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Komatsu HM300-1 Dump Truck Service Manual SEBM024815 – PDF DOWNLOAD
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Komatsu HM300-1 Dump Truck Service Manual SEBM024815
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HM300-1
Serial number
1001 and up
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Description
Komatsu HM300-1 Dump Truck Service Manual SEBM024815
FILE DETAILS:
Komatsu HM300-1 Dump Truck Service Manual SEBM024815
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HM300-1
Serial Number: 1001 and up
Book Code: SEBM024815
Language: English
Pages: 1056
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM300-1 Dump Truck Service Manual SEBM024815
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu HM300-1 Dump Truck Service Manual SEBM024815
COVER ................................................................................................................................................... 1 CONTENTS................................................................................................................................................. 2 01 GENERAL............................................................................................................................................... 27 SPECIFICATION DRAWINGS............................................................................................................................... 28 SPECIFICATIONS....................................................................................................................................... 29 WEIGHT TABLE......................................................................................................................................... 32 FUEL, COOLANT AND LUBRICANTS......................................................................................................................... 33 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.......................................................................................................... 36 RADIATOR, OIL COOLER, AFTERCOOLER.................................................................................................................... 37 POWER TRAIN SKELETON................................................................................................................................. 38 OUTPUT SHAFT......................................................................................................................................... 40 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING................................................................................................... 42 TORQUE CONVERTER..................................................................................................................................... 44 TRANSMISSION......................................................................................................................................... 50 TRANSMISSION VALVE................................................................................................................................... 69 ECMV (ELECTRONIC CONTROL MODULATION VALVE)........................................................................................................... 70 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE........................................................................................................... 77 DRIVE SHAFT.......................................................................................................................................... 79 AXLE................................................................................................................................................. 80 DIFFERENTIAL......................................................................................................................................... 83 LIMITED SLIP DIFFERENTIAL............................................................................................................................ 89 FINAL DRIVE.......................................................................................................................................... 93 STEERING COLUMN...................................................................................................................................... 98 BRAKE PIPING......................................................................................................................................... 99 BRAKE VALVE.......................................................................................................................................... 101 ACCUMULATOR CHARGE VALVE............................................................................................................................. 104 ACCUMULATOR.......................................................................................................................................... 108 SLACK ADJUSTER....................................................................................................................................... 109 BRAKE................................................................................................................................................ 111 PROPORTIONAL REDUCING VALVE.......................................................................................................................... 116 BRAKE SYSTEM TANK.................................................................................................................................... 117 PARKING BRAKE........................................................................................................................................ 118 PARKING BRAKE CALIPER................................................................................................................................ 120 SPRING CYLINDER...................................................................................................................................... 121 PARKING BRAKE SOLENOID............................................................................................................................... 122 SUSPENSION........................................................................................................................................... 123 SUSPENSION CYLINDER.................................................................................................................................. 128 OSCILLATION HITCH.................................................................................................................................... 130 STEERING, HOIST OIL PRESSURE PIPING DIAGRAM.......................................................................................................... 133 DUMP BODY CONTROL.................................................................................................................................... 134 HYDRAULIC TANK AND FILTER............................................................................................................................ 135 FLOW AMP VALVE....................................................................................................................................... 136 STEERING VALVE....................................................................................................................................... 139 STEERING CYLINDER.................................................................................................................................... 143 HOIST VALVE.......................................................................................................................................... 144 EPC VALVE............................................................................................................................................ 150 PILOT CHECK VALVE.................................................................................................................................... 151 HOIST CYLINDER....................................................................................................................................... 152 HYDRAULIC PUMP....................................................................................................................................... 153 CAB TILT............................................................................................................................................. 157 AIR CONDITIONER...................................................................................................................................... 158 HEARTER.............................................................................................................................................. 163 MACHINE MONITOR SYSTEM............................................................................................................................... 166 AUTOMATIC SHIFT CONTROL SYSTEM....................................................................................................................... 179 TRANSMISSION CONTROLLER.............................................................................................................................. 181 AUTO EMERGENCY STEERING SYSTEM....................................................................................................................... 187 SENSORS, SWITCHES.................................................................................................................................... 188 RETARDER CONTROL SYSTEM.............................................................................................................................. 196 BRAKE CONTROL SYSTEM (E-SPEC)........................................................................................................................ 206 DUMP CONTROL LEVER................................................................................................................................... 215 20 TESTING AND ADJUSTING................................................................................................................................. 220 STANDARD VALUE TABLE FOR ENGINE...................................................................................................................... 221 STANDARD VALUE TABLE FOR CHASSIS..................................................................................................................... 222 STANDARD VALUE TABLE FOR ELECTRICAL PARTS............................................................................................................ 226 TESTING AND ADJUSTING................................................................................................................................ 238 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING................................................................................................ 239 MEASURING ENGINE SPEED........................................................................................................................... 241 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)................................................................................................... 242 MEASURING EXHAUST TEMPERATURE.................................................................................................................... 243 MEASURING EXHAUST COLOR.......................................................................................................................... 245 MEASURING COMPRESSION PRESSURE................................................................................................................... 