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KOMATSU HM300-1 SHOP MANUAL SEBM024817 – PDF DOWNLOAD
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Description
KOMATSU HM300-1 SHOP MANUAL SEBM024817 – PDF DOWNLOAD
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KOMATSU HM300-1 SHOP MANUAL SEBM024817 – PDF DOWNLOAD
Language : English
Pages : 1114
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HM300-1 SHOP MANUAL SEBM024817 – PDF DOWNLOAD
SEBM024817(HM300-1)......................................................................................................................................... 1 CONTENTS................................................................................................................................................ 2 SAFETY.................................................................................................................................................. 3 SAFETY NOTICE....................................................................................................................................... 3 FOREWORD................................................................................................................................................ 5 GENERAL............................................................................................................................................. 5 HOW TO READ THE SHOP MANUAL......................................................................................................................... 6 HOISTING INSTRUCTIONS............................................................................................................................... 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.......................................................................................... 8 COATING MATERIALS................................................................................................................................... 10 STANDARD TIGHTENING TORQUE.......................................................................................................................... 12 ELECTRIC WIRE CODE.................................................................................................................................. 15 CONVERSION TABLE.................................................................................................................................... 16 UNITS............................................................................................................................................... 22 01 GENERAL.............................................................................................................................................. 23 SPECIFICATION DRAWINGS.............................................................................................................................. 24 SPECIFICATIONS...................................................................................................................................... 25 WEIGHT TABLE........................................................................................................................................ 28 FUEL, COOLANT AND LUBRICANTS........................................................................................................................ 29 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................................................... 33 RADIATOR, OIL COOLER, AFTERCOOLER................................................................................................................... 34 POWER TRAIN SKELETON................................................................................................................................ 36 OUTPUT SHAFT........................................................................................................................................ 38 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING.................................................................................................. 40 TORQUE CONVERTER.................................................................................................................................... 42 TRANSMISSION........................................................................................................................................ 48 TRANSMISSION VALVE.................................................................................................................................. 68 ECMV (Electronic Control Modulation Valve).......................................................................................................... 69 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.......................................................................................................... 76 DRIVE SHAFT......................................................................................................................................... 78 AXLE................................................................................................................................................ 79 DIFFERENTIAL........................................................................................................................................ 82 LIMITED SLIP DIFFERENTIAL........................................................................................................................... 88 FINAL DRIVE......................................................................................................................................... 94 STEERING COLUMN..................................................................................................................................... 99 BRAKE PIPING........................................................................................................................................ 100 BRAKE VALVE......................................................................................................................................... 102 ACCUMULATOR CHARGE VALVE............................................................................................................................ 105 ACCUMULATOR......................................................................................................................................... 109 SLACK ADJUSTER...................................................................................................................................... 110 BRAKE............................................................................................................................................... 112 PROPORTIONAL REDUCING VALVE......................................................................................................................... 117 BRAKE SYSTEM TANK................................................................................................................................... 118 PARKING BRAKE....................................................................................................................................... 120 PARKING BRAKE CALIPER............................................................................................................................... 122 SPRING CYLINDER..................................................................................................................................... 123 PARKING BRAKE SOLENOID.............................................................................................................................. 124 SUSPENSION.......................................................................................................................................... 126 SUSPENSION CYLINDER................................................................................................................................. 132 OSCILLATION HITCH................................................................................................................................... 134 STEERING, HOIST OIL PRESSURE PIPING DIAGRAM......................................................................................................... 138 DUMP BODY CONTROL................................................................................................................................... 139 HYDRAULIC TANK AND FILTER........................................................................................................................... 140 FLOW AMP VALVE...................................................................................................................................... 141 STEERING VALVE...................................................................................................................................... 144 STEERING CYLINDER................................................................................................................................... 148 HOIST VALVE......................................................................................................................................... 150 EPC VALVE........................................................................................................................................... 156 PILOT CHECK VALVE................................................................................................................................... 157 HOIST CYLINDER...................................................................................................................................... 159 HYDRAULIC PUMP...................................................................................................................................... 160 CAB TILT............................................................................................................................................ 164 AIR CONDITIONER..................................................................................................................................... 165 HEARTER............................................................................................................................................. 170 MACHINE MONITOR SYSTEM.............................................................................................................................. 174 AUTOMATIC SHIFT CONTROL SYSTEM...................................................................................................................... 187 TRANSMISSION CONTROLLER............................................................................................................................. 189 AUTO EMERGENCY STEERING SYSTEM...................................................................................................................... 195 SENSORS, SWITCHES................................................................................................................................... 196 RETARDER CONTROL SYSTEM............................................................................................................................. 204 BRAKE CONTROL SYSTEM (E-SPEC)....................................................................................................................... 214 DUMP CONTROL LEVER.................................................................................................................................. 224 20 TESTING AND ADJUSTING................................................................................................................................ 