 1....................................................................................................... 75 Power train skeleton.................................................................................................. 76 Torque converter and transmission hydraulic piping.................................................................... 80 Brake cooling oil control valve (BCV)................................................................................. 82 Power train pump...................................................................................................... 83 Torque converter...................................................................................................... 86 Transmission.......................................................................................................... 92 Transmission control valve............................................................................................ 120 ECMV.................................................................................................................. 121 Main relief, torque converter relief valve............................................................................ 128 Power train, Part 2....................................................................................................... 131 Drive shaft........................................................................................................... 132 Axle.................................................................................................................. 136 Differential.......................................................................................................... 140 Limited slip differential............................................................................................. 152 Final drive........................................................................................................... 156 Steering system........................................................................................................... 163 Steering column....................................................................................................... 164 Brake system.............................................................................................................. 167 Brake piping.......................................................................................................... 168 Brake valve........................................................................................................... 170 Accumulator charge valve.............................................................................................. 173 Accumulator........................................................................................................... 177 Slack adjuster........................................................................................................ 178 Brake................................................................................................................. 180 Proportional reducing valve........................................................................................... 185 Brake system tank..................................................................................................... 186 Parking brake......................................................................................................... 188 Parking brake solenoid valve.......................................................................................... 192 Undercarriage and frame................................................................................................... 195 Suspension............................................................................................................ 196 Suspension cylinder................................................................................................... 201 Oscillation hitch..................................................................................................... 203 Hydraulic system.......................................................................................................... 207 Steering, hoist oil pressure piping diagram........................................................................... 208 Dump body control..................................................................................................... 209 Hydraulic tank and filter............................................................................................. 210 Flow amp valve........................................................................................................ 211 Steering valve........................................................................................................ 214 Steering cylinder..................................................................................................... 218 Hoist valve........................................................................................................... 220 Dump control valve (EPC valve)........................................................................................ 226 Pilot check valve..................................................................................................... 230 Hoist cylinder........................................................................................................ 231 Hydraulic pump........................................................................................................ 232 Cab and its attachments................................................................................................... 237 ROPS cab.............................................................................................................. 238 Cab tilt.............................................................................................................. 239 Air conditioner....................................................................................................... 240 Rear view monitor..................................................................................................... 248 Controller related.................................................................................................... 251 Electrical system, Part 1................................................................................................. 253 Machine monitor system................................................................................................ 254 Electrical system, Part 2................................................................................................. 275 Automatic shift control system........................................................................................ 276 Transmission controller............................................................................................... 279 Retarder control system............................................................................................... 308 Auto emergency steering system........................................................................................ 320 Battery disconnector switch........................................................................................... 322 Dump control lever.................................................................................................... 324 Electrical system, Part 3................................................................................................. 329 Sensors, switches..................................................................................................... 330 KOMTRAX terminal system (if equipped)................................................................................. 338 20 Standard value table....................................................................................................... 0 Standard service value table.............................................................................................. 341 Standard value table for engine....................................................................................... 342 Standard value table for chassis...................................................................................... 