246 ADJUSTING VALVE CLEARANCE........................................................................................................................ 247 MEASURING BLOW-BY PRESSURE....................................................................................................................... 248 MEASURING ENGINE OIL PRESSURE.................................................................................................................... 249 HANDING EQUIPMENT IN FUEL CIRCUIT................................................................................................................ 250 RELEASING REMAINING PRESSURE IN FUEL SYSTEM...................................................................................................... 250 MEASURING FUEL PRESSURE.......................................................................................................................... 251 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................................... 252 REDUCED CYLINDER MODE OPERATION FOR ENGINE....................................................................................................... 254 CHECKING FOR LEAKAGE IN FUEL CIRCUIT............................................................................................................. 255 ADJUSTING ENGINE SPEED SENSOR.................................................................................................................... 256 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................... 257 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................................... 257 ADJUSTING THE BODY MOUNT......................................................................................................................... 258 TESTING TORQUE CONVERTER STALL SPEED............................................................................................................. 260 MEASURING POWER TRAIN OIL PRESSURE............................................................................................................... 261 ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................................. 268 TESTING AND ADJUSTING BRAKE OIL PRESSURE......................................................................................................... 270 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS............................................ 274 TESTING BRAKE PERFORMANCE........................................................................................................................ 278 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................. 280 TESTING WEAR OF WHEEL BRAKE DISC................................................................................................................. 282 TESTING WEAR OF PARKING BRAKE PAD................................................................................................................ 283 METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE.................................................................................................... 284 TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE.................................................................................................. 285 TESTING AND ADJUSTING SUSPENSION CYLINDER........................................................................................................ 287 METHOD OF TILTING CAB UP......................................................................................................................... 291 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE...................................................................................................... 294 ADJUSTING BODY POSITIONER SENSOR................................................................................................................. 297 PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT......................................................................... 298 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT.................................................................................................. 298 ADJUSTING TRANSMISSION CONTROLLER................................................................................................................ 299 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM........................................................................... 300 ADJUSTING MACHINE MONITOR........................................................................................................................ 304 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................. 308 PM-CLINIC INSPECTION SHEET....................................................................................................................... 342 TROUBLESHOOTING...................................................................................................................................... 345 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................................... 346 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................................ 347 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................. 348 CHECKS BEFORE TROUBLESHOOTING.................................................................................................................... 356 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................................... 357 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................................... 372 T-ADAPTER TABLE.................................................................................................................................. 395 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................................ 398 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)........................................................................................... 402 ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.................................................................................................. 404 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE................................................................. 407 ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))............................................................................................ 419 ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))................................................................................ 420 ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))................................................................................ 421 ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA)).......................................................................... 421 ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))........................................................................... 422 ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))..................................................................... 424 ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))........................................................................ 424 ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA)).......................................................... 425 ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB)).......................................................... 426 ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))......................................................... 427 ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))......................................................... 428 ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 429 ENG-13 FAILURE CODE [ADAZKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).......................................................... 430 ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 434 ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 435 ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 436 ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB)).......................................................... 437 ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 441 ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA)).............................................................. 442 ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))......................................................................... 443 ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))................................................................................ 444 ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))................................................................................. 445 ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))................................................. 446 ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................... 448 ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))................................................. 449 ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX)).............................................. 451 ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))......................................................... 452 ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))........................... 454 ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))............................. 456 ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))............................ 457 ENG-31 FAILURE CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))........................................................................... 458 ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))....................................................................... 459 ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))................................................................ 461 ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))....................... 463 ENG-35 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))..................................... 464 ENG-36 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))........................................................ 465 ENG-37 FAILURE CODE [DH40KX] (COMMON PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))....................................................... 467 ENG-38 FAILURE CODE [DH10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))........................................................ 469 ENG-39 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC)).................................................................... 471 ENG-40 FAILURE CODE [DLH1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))..................................................................... 472 ENG-41 ENGINE DOES NOT STARTS (STARTING MOTOR DOES NOT TURN)................................................................................. 473 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)...................................................................................... 476 TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 479 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE................................................................. 485 TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))................................................................................... 511 TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE THE TABLE IN CONTENTS (LO))............................................................ 512 TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))........................................................................... 