229 STANDARD VALUE TABLES............................................................................................................................... 229 STANDARD VALUE TABLE FOR ENGINE................................................................................................................. 230 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................ 231 STANDARD VALUE TABLE FOR ELECTRICAL PARTS....................................................................................................... 235 TESTING AND ADJUSTING............................................................................................................................... 247 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................... 248 MEASURING ENGINE SPEED.......................................................................................................................... 250 MEASURING AIR SUPPLYPRESSURE (BOOST PRESSURE)................................................................................................... 251 MEASURING EXHAUST TEMPERATURE................................................................................................................... 252 MEASURING EXHAUST COLOR......................................................................................................................... 254 MEASURING COMPRESSION PRESSURE.................................................................................................................. 255 ADJUSTING VALVE CLEARANCE....................................................................................................................... 256 MEASURING BLOW-BY PRESSURE...................................................................................................................... 257 MEASURING ENGINE OIL PRESSURE................................................................................................................... 258 HANDLING EQUIPMENT IN FUEL CIRCUIT.............................................................................................................. 259 RELEASING REMAINING PRESSURE IN FUEL SYSTEM..................................................................................................... 259 MEASURING FUEL PRESSURE......................................................................................................................... 260 BLEEDING AIR FROM FUEL CIRCUIT.................................................................................................................. 261 REDUCED CYLINDER MODE OPERATION FOR ENGINE...................................................................................................... 263 CHECKING FOR LEAKAGE IN FUEL CIRCUIT............................................................................................................ 264 ADJUSTING ENGINE SPEED SENSOR................................................................................................................... 265 TESTING AND ADJUSTING ALTERNATOR BELT TENSION................................................................................................... 266 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................................................... 266 ADJUSTING THE BODY MOUNT........................................................................................................................ 267 TESTING TORQUE CONVERTER STALL SPEED............................................................................................................ 269 MEASURING POWER TRAIN OIL PRESSURE.............................................................................................................. 270 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................................. 277 TESTING AND ADJUSTING BRAKE OIL PRESSURE........................................................................................................ 280 TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS........................................... 284 TESTING BRAKE PERFORMANCE....................................................................................................................... 292 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................................................. 295 TESTING WEAR OF WHEEL BRAKE DISC................................................................................................................ 298 TESTING WEAR OF PARKIN GBRAKE PAD............................................................................................................... 299 METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE................................................................................................... 300 TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE................................................................................................. 301 TESTING AND ADJUSTING SUSPENSION CYLINDER....................................................................................................... 303 METHOD OF TILTING CAB UP........................................................................................................................ 307 TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE..................................................................................................... 310 ADJUSTING BODY POSITIONER SENSOR................................................................................................................ 313 PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT........................................................................ 314 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT................................................................................................. 314 ADJUSTING TRANSMISSION CONTROLLER............................................................................................................... 315 METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM.......................................................................... 316 ADJUSTING MACHINE MONITOR....................................................................................................................... 320 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................ 324 Pm-CLINIC INSPECTION SHEET...................................................................................................................... 358 TROUBLESHOOTING..................................................................................................................................... 361 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................... 362 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................... 363 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................................................ 364 CHECKS BEFORE TROUBLESHOOTING................................................................................................................... 372 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................................... 373 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................................... 388 T-ADAPTER TABLE................................................................................................................................. 412 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS............................................................................... 415 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE).............................................................................................. 419 ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM..................................................................................................... 422 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE.................................................................... 426 ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))........................................................................................... 438 ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))............................................................................... 439 ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: * SEE CONTENTS (L2)).............................................................................. 440 ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))......................................................................... 440 ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: * SEE CONTENTS (L3))......................................................................... 441 ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA)).................................................................... 443 ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))....................................................................... 443 ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))......................................................... 444 ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))......................................................... 445 ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))........................................................ 446 ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))........................................................ 447 ENG-12 FAILURE CODE [ADA1KA] (NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))............................................................ 448 ENG-13 FAILURE CODE [ADAZKB] (NO. 1, 2, 3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))...................................................... 449 ENG-14 FAILURE CODE [ADB1KA] (NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))............................................................ 453 ENG-15 FAILURE CODE [ADC1KA] (NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))............................................................ 454 ENG-16 FAILURE CODE [ADD1KA] (NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))............................................................ 455 ENG-17 FAILURE CODE [ADDZKB] (NO. 4, 5, 6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))...................................................... 456 ENG-18 FAILURE CODE [ADE1KA] (NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))............................................................ 460 ENG-19 FAILURE CODE [ADF1KA] (NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))........................................................... 461 ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))........................................................................ 462 ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))............................................................................... 463 ENG-22 FAILURE CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)).............................................................................. 464 ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))................................................ 465 ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))................................................... 467 ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))................................................ 468 ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))............................................. 470 ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))........................................................ 