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Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200 – PDF DOWNLOAD
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Komatsu HM300-1L Articulated Truck Shop Manual
SERIAL NUMBERS:
WA250-5L A73001 and up
WA250PT-5L A79001 and up
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Description
Komatsu HM300-1L Articulated Truck Shop Manual CEBM015200
FILE DETAILS:
Komatsu HM300-1L Articulated Truck Shop Manual
Brands: Komatsu
Equipment Type: Articulated Truck
Manuals Type: Shop Manual
Machine Model: HM300-1L
Serial Number: A73001, A739001 and up
Book Code: CEBM015200
Language: English
Pages: 1236
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu HM300-1L Articulated Truck Shop Manual
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 sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
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.
TESTING, ADJUSTING AND TROUBLESHOOTING:
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 to Causes are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu HM300-1L Articulated Truck Shop Manual
COVER............................................................................................................................... 1 FOREWORD............................................................................................................................ 2 SAFETY.......................................................................................................................... 3 SAFETY NOTICE............................................................................................................... 3 IMPORTANT SAFETY NOTICE................................................................................................. 3 GENERAL PRECAUTIONS..................................................................................................... 3 PREPARATIONS FOR WORK................................................................................................... 3 PRECAUTIONS DURING WORK................................................................................................. 3 CONTENTS........................................................................................................................ 2 GENERAL......................................................................................................................... 5 GENERAL..................................................................................................................... 5 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................ 5 TESTING, ADJUSTING AND TROUBLESHOOTING...................................................................................... 5 DISASSEMBLY AND ASSEMBLY.................................................................................................... 5 DRAWINGS AND SCHEMATICS..................................................................................................... 5 HOW TO READ THE SHOP MANUAL..................................................................................................... 6 Volumes..................................................................................................................... 6 Distribution And Updating................................................................................................... 6 Filing Method............................................................................................................... 6 Revised Edition Mark........................................................................................................ 6 Revisions................................................................................................................... 6 Symbols..................................................................................................................... 6 HOISTING INSTRUCTIONS........................................................................................................... 7 HOISTING.................................................................................................................... 7 Wire Ropes.................................................................................................................. 7 PUSH PULL COUPLER............................................................................................................... 8 Type 1...................................................................................................................... 8 Disconnection........................................................................................................... 8 Connection.............................................................................................................. 8 Type 2...................................................................................................................... 9 Disconnection........................................................................................................... 9 Connection.............................................................................................................. 9 Type 3...................................................................................................................... 10 Disconnection........................................................................................................... 10 Connection.............................................................................................................. 10 COATING MATERIALS............................................................................................................... 11 STANDARD TIGHTENING TORQUE...................................................................................................... 13 Torque For Bolts And Nuts................................................................................................... 13 Torque For Hose Nuts........................................................................................................ 14 Torque For Split Flange Bolts............................................................................................... 14 Torque For Flared Nuts...................................................................................................... 14 Torques For O-ring Boss Piping Joints....................................................................................... 15 Tightening Torques For O-ring Boss Plugs.................................................................................... 15 Torque Table For Hoses (Taper Seal Type And Face Seal Type)................................................................. 15 ELECTRIC WIRE CODE.............................................................................................................. 16 Classification By Thickness................................................................................................. 16 Classification By Color And Code............................................................................................ 16 CONVERSION TABLES............................................................................................................... 17 Method Of Using The Conversion Table........................................................................................ 17 01 GENERAL.......................................................................................................................... 23 SPECIFICATION DRAWING........................................................................................................... 24 SPECIFICATIONS.................................................................................................................. 25 WEIGHT TABLE.................................................................................................................... 28 FUEL, COOLANT AND LUBRICANTS.................................................................................................... 29 ENGINE OIL SPECIFICATIONS................................................................................................... 30 NORMAL OPERATION........................................................................................................ 30 ARCTIC OPERATION........................................................................................................ 30 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.... 31 FINAL DRIVE OIL SPECIFICATIONS.......................................................................................... 31 DRIVE AXLE OIL SPECIFICATIONS........................................................................................... 31 DIESEL FUEL SPECIFICATIONS.................................................................................................. 31 COOLANT SPECIFICATIONS...................................................................................................... 32 GENERAL................................................................................................................. 