513 TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))......................................................................................... 514 TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))........................................................................................ 515 TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))........................................................................................ 516 TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))....................................................................................... 517 TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))....................................................................................... 518 TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))....................................................................................... 519 TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE THE TABLE CONTENTS (L1)) ............................................................... 520 TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................... 521 TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE THE TABLE IN CONTENTS (L1))............................................................ 522 TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................... 523 TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE THE TABLE IN CONTENTS (L1))............................................................ 524 TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................... 525 TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE THE TABLE IN CONTENTS (L1))........................................................... 526 TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................. 527 TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE THE TABLE IN CONTENTS (L1))........................................................... 528 TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................. 529 TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE HTE TABLE IN CONTENTS (L1))........................................................... 530 TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................. 531 TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE THE TABLE IN CONTENTS (L1))....................................................... 532 TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA)).............................................................. 533 TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE THE TABLE IN CONTENTS (L1)).................................. 534 TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))......................................... 535 TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))............................................................. 536 TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM)) ................................................... 537 TM-28 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))........................................................ 539 TM-29 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................. 540 TM-30 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))............................................................................ 541 TM-31 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))............................................................................... 543 TM-32 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))........................................................................... 545 TM-33 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))..................................................................... 546 TM-34 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))......................................................................... 547 TM-35 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (NS)).................................................................................... 548 TM-36 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................... 549 TM-37 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))................................... 551 TM-38 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ)).............................................. 553 TM-39 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE THE TABLE IN CONTENTS (L4)).................................................. 554 TM-40 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))............................................................ 556 TM-41 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK)).............................................. 557 TM-42 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))....................... 559 TM-43 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))....................... 560 TM-44 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............. 561 TM-45 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))..................................... 562 TM-46 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))............................ 563 TM-47 FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KQ))............................... 564 TM-48 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KQ))................................ 565 TM-49 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA)).............................................................. 565 TM-50 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))........................................ 566 TM-51 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))............................................................. 567 TM-52 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA)).................................................................. 568 TM-53 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA)).................................................................. 569 TM-54 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))................................................................. 570 TM-55 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))................................................................. 571 TM-56 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))................................................................. 572 TM-57 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))................................................................... 573 TM-58 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))............................................................................ 574 TM-59 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))............................................................................ 576 TM-60 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))..................................... 578 TM-61 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE THE TABLE IN CONTENTS (L8))......................................... 580 TM-62 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE THE TABLE IN CONTENTS (L8)).......................................... 582 TM-63 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))....................................... 584 TM-64 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX)).......................................... 586 TM-65 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE THE TABLE IN CONTENTS (L6)).......................................... 588 TM-66 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (KA)).......................................................................... 589 TM-67 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))......................................................... 590 TM-68 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))........................................................................ 592 TM-69 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))........................................................... 593 TM-70 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))...................................................... 594 TM-71 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))......................................... 595 TM-72 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION (KA))............................................. 596 TM-73 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))................................ 597 TM-74 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))................................................... 598 TM-75 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))........................................ 599 TM-76 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA)).................................................. 601 TM-77 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB)).................................................. 602 TM-78 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))................................................................ 603 TM-79 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))................................................................ 604 TM-80 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))..................................................................... 605 TM-81 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))..................................................................... 606 TM-82 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))..................................................................... 607 TM-83 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))..................................................................... 608 TM-84 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA)).................................................................... 609 TM-85 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB)).................................................................... 610 TM-86 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA)).................................................................... 611 TM-87 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB)).................................................................... 612 TM-88 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA)).................................................................... 613 TM-89 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB)).................................................................... 614 TM-90 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))...................................................................... 615 TM-91 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))...................................................................... 616 TM-92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY........................................................................................ 617 TM-93 EMERGENCY STEERING DOES NOT OPERATE.................................................................................................... 620 TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)..................................................................................... 624 BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM................................................................................................... 626 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE................................................................. 631 BK-1 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)).................................................................. 643 BK-2 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))................................................................... 