471 ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)).......................... 473 ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))............................ 475 ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))........................... 476 ENG-31 FAILURE CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)).......................................................................... 477 ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: * SEE CONTENTS (L5))..................................................................... 478 ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: * SEE CONTENTS (L6)).............................................................. 480 ENG-34 FAILURE CODE [DGE2KX] (ENGINE COOLANT TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX)).................... 482 ENG-35 FAILURE CODE [DGE3L6] (ENGINE COOLANT TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): * SEE CONTENTS (L6))................................. 483 ENG-36 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...................................................... 484 ENG-37 FAILURE CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................................. 486 ENG-38 FAILURE CODE [DK10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...................................................... 488 ENG-39 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: * SEE CONTENTS (LC)).................................................................. 490 ENG-40 FAILURE CODE [DLH1LC] (ENGINE G SPEED SENSOR: * SEE CONTENTS (LC))................................................................... 491 ENG-41 ENGINE DOES NOT START (STARTING MOTOR DOES NOT TURN)................................................................................. 492 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)......................................................................................... 495 TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...................................................................................................... 498 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE.................................................................... 504 TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW)).................................................................................. 530 TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: * SEE THE TABLE IN CONTENTS. (LO))......................................................... 531 TM-3 FAILURE CODE [15B0NX] (TRANSMISSION OIL FILTER: CLOGGED (NX)).......................................................................... 532 TM-4 FAILURE CODE [15G0MW] (R CLUTCH: SLIPPING (MW))........................................................................................ 533 TM-5 FAILURE CODE [15H0MW] (HI CLUTCH: SLIPPING (MW))....................................................................................... 534 TM-6 FAILURE CODE [15J0MW] (LO CLUTCH: SLIPPING (MW))....................................................................................... 535 TM-7 Failure code [15K0MW] (1st clutch: Slipping (MW))...................................................................................... 536 TM-8 FAILURE CODE [15L0MW] (2ND CLUTCH: SLIPPING (MW))...................................................................................... 537 TM-9 FAILURE CODE [15M0MW] (3RD CLUTCH: SLIPPING (MW))...................................................................................... 538 TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: * SEE THE TABLE IN CONTENTS. (L1)).......................................................... 539 TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................... 540 TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))......................................................... 541 TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................. 542 TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))........................................................ 543 TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA)).................................................................. 544 TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))....................................................... 545 TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................. 546 TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))....................................................... 547 TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................. 548 TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))....................................................... 549 TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))................................................................. 550 TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: * SEE THE TABLE IN CONTENTS. (L1))................................................... 551 TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))............................................................. 552 TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: * SEE THE TABLE IN CONTENTS. (L1)).............................. 553 TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))....................................... 554 TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))........................................................... 555 TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))................................................... 556 TM-28 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))...................................................... 558 TM-29 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))................................. 559 TM-30 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))........................................................................... 560 TM-31 FAILURE CODE [AA10NX] (AIR CLEANER ELEMENT: CLOGGED (NX))............................................................................. 562 TM-32 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA)).......................................................................... 564 TM-33 FAILURE CODE [B@BCZK] (RADIATOR COOLANT: DROP IN LEVEL (ZK)).......................................................................... 565 TM-34 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))........................................................................ 566 TM-35 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (NS))................................................................................... 567 TM-36 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ)).................................................. 568 TM-37 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))................................. 570 TM-38 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................. 572 TM-39 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: * SEE THE TABLE IN CONTENTS. (L4))............................................... 573 TM-40 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))........................................................... 575 TM-41 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............................................. 576 TM-42 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...................... 578 TM-43 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...................... 579 TM-44 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))............ 580 TM-45 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))................................... 581 TM-46 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))........................... 582 TM-47 FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KQ)).............................. 583 TM-48 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KQ))............................... 584 TM-49 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA).............................................................. 584 TM-50 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))...................................... 585 TM-51 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))........................................................... 586 TM-52 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))................................................................. 587 TM-53 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))................................................................. 588 TM-54 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))................................................................ 589 TM-55 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))................................................................ 590 TM-56 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))................................................................ 591 TM-57 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA)).................................................................. 592 TM-58 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))........................................................................... 593 TM-59 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))........................................................................... 595 TM-60 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))................................... 597 TM-61 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): * SEE THE TABLE IN CONTENTS. (L8))..................................... 599 TM-62 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): * SEE THE TABLE IN CONTENTS. (L8))...................................... 601 TM-63 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...................................... 603 TM-64 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))......................................... 605 TM-65 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: * SEE THE TABLE IN CONTENTS. (L6))....................................... 607 TM-66 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (KA))......................................................................... 608 TM-67 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSID ERANGE (KX))....................................................... 609 TM-68 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))....................................................................... 611 TM-69 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: * SEE THE TABLE IN CONTENTS. (LC))........................................................ 612 TM-70 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))..................................................... 613 TM-71 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: * SEE THE TABLE IN CONTENTS. (LC))...................................... 614 TM-72 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION (KA)).............................................. 615 TM-73 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEEDSENSOR: * SEE THE TABLE IN CONTENTS. (LC))................................ 616 TM-74 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA)).................................................. 617 TM-75 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. (LC)).................................. 618 TM-76 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))................................................ 