343 30 Testing and adjusting...................................................................................................... 0 Testing and adjusting, Part 1............................................................................................. 349 Tools for testing, adjusting, and troubleshooting..................................................................... 351 Sketches of special tools............................................................................................. 356 Measuring engine speed................................................................................................ 357 Testing intake air pressure (boost pressure).......................................................................... 358 Testing exhaust temperature........................................................................................... 359 Testing exhaust gas color............................................................................................. 360 Adjusting valve clearance............................................................................................. 361 Testing compression pressure.......................................................................................... 362 Testing blow-by pressure.............................................................................................. 364 Testing engine oil pressure........................................................................................... 365 Testing EGR valve and bypass valve drive oil pressure................................................................. 366 Handling of fuel system devices....................................................................................... 367 Releasing residual pressure from fuel system.......................................................................... 367 Testing fuel pressure................................................................................................. 368 Testing fuel return and leakage amount................................................................................ 369 Bleeding air from fuel circuit........................................................................................ 372 Testing the fuel circuit for leakage.................................................................................. 374 Testing and adjusting fan belt tension................................................................................ 375 Testing and adjusting alternator belt tension......................................................................... 376 Testing and adjusting air conditioner compressor belt tension......................................................... 377 Testing and adjusting, Part 2............................................................................................. 379 Testing torque converter stall speed.................................................................................. 381 Testing power train oil pressure...................................................................................... 382 Testing and adjusting of differential lock oil pressure (differential lock spec.)..................................... 390 Adjusting transmission speed sensor................................................................................... 395 Testing and adjusting brake oil pressure.............................................................................. 397 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas................. 401 Testing brake performance............................................................................................. 405 Bleeding air from brake circuit....................................................................................... 406 Testing wear of wheel brake disc...................................................................................... 407 Testing the parking brake pad wear.................................................................................... 408 Emergency release of the parking brake................................................................................ 409 Testing and adjusting steering circuit oil pressure................................................................... 410 Testing and adjusting suspension cylinder............................................................................. 412 Method of tilting cab up.............................................................................................. 416 Testing and adjusting dump circuit oil pressure....................................................................... 418 Adjusting body positioner sensor...................................................................................... 420 Adjusting length of spring in body heating spherical joint............................................................ 421 Handling of voltage circuit of engine controller...................................................................... 421 Adjusting transmission controller..................................................................................... 421 Method for emergency escape at electrical system failure.............................................................. 422 Testing and adjusting, Part 3............................................................................................. 427 Setting and adjusting various equipments.............................................................................. 428 Special function of machine monitor................................................................................... 437 How to start operation of KOMTRAX terminal............................................................................ 482 Lamp display of KOMTRAX terminal...................................................................................... 487 Pm Clinic check sheet................................................................................................. 490 40 Troubleshooting............................................................................................................ 0 General information on troubleshooting.................................................................................... 495 Points to remember when troubleshooting............................................................................... 496 Sequence of events in troubleshooting................................................................................. 497 Check before troubleshooting.......................................................................................... 498 Classification and procedures for troubleshooting..................................................................... 499 Connection table for connector pin numbers............................................................................ 502 T- branch box and T- branch adapter table............................................................................. 538 Troubleshooting by failure code, General.................................................................................. 543 Troubleshooting by failure code, General.............................................................................. 544 Failure codes table............................................................................................... 544 Before troubleshooting by failure code............................................................................ 552 Information in troubleshooting table.............................................................................. 559 Troubleshooting by failure code, Part 1................................................................................... 562 Troubleshooting by failure code, Part 1............................................................................... 564 Failure code [1500L0] Double engagement........................................................................... 564 Failure code [15B0NX] Transmission oil filter: Clogged............................................................ 565 Failure code [15F0KM] R → F shifting abuse 1...................................................................... 