643 BK-3 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................................ 644 BK-4 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))........................................................... 646 BK-5 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))........................................................... 647 BK-6 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).................................................... 648 BK-7 FAILURE CODE [DB11KK] (RETARDER CONTROLLER (*1) MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)........................ 650 BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER (*1) LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)........................ 651 BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER (*1) BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK).............. 652 BK-10 FAILURE CODE [DB19KM] (RETARDER CONTROLLER (*1) WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))........................... 653 BK-11 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER (*1) S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))...................................... 654 BK-12 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))....................................... 655 BK-13 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))........................................ 657 BK-14 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (L5))......................................................... 659 BK-15 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX)).................................................... 662 BK-16 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE THE TABLE IN CONTENTS (L8)).................................................... 664 BK-17 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))........................................................ 665 BK-18 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))................................................... 667 BK-19 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))................................................... 668 BK-20 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)....................... 669 BK-21 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)).............................................. 670 BK-22 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)).............................................. 672 BK-23 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))................................................ 674 BK-24 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))................................................ 675 BK-25 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))........................... 676 BK-26 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))............................................... 677 BK-27 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))............................................... 678 BK-28 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)).......................... 679 BK-29 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA)).................................................................... 680 BK-30 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB)).................................................................... 681 BK-31 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))............................................... 682 BK-32 PARKING BRAKE DOES NOT WORK PROPERLY................................................................................................... 683 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)............................................................................................. 686 MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.................................................................................................. 687 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ................................................................ 691 MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))................................................................................. 695 MON-2 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))................................................................................ 695 MON-3 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))................................................................................ 695 MON-4 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))..................................................... 696 MON-5 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))..................................................... 697 MON-6 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))........................................................ 698 MON-7 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))..... 699 MON-8 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).... 701 MON-9 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))........... 703 MON-10 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB)).............................................................................. 705 MON-11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY................................................................... 706 MON-12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED....................................................................... 707 MON-13 ALARM BUZZER DOES NOT SOUND........................................................................................................... 708 MON-14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY............................................... 709 MON-15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY....................................................................... 710 MON-16 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY......................................................................................... 711 MON-17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY................................................................................... 714 MON-18 AISS FUNCTION DOES NOT WORK PROPERLY.................................................................................................. 715 MON-19 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)........................................................... 716 MON-20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY.................................................................................. 718 MON-21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY.................................................................................... 720 MON-22 NIGHT LIGHTING IS NOT NORMAL.......................................................................................................... 725 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)......................................................................................... 732 H-1 MACHINE DOES NOT START................................................................................................................... 733 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)......................................................................................... 734 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)...................................................................................... 734 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING................................................................................................ 735 H-5 TRANSMISSION DOES NOT SHIFT UP........................................................................................................... 736 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING.............................................................................................. 737 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR..................................................................................... 740 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH................................................................................................. 741 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW..................................................................................................... 742 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE............................................................................... 743 H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE.............................................................................. 744 H-12 STEERING WHEEL IS HEAVY................................................................................................................. 745 H-13 STEERING WHEEL DOES NOT WORK............................................................................................................ 746 H-14 STEERING WHEEL VIBRATES................................................................................................................. 747 H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER......................................................................................... 748 H-16 DUMP DOES NOT WORK...................................................................................................................... 749 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY.................................................................................................. 750 TROUBLESHOOTING OF THE ENGINE BODY (S MODE)...................................................................................................... 751 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................... 752 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................... 753 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................ 756 S-2 ENGINE DOES NOT START.................................................................................................................... 757 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................................... 760 S-4 ENGINE STOPS DURING OPERATIONS........................................................................................................... 761 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................................ 762 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..................................................................................................... 763 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................................... 764 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................. 765 S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................................... 766 S-10 FUEL CONSUMPTION IS EXCESSIVE........................................................................................................... 767 S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN).................................................................. 768 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................................................. 769 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).................................................................................................... 770 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................................... 771 S-15 ABNORMAL NOISE IS MADE.................................................................................................................. 772 S-16 VIBRATION IS EXCESSIVE.................................................................................................................. 