620 TM-77 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))................................................ 621 TM-78 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))............................................................... 622 TM-79 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))............................................................... 623 TM-80 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA)).................................................................... 624 TM-81 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB)).................................................................... 625 TM-82 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA)).................................................................... 626 TM-83 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB)).................................................................... 627 TM-84 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))................................................................... 628 TM-85 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))................................................................... 629 TM-86 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))................................................................... 630 TM-87 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))................................................................... 631 TM-88 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))................................................................... 632 TM-89 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))................................................................... 633 TM-90 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))..................................................................... 634 TM-91 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))..................................................................... 635 TM-92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY....................................................................................... 636 TM-93 EMERGENCY STEERING DOES NOT OPERATE................................................................................................... 639 TROUBLESHOOTING OF RETARDER CONTROLLER(q1) SYSTEM (BK MODE)......................................................................................... 643 BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...................................................................................................... 646 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE.................................................................... 658 BK-1 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))................................................................. 670 BK-2 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)).................................................................. 670 BK-3 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))........................................................... 671 BK-4 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ)).......................................................... 673 BK-5 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ)).......................................................... 674 BK-6 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)).................................................. 675 BK-7 FAILURE CODE [DB11KK] (RETARDER CONTROLLER(q1) MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))....................... 677 BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER(q1) LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))....................... 678 BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER(q1) BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))............. 679 BK-10 FAILURE CODE [DB19KM] (RETARDER CONTROLLER(q1) WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))........................... 680 BK-11 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER(q1) S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))...................................... 681 BK-12 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))...................................... 682 BK-13 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))....................................... 684 BK-14 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: * SEE SEPARATE TABLE (L5))....................................................... 686 BK-15 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))................................................... 689 BK-16 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: * SEE THE TABLE IN CONTENTS. (L8))................................................. 691 BK-17 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))....................................................... 692 BK-18 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA)).................................................. 694 BK-19 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA)).................................................. 695 BK-20 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (Machine with exhaust brake)...................... 696 BK-21 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................. 697 BK-22 FAILURE CODE [DW73KZ] (DUMP SELECTOR VALVE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))............................................. 699 BK-23 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))............................................... 703 BK-24 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))............................................... 704 BK-25 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)).......................... 705 BK-26 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVESOLENOID: DISCONNECTION (KA))............................................... 706 BK-27 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB)).............................................. 707 BK-28 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))......................... 708 BK-29 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))................................................................... 709 BK-30 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))................................................................... 712 BK-31 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY)).............................................. 715 BK-32 PARKING BRAKE DOES NOT WORK PROPERLY.................................................................................................. 718 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)................................................................................................ 721 MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM..................................................................................................... 722 CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE.................................................................... 726 MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))................................................................................ 730 MON-2 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))............................................................................... 730 MON-3 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))............................................................................... 730 MON-4 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))................................................... 731 MON-5 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))................................................... 732 MON-6 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))...................................................... 733 MON-7 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).... 734 MON-8 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER(q1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).... 736 MON-9 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR)).......... 738 MON-10 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))............................................................................. 740 MON-11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY.................................................................. 741 MON-12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED...................................................................... 742 MON-13 ALARM BUZZER DOES NOT SOUND.......................................................................................................... 743 MON-14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY.............................................. 744 MON-15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY...................................................................... 745 MON-16 Character display cannot be switched properly........................................................................................ 746 MON-17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY.................................................................................. 749 MON-18 AISS FUNCTION DOES NOT WORK PROPERLY................................................................................................. 750 MON-19 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE).......................................................... 751 MON-20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY................................................................................. 753 MON-21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY................................................................................... 755 MON-22 NIGHT LIGHTING IS NOT NORMAL......................................................................................................... 760 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)............................................................................................ 767 H-1 MACHINE DOES NOT START...................................................................................................................... 768 H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)............................................................................................ 769 H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)......................................................................................... 769 H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING................................................................................................... 770 H-5 Transmission does not shift up.............................................................................................................. 771 H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING................................................................................................. 772 H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR........................................................................................ 775 H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.................................................................................................... 