567 Failure code [15F0MB] R → F shifting abuse 2...................................................................... 567 Failure code [15F7KM] Transmission forward clutch abuse........................................................... 568 Failure code [15G0MW] Trouble in reverse clutch system (Slip)..................................................... 569 Failure code [15G7KM] Transmission reverse clutch abuse........................................................... 571 Failure code [15H0MW] Trouble in Hi clutch system (Slip).......................................................... 572 Failure code [15J0MW] Trouble in Lo clutch system (Slip).......................................................... 574 Failure code [15K0MW] Trouble in 1st clutch system (Slip)......................................................... 576 Failure code [15L0MW] Trouble in 2nd clutch system (Slip)......................................................... 578 Failure code [15M0MW] Trouble in 3rd clutch system (Slip)......................................................... 580 Failure code [15SBL1] Trouble in reverse clutch pressure control valve I.......................................... 582 Failure code [15SBMA] Trouble in reverse clutch pressure control valve II......................................... 585 Failure code [15SCL1] Trouble in Hi clutch pressure control valve I............................................... 587 Failure code [15SCMA] Trouble in Hi clutch pressure control valve II.............................................. 590 Failure code [15SDL1] Trouble in Lo clutch pressure control valve I............................................... 592 Failure code [15SDMA] Trouble in Lo clutch pressure control valve II.............................................. 594 Troubleshooting by failure code, Part 2................................................................................... 598 Failure code [15SEL1] Trouble in 1st clutch pressure control valve I.................................................. 600 Failure code [15SEMA] Trouble in 1st clutch pressure control valve II................................................. 603 Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I.................................................. 605 Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II................................................. 609 Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I.................................................. 611 Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II................................................. 615 Failure code [15SJMA] Trouble in lockup clutch pressure control valve II.............................................. 617 Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II......................... 619 Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2............................... 621 Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............................... 623 Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2................................ 625 Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1................................ 627 Failure code [2C4MNX] Clogging of retarder cooling oil filter......................................................... 629 Failure code [2F00KM] Dragging of parking brake....................................................................... 631 Failure code [2G42ZG] Lowering of accumulator oil pressure (front).................................................... 633 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)..................................................... 633 Failure code [989A00] Operation of engine overrun prevention system................................................... 634 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope).................................... 634 Failure code [A570NX] Clogging of engine oil filter................................................................... 635 Failure code [AA10NX] Clogging of air cleaner......................................................................... 637 Failure code [AB00MA] Trouble in battery charge circuit............................................................... 639 Failure code [B@BAZG] Lowering of engine oil pressure................................................................. 640 Failure code [B@BAZK] Lowering of engine oil level.................................................................... 641 Failure code [B@BCNS] Overheating of engine........................................................................... 642 Failure code [B@BCZK] Lowering of coolant level....................................................................... 643 Failure code [B@BFZK] Lowering of fuel level.......................................................................... 645 Failure code [B@C6NS] Overheating of brake cooling oil (front)........................................................ 646 Failure code [B@C8NS] Overheating of brake cooling oil (center)....................................................... 646 Failure code [B@CENS] Overheating of torque converter oil............................................................. 647 Failure code [B@JANS] Overheating of steering oil..................................................................... 647 Troubleshooting by failure code, Part 3................................................................................... 650 Failure code [CA111] Trouble in engine controller..................................................................... 653 Failure code [CA115] Trouble in engine Ne and Bkup speed sensors...................................................... 655 Failure code [CA122] Abnormally high charge pressure.................................................................. 657 Failure code [CA123] Abnormally low charge pressure................................................................... 659 Failure code [CA131] Abnormally high throttle sensor signal........................................................... 661 Failure code [CA132] Abnormally low throttle sensor signal............................................................ 663 Failure code [CA135] Abnormally high engine oil pressure.............................................................. 665 Failure code [CA141] Abnormally low engine oil pressure............................................................... 667 Failure code [CA144] Abnormally high coolant temperature.............................................................. 669 Failure code [CA145] Abnormally low coolant temperature............................................................... 671 Failure code [CA153] Abnormally high charge temperature............................................................... 673 Failure code [CA154] Abnormally low charge temperature................................................................ 675 Failure code [CA187] Abnormally low voltage in sensor power supply 2.................................................. 676 Failure code [CA221] Abnormally high ambient pressure................................................................. 677 Failure code [CA222] Abnormally low ambient pressure.................................................................. 679 Failure code [CA227] Abnormally high voltage in sensor power supply 2................................................. 681 Failure code [CA234] Engine overspeed................................................................................. 683 Failure code [CA238] Trouble in Ne speed sensor power supply.......................................................... 685 Failure code [CA263] Abnormally high fuel temperature................................................................. 687 Failure code [CA265] Abnormally low fuel temperature.................................................................. 689 Failure code [CA271] Short circuit in PCV1............................................................................ 690 Failure code [CA272] Disconnection in PCV1............................................................................ 691 Failure code [CA273] Short circuit in PCV2............................................................................ 692 Failure code [CA274] Disconnection in PCV2............................................................................ 693 Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)............................................. 695 Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)............................................. 697 Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)............................................. 699 Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)............................................. 701 Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)............................................. 703 Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)............................................. 705 Failure code [CA342] Matching error in engine controller data......................................................... 707 Failure code [CA351] Trouble in injector drive circuit................................................................ 709 Failure code [CA352] Abnormally low voltage in sensor power supply 1.................................................. 711 Failure code [CA386] Abnormally high voltage in sensor power supply 1................................................. 713 Troubleshooting by failure code, Part 4................................................................................... 716 Failure code [CA431] Trouble in idle validation switch................................................................ 719 Failure code [CA432] Trouble in idle validation process............................................................... 723 Failure code [CA441] Abnormally low voltage in power supply........................................................... 723 Failure code [CA442] Abnormally high voltage in power supply.......................................................... 724 Failure code [CA449] Abnormally high common rail pressure 2........................................................... 724 Failure code [CA451] Abnormally high common rail pressure............................................................. 725 Failure code [CA452] Abnormally low common rail pressure.............................................................. 727 Failure code [CA553] Abnormally high common rail pressure 1........................................................... 727 Failure code [CA554] In-range error in common rail pressure sensor.................................................... 728 Failure code [CA559] Supply pump low pressure 1....................................................................... 730 Failure code [CA689] Trouble in engine Ne speed sensor................................................................ 733 Failure code [CA731] Phase error in engine Bkup speed sensor.......................................................... 735 Failure code [CA757] Loss of all data in engine controller............................................................ 735 Failure code [CA778] Trouble in engine Bkup speed sensor.............................................................. 737 Failure code [CA1117] Loss of partial data in engine controller....................................................... 739 Failure code [CA1228] Trouble in EGR valve servo 1.................................................................... 739 Failure code [CA1625] Trouble in EGR valve servo 2.................................................................... 740 Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit............................................ 741 Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit............................................ 743 Failure code [CA1628] Trouble in bypass valve servo 1................................................................. 744 Failure code [CA1629] Trouble in bypass valve servo 2................................................................. 745 Failure code [CA1631] Abnormally high signal in bypass valve lift sensor.............................................. 747 Failure code [CA1632] Abnormally low signal in bypass valve lift sensor............................................... 749 Failure code [CA1633] Trouble in KOMNET............................................................................... 751 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor.............................................. 753 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor............................................. 755 Failure code [CA2185] Abnormally high voltage in throttle sensor power supply......................................... 757 Failure code [CA2186] Abnormally low voltage in throttle sensor power supply.......................................... 759 Failure code [CA2249] Low pressure in supply pump 2................................................................... 759 Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor......................................... 761 Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor.......................................... 763 Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit............................................... 765 Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit............................................... 767 Failure code [CA2555] Disconnection in intake air heater relay........................................................ 767 Failure code [CA2556] Short circuit in intake air heater relay........................................................ 769 Troubleshooting by failure code, Part 5................................................................................... 772 Failure code [DAF9KM] Wrong connection of connector................................................................... 774 Failure code [DAFRKR] Trouble in CAN communication (machine monitor).................................................. 775 Failure code [DAQ0KK] Lowering of source voltage...................................................................... 777 Failure code [DAQ0KT] Trouble in non-volatile memory.................................................................. 779 Failure code [DAQ2KK] Trouble in solenoid power supply system......................................................... 781 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)....................................... 783 Failure code [DAQRKR] Trouble in CAN communication (Transmission controller).......................................... 785 Failure code [DAQRMA] Disagreement of option setting (Transmission controller)........................................ 787 Failure code [DB10KT] Trouble in non-volatile memory.................................................................. 787 Failure code [DB12KK] Trouble in solenoid power supply system......................................................... 789 Failure code [DB13KK] Lowering of battery direct voltage.............................................................. 791 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 793 Failure code [DB1QMA] Disagreement of option setting (Retarder controller)............................................ 793 Failure code [DB1RKR] Trouble in CAN communication (Retarder controller).............................................. 795 Failure code [DB2RKR] Trouble in CAN communication (Engine controller)................................................ 797 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal....................................... 799 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve.......................................................... 801 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve.......................................................... 802 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve......................................................... 803 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve......................................................... 804 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve......................................................... 805 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve..................................................... 806 Failure code [DF10KA] Input of no lever signals....................................................................... 807 Failure code [DF10KB] Input of multiple lever signals................................................................. 811 Failure code [DGF1KX] Transmission oil temperature out of range....................................................... 815 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)........................................... 817 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 819 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................ 821 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................................... 823 Failure code [DGR6KX] Steering oil temperature out of range........................................................... 825 Troubleshooting by failure code, Part 6................................................................................... 828 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system................................. 831 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system.... 833 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor................................................. 835 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system....................................... 837 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system........................................ 839 Failure code [DJF1KA] Disconnection in fuel level sensor system....................................................... 841 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................ 843 Failure code [DK52KX] Trouble in dump lever potentiometer 1........................................................... 845 Failure code [DK53L8] Trouble in dump lever potentiometer 2........................................................... 847 Failure code [DK54KX] Trouble in dump positioner sensor............................................................... 849 Failure code [DKH0KX] Pitch angle sensor signal out of range.......................................................... 851 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system................................... 853 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor................................................ 854 Failure code [DLF2KA] Trouble in transmission intermediate shaft speed sensor......................................... 855 Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system............................ 856 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system.................................. 857 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system.................................. 858 Failure code [DV00KB] Short circuit in buzzer output circuit.......................................................... 859 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system...................... 861 Failure code [DW73KZ] Trouble in dump selector valve output system.................................................... 863 Failure code [DW78KZ] Trouble in rear wheel BCV command output system................................................. 865 Failure code [DW79KZ] Trouble in front wheel BCV command output system................................................ 867 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1........................... 869 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve..... 871 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve...... 873 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve......... 875 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2........................... 877 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1.......................... 879 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve.... 881 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve..... 883 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve........ 885 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2.......................... 887 Troubleshooting by failure code, Part 7................................................................................... 890 Troubleshooting by failure code, Part 7............................................................................... 892 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve........................................... 892 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve............................................ 894 Failure code [DX13KY] Hot short in output circuit of dump EPC valve............................................... 896 Failure code [DX14KZ] Trouble in rear wheel differential lock command output system............................... 897 Failure code [DX15KZ] Trouble in front wheel differential lock command output system.............................. 899 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid.............. 901 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid............... 903 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.................. 905 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................................... 906 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid.................................... 907 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid....................................... 909 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid....................................... 910 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve............................. 912 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve................................ 914 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid....................................... 917 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve............................. 919 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve................................ 921 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid...................................... 924 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve............................ 926 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve............................... 928 Troubleshooting by failure code, Part 8................................................................................... 932 Troubleshooting by failure code, Part 8............................................................................... 933 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid...................................... 933 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve............................ 935 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve............................... 937 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid...................................... 940 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve............................ 942 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve............................... 944 Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid.................................. 947 Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve........................ 949 Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve........................... 951 Troubleshooting for electrical system (E-mode)............................................................................ 955 Before troubleshooting for electrical system.......................................................................... 957 Information in troubleshooting table.................................................................................. 963 E-1 Engine does not start (Starting motor does not turn).............................................................. 964 E-2 Auto preheater does not operate................................................................................... 968 E-3 When starting switch is turned ON, machine monitor displays nothing............................................... 972 E-4 When starting switch is turned OFF, machine monitor cannot be operated............................................ 974 E-5 Alarm buzzer does not stop sounding............................................................................... 976 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section.................... 977 E-7 Display of character display section cannot be changed............................................................ 978 E-8 Power mode selection function does not operate normally........................................................... 982 E-9 AISS function does not operate normally........................................................................... 984 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification)......... 986 E-11 Interaxle differential lock-up function does not operate normally................................................ 990 E-12 Display of seat belt caution lamp is abnormal.................................................................... 992 E-13 Turn signal lamps and pilot lamps do not operate normally........................................................ 994 E-14 Night lighting is abnormal....................................................................................... 999 E-15 Backup lamp and backup buzzer operate abnormally.................................................................1005 E-16 Emergency steering system does not operate.......................................................................1009 E-17 Air conditioner does not operate normally........................................................................1013 Troubleshooting of hydraulic and mechanical system (H-mode)...............................................................1019 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................1021 Information in troubleshooting table..............................................................................1021 H-1 Machine does not start........................................................................................1022 H-2 Travel is not smooth (Machine hunts)..........................................................................1024 H-3 Lockup is not reset...........................................................................................1024 H-4 Start shock and gear shift shock are abnormally large.........................................................1025 H-5 Gear is not shifted up........................................................................................1026 H-6 Travel speed or power is low..................................................................................1028 H-7 Start and gearshift time lag is large.........................................................................1031 H-8 Torque converter oil temperature is high......................................................................1033 H-9 Torque converter oil temperature is low.......................................................................1034 H-10 Front brake does not work fully..............................................................................1035 H-11 Center brake does not work fully.............................................................................1036 H-12 Rear brake does not work fully...............................................................................1037 H-13 Steering wheel is heavy......................................................................................1038 H-14 Steering wheel does not move.................................................................................1039 H-15 Steering wheel waggle........................................................................................1040 H-16 Dump body raising speed is low...............................................................................1041 H-17 Dump body does not move......................................................................................1042 H-18 Hydraulic drift of dump body is large........................................................................1043 Troubleshooting of engine (S-mode)........................................................................................1045 Method of using troubleshooting chart.................................................................................1048 S-1 Starting performance of engine is poor...........................................................................1052 S-2 Engine does not start............................................................................................1054 S-3 Engine does not pick up smoothly.................................................................................1058 S-4 Engine stops during operation....................................................................................1059 S-5 Engine does not rotate smoothly..................................................................................1060 S-6 Engine lack output (or lacks power)..............................................................................1061 S-7 Exhaust gas is black (incomplete combustion).....................................................................1062 S-8 Oil consumption is excessive (or exhaust gas is blue)............................................................1064 S-9 Oil becomes dirty quickly........................................................................................1065 S-10 Fuel consumption is excessive...................................................................................1066 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................1067 S-12 Oil pressure drops..............................................................................................1068 S-13 Oil level rises (Entry of coolant or fuel)......................................................................1070 S-14 Coolant temperature becomes too high (Overheating)..............................................................1072 S-15 Abnormal noise is made..........................................................................................1073 S-16 Vibration is excessive..........................................................................................1074 50 Disassembly and assembly................................................................................................... 0 General information on disassembly and assembly...........................................................................1077 How to read this manual...............................................................................................1078 Coating materials list................................................................................................1080 Special tool list.....................................................................................................1083 Sketches of special tools.............................................................................................1089 Engine and cooling system.................................................................................................1103 Removal and installation of fuel supply pump..........................................................................1104 Removal and installation of engine assembly...........................................................................1107 Removal and installation of cylinder head assembly....................................................................1115 Removal and installation of fuel injector assembly....................................................................1128 Removal and installation of radiator assembly.........................................................................1133 Removal and installation of cooling assembly..........................................................................1137 Removal and installation of aftercooler...............................................................................1141 Removal and installation of engine front seal.........................................................................1144 Removal and installation of engine rear seal..........................................................................1146 Replacement procedure of exhaust pipe fire prevention cover1..........................................................1150 Power train, Part 1.......................................................................................................1159 