773 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................. 774 HOW TO READ THIS MANUAL.............................................................................................................................. 776 REMOVAL AND INSTALLATION OF ASSEMBLIES........................................................................................................... 776 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES........................................................................................................... 777 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................. 778 SPECIAL TOOL LIST.................................................................................................................................... 780 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY................................................................................................ 784 SPECIAL TOOL..................................................................................................................................... 784 REMOVAL.......................................................................................................................................... 784 INSTALLATION..................................................................................................................................... 787 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY................................................................................................... 789 REMOVAL.......................................................................................................................................... 789 INSTALLATION..................................................................................................................................... 790 REMOVAL AND INSTALLATION OF NOZZLE TIP............................................................................................................... 793 SPECIAL TOOL..................................................................................................................................... 793 REMOVAL.......................................................................................................................................... 793 INSTALLATION..................................................................................................................................... 794 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 795 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY................................................................................................... 796 SPECIAL TOOL..................................................................................................................................... 796 REMOVAL.......................................................................................................................................... 796 INSTALLATION..................................................................................................................................... 800 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY.......................................................................................................... 804 SPECIAL TOOL..................................................................................................................................... 804 REMOVAL.......................................................................................................................................... 804 INSTALLATION..................................................................................................................................... 808 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY........................................................................................................ 809 REMOVAL.......................................................................................................................................... 809 INSTALLATION..................................................................................................................................... 811 REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY.................................................................................................... 812 SPECIAL TOOL..................................................................................................................................... 812 REMOVAL.......................................................................................................................................... 812 INSTALLATION..................................................................................................................................... 814 ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY.................................................................................................... 817 DISASSEMBLY...................................................................................................................................... 817 ASSEMBLY......................................................................................................................................... 818 REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY............................................................................. 820 SPECIAL TOOL..................................................................................................................................... 820 REMOVAL.......................................................................................................................................... 820 INSTALLATION..................................................................................................................................... 825 CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY................................................................ 827 DISCONNECTION.................................................................................................................................... 827 CONNECTION....................................................................................................................................... 828 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY................................................................................................ 829 SPECIAL TOOL..................................................................................................................................... 829 DISASSEMBLY...................................................................................................................................... 829 ASSEMBLY......................................................................................................................................... 832 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 837 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY.................................................................................................... 838 SPECIAL TOOL..................................................................................................................................... 838 DISASSEMBLY...................................................................................................................................... 838 ASSEMBLY......................................................................................................................................... 855 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 881 DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY.............................................................................................. 884 SPECIAL TOOL..................................................................................................................................... 884 DISASSEMBLY...................................................................................................................................... 884 ASSEMBLY......................................................................................................................................... 888 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 898 REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY............................................................................................. 899 SPECIAL TOOL..................................................................................................................................... 899 REMOVAL.......................................................................................................................................... 899 INSTALLATION..................................................................................................................................... 901 DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY............................................................................................. 903 SPECIAL TOOL..................................................................................................................................... 903 DISASSEMBLY...................................................................................................................................... 903 ASSEMBLY......................................................................................................................................... 908 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 920 REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY............................................................................................... 923 REMOVAL.......................................................................................................................................... 923 INSTALLATION..................................................................................................................................... 924 DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY .............................................................................................. 925 SPECIAL TOOL..................................................................................................................................... 925 DISASSEMBLY...................................................................................................................................... 925 ASSEMBLY......................................................................................................................................... 929 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 939 REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY..................................................................................... 940 REMOVAL.......................................................................................................................................... 940 INSTALLATION..................................................................................................................................... 941 DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY..................................................................................... 942 SPECIAL TOOL..................................................................................................................................... 942 DISASSEMBLY...................................................................................................................................... 942 ASSEMBLY......................................................................................................................................... 