776 H-9 TORQUE CONVERTER OIL PRESSURE IS LOW........................................................................................................ 777 H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE.................................................................................. 778 H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE................................................................................. 779 H-12 STEERING WHEEL IS HEAVY.................................................................................................................... 780 H-13 STEERING WHEEL DOES NOT WORK............................................................................................................... 781 H-14 STEERING WHEEL VIBRATES.................................................................................................................... 782 H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER............................................................................................ 783 H-16 DUMP DOES NOT WORK......................................................................................................................... 784 H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY..................................................................................................... 785 TROUBLESHOOTING OF THE ENGINE BODY (S MODE)......................................................................................................... 787 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................... 788 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................... 789 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................................................... 793 S-2 ENGINE DOES NOT START....................................................................................................................... 794 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)........................................................................................ 797 S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................................. 798 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................................... 799 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................................................ 800 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).............................................................................................. 801 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)..................................................................................... 802 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................ 803 S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................................................. 804 S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)..................................................................... 805 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................................................. 806 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....................................................................................................... 807 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................................................... 808 S-15 ABNORMAL NOISE IS MADE..................................................................................................................... 809 S-16 VIBRATION IS EXCESSIVE..................................................................................................................... 810 30 DISASSEMBLY AND ASSEMBLY............................................................................................................................. 811 HOW TO READ THIS MANUAL............................................................................................................................. 813 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................. 815 SPECIAL TOOL LIST................................................................................................................................... 817 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY............................................................................................... 821 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.................................................................................................. 826 REMOVAL AND INSTALLATION OF NOZZLE TIP.............................................................................................................. 830 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.................................................................................................. 833 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY........................................................................................................ 841 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...................................................................................................... 846 REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY.................................................................................................. 849 ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY.................................................................................................. 854 REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY........................................................................... 857 CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY............................................................... 864 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY............................................................................................... 866 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY................................................................................................... 875 DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY............................................................................................ 921 REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY........................................................................................... 936 DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY........................................................................................... 940 REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY.............................................................................................. 960 DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY.............................................................................................. 962 REMOVAL AND INSTALLATION OF FRONT FINALDRIVE AND BRAKE ASSEMBLY..................................................................................... 977 DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY.................................................................................... 979 REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY................................................................................... 993 DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY................................................................................... 995 DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY...............................................................................................1006 REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY...................................................................................................1014 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY......................................................................................................1016 REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY.....................................................................................1019 INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY......................................................................................1021 DISASSEMBLY AND ASSEMBLY OF FRONT AND REAR SUSPENSION CYLINDER ASSEMBLY.............................................................................1022 REMOVAL AND INSTALLATION OF EQUALIZER BAR...........................................................................................................1024 REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY....................................................................................................1026 DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY....................................................................................................1036 DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY.................................................................................................1043 REMOVAL AND INSTALLATION OF FLOW AMP VALVE..........................................................................................................1053 REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY....................................................................................................1055 DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY..............................................................................................1058 DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY.................................................................................................1061 REMOVAL AND INSTALLATION OF BODY ASSEMBLY...........................................................................................................1065 DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY................................................................................................1068 90 OTHERS..............................................................................................................................................1079 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...............................................................................................................1080 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM........................................................................................................1081 BRAKE HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................................1083 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM.............................................................................................................1085 BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM (- 30°C SPECIFICATION)......................................................................................1087 DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER......................................................................................................1089 DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB...........................................................................................................1091 DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB..........................................................................................................1107 DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER.........................................................................................1113 DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR........................................................................................................1114
DESCRIPTION:
KOMATSU HM300-1 SHOP MANUAL SEBM024817 – PDF DOWNLOAD
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.
S.S 28/12/24