Removal and installation of output shaft assembly.....................................................................1160 Disassembly and assembly of output shaft assembly.....................................................................1164 Removal and installation of transmission and front differential assembly..............................................1167 Disconnection and coupling of front differential and transmission.....................................................1175 Disassembly and assembly of torque converter assembly.................................................................1176 Disassembly and assembly of transmission assembly.....................................................................1184 Power train, Part 2.......................................................................................................1227 Disassembly and assembly of front differential assembly...............................................................1228 Removal and installation of center differential assembly..............................................................1247 Disassembly and assembly of center differential assembly..............................................................1251 Removal and installation of rear differential assembly................................................................1267 Disassembly and assembly of rear differential assembly................................................................1269 Power train, Part 3.......................................................................................................1283 Removal and installation of front final drive and brake assembly......................................................1284 Disassembly and assembly of front final drive and brake assembly......................................................1286 Removal and installation of center final drive and brake assembly.....................................................1299 Disassembly and assembly of center final drive and brake assembly.....................................................1301 Removal and installation of rear final drive assembly.................................................................1312 Disassembly and assembly of rear final drive assembly.................................................................1314 Removal and installation of center axle assembly......................................................................1321 Removal and installation of rear axle assembly........................................................................1324 Undercarriage and frame...................................................................................................1328 Removal and installation of front suspension cylinder assembly........................................................1329 Removal and installation of rear suspension cylinder assembly.........................................................1331 Disassembly and assembly of front and rear suspension cylinder assembly...............................................1332 Removal and installation of equalizer bar assembly....................................................................1334 Removal and installation of front wheel assembly......................................................................1336 Removal and installation of rear front wheel assembly.................................................................1337 Removal and installation of rear rear wheel assembly..................................................................1337 Removal and installation of hitch frame assembly......................................................................1338 Disassembly and assembly of hitch frame...............................................................................1346 Removal and installation of body assembly.............................................................................1351 Hydraulic system..........................................................................................................1354 Disassembly and assembly of steering valve............................................................................1355 Removal and installation of flow amplifier valve assembly.............................................................1365 Removal and installation of hoist valve assembly......................................................................1367 Disassembly and assembly of hoist valve assembly......................................................................1369 Disassembly and assembly of steering cylinder assembly................................................................1371 Disassembly and assembly of hoist cylinder assembly...................................................................1377 Cab and its attachments...................................................................................................1386 Removal and installation of operator’s cab............................................................................1387 Removal and installation of operator’s cab glass (Stuck glass)........................................................1392 Disassembly and assembly of operator's seat assembly..................................................................1399 Removal and installation of air conditioner unit assembly.............................................................1409 Electrical system.........................................................................................................1416 Removal and installation of retarder controller assembly..............................................................1417 Removal and installation of transmission controller assembly..........................................................1419 Removal and installation of engine controller assembly................................................................1421 90 Diagrams and drawings...................................................................................................... 0 Hydraulic diagrams and drawings...........................................................................................1424 Power train hydraulic circuit diagram.................................................................................1426 Steering and hoist hydraulic circuit diagram..........................................................................1427 Brake hydraulic circuit diagram.......................................................................................1429 Brake cooling hydraulic circuit diagram...............................................................................1430 Differential lock hydraulic circuit diagram...........................................................................1431 Electrical diagrams and drawings..........................................................................................1433 Electrical circuit diagram for inside cab (1/4).......................................................................1435 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 - 2092...............................................1436 Electrical circuit diagram for inside cab (2/4) Serial No.: 2093 and up...............................................1437 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 - 2092...............................................1438 Electrical circuit diagram for inside cab (3/4) Serial No.: 2093 and up...............................................1439 Electrical circuit diagram for inside cab (4/4).......................................................................1440 Electrical circuit diagram for outside cab (1/3)......................................................................1441 Electrical circuit diagram for outside cab (2/3)......................................................................1442 Electrical circuit diagram for outside cab (3/3)......................................................................1443 Connectors table and arrangement drawing..............................................................................1444
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