946 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 953 REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY.................................................................................... 956 REMOVAL.......................................................................................................................................... 956 INSTALLATION..................................................................................................................................... 957 DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY.................................................................................... 958 SPECIAL TOOL..................................................................................................................................... 958 DISASSEMBLY...................................................................................................................................... 958 ASSEMBLY......................................................................................................................................... 960 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 966 DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY................................................................................................ 969 SPECIAL TOOL..................................................................................................................................... 969 DISASSEMBLY...................................................................................................................................... 969 ASSEMBLY......................................................................................................................................... 971 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 976 REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY..................................................................................................... 977 REMOVAL.......................................................................................................................................... 977 INSTALLATION..................................................................................................................................... 978 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY....................................................................................................... 979 REMOVAL.......................................................................................................................................... 979 INSTALLATION..................................................................................................................................... 981 REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY....................................................................................... 982 REMOVAL.......................................................................................................................................... 982 INSTALLATION..................................................................................................................................... 983 INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY........................................................................................ 984 REMOVAL.......................................................................................................................................... 984 INSTALLATION..................................................................................................................................... 984 REMOVAL AND INSTALLATION OF EQUALIZER BAR............................................................................................................ 987 REMOVAL.......................................................................................................................................... 987 INSTALLATION..................................................................................................................................... 988 REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY..................................................................................................... 989 SPECIAL TOOL..................................................................................................................................... 989 REMOVAL.......................................................................................................................................... 989 INSTALLATION..................................................................................................................................... 994 SKETCHES OF SPECIAL TOOLS........................................................................................................................ 998 DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY..................................................................................................... 999 SPECIAL TOOL..................................................................................................................................... 999 DISASSEMBLY...................................................................................................................................... 999 ASSEMBLY.........................................................................................................................................1000 SKETCHES OF SPECIAL TOOLS........................................................................................................................1005 DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY..................................................................................................1006 DISASSEMBLY......................................................................................................................................1008 ASSEMBLY.........................................................................................................................................1011 REMOVAL AND INSTALLATION OF FLOW AMP VALVE...........................................................................................................1016 SPECIAL TOOL.....................................................................................................................................1016 REMOVAL..........................................................................................................................................1016 INSTALLATION.....................................................................................................................................1017 REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY.....................................................................................................1018 SPECIAL TOOL.....................................................................................................................................1018 REMOVAL..........................................................................................................................................1018 INSTALLATION.....................................................................................................................................1019 DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY...............................................................................................1021 SPECIAL TOOL.....................................................................................................................................1021 DISASSEMBLY......................................................................................................................................1021 ASSEMBLY.........................................................................................................................................1022 DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY..................................................................................................1024 SPECIAL TOOL.....................................................................................................................................1024 DISASSEMBLY......................................................................................................................................1024 ASSEMBLY.........................................................................................................................................1026 REMOVAL AND INSTALLATION OF BODY ASSEMBLY............................................................................................................1028 REMOVAL..........................................................................................................................................1028 INSTALLATION.....................................................................................................................................1029 DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY.................................................................................................1031 DISASSEMBLY......................................................................................................................................1031 ASSEMBLY.........................................................................................................................................1036 90 OTHERS................................................................................................................................................1041 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................1042 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................1043 BRAKE HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................1044 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................1045 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM (-30°C SPECIFICATION)........................................................................................1046 DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER.......................................................................................................1047 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)......................................................................................................1048 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)......................................................................................................1049 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)......................................................................................................1050 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)......................................................................................................1051 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3).....................................................................................................1052 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/3).....................................................................................................1053 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (3/3).....................................................................................................1054 DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER..........................................................................................1055 DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR.........................................................................................................1056
KOMATSU HM300-1 DUMP TRUCK SERVICE MANUAL SEBM024815 – PDF DOWNLOAD:
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Gregory Quentin –
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