32 WATER................................................................................................................... 32 ANTIFREEZE.............................................................................................................. 32 SUPPLEMENTAL COOLANT ADDITIVES.......................................................................................... 34 COOLING SYSTEM TEST KIT................................................................................................. 38 10 STRUCTURE AND FUNCTION........................................................................................................... 39 COOLING SYSTEMS................................................................................................................. 42 POWER TRAIN..................................................................................................................... 43 DRIVE SYSTEM................................................................................................................ 43 OUTPUT SHAFT.................................................................................................................... 45 TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING.............................................................................. 47 TORQUE CONVERTER................................................................................................................ 48 TRANSMISSION POWER FLOW......................................................................................................... 52 WHEN LOCK-UP CLUTCH IS DISENGAGED........................................................................................... 52 WHEN LOCK-UP CLUTCH IS ENGAGED.............................................................................................. 52 OIL FLOW.................................................................................................................... 53 TRANSMISSION.................................................................................................................... 54 FL - R CLUTCH............................................................................................................... 59 FH - 1ST CLUTCH............................................................................................................. 60 2ND - 3RD CLUTCH............................................................................................................ 61 DIFFERENTIAL LOCK........................................................................................................... 62 CLUTCH AND TRANSMISSION OPERATIONS.............................................................................................. 64 FORWARD 1ST................................................................................................................. 65 FORWARD 2ND................................................................................................................. 66 FORWARD 3RD................................................................................................................. 67 FORWARD 4TH................................................................................................................. 68 FORWARD 5TH................................................................................................................. 69 FORWARD 6TH................................................................................................................. 70 REVERSE 1ST................................................................................................................. 71 TRANSMISSION VALVE.............................................................................................................. 72 ECMV (ELECTRONIC CONTROL MODULATION VALVE)...................................................................................... 73 ECMV LOCK-UP CLUTCH......................................................................................................... 74 DURING DIRECT TRAVEL........................................................................................................ 75 FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL........................................................................... 75 ECMV SPEED CLUTCH........................................................................................................... 76 ECMV OUTLINE............................................................................................................ 76 ECMV AND PROPORTIONAL SOLENOID.......................................................................................... 76 ECMV AND FILL SWITCH.................................................................................................... 76 ECMV OPERATION.......................................................................................................... 77 ECMV FOR DIFFERENTIAL LOCK.................................................................................................. 79 MAIN AND TORQUE CONVERTER RELIEF VALVE.......................................................................................... 80 TORQUE CONVERTER RELIEF VALVE............................................................................................... 81 MAIN RELIEF VALVE........................................................................................................... 81 DRIVE SHAFT..................................................................................................................... 82 DRIVE AXLE...................................................................................................................... 83 FRONT....................................................................................................................... 83 CENTER...................................................................................................................... 84 REAR........................................................................................................................ 85 LOCKING DIFFERENTIAL............................................................................................................ 86 FRONT....................................................................................................................... 86 CENTER...................................................................................................................... 88 REAR........................................................................................................................ 90 LIMITED SLIP DIFFERENTIAL....................................................................................................... 92 FINAL DRIVE SYSTEM.............................................................................................................. 96 FRONT....................................................................................................................... 96 CENTER...................................................................................................................... 98 REAR........................................................................................................................ 100 STEERING COLUMN................................................................................................................. 102 WHEEL BRAKING SYSTEM............................................................................................................ 103 PIPING DIAGRAM.............................................................................................................. 103 BRAKE VALVE................................................................................................................. 105 ACCUMULATOR CHARGE VALVE.................................................................................................... 108 ACCUMULATOR................................................................................................................. 112 SLACK ADJUSTER.............................................................................................................. 113 FRONT BRAKE................................................................................................................. 115 CENTER, REAR BRAKE.......................................................................................................... 117 PROPORTIONAL REDUCING VALVE................................................................................................. 120 BRAKE SYSTEM TANK........................................................................................................... 121 PARKING BRAKE................................................................................................................... 122 PARKING BRAKE CALIPER....................................................................................................... 124 SPRING CYLINDER............................................................................................................. 125 PARKING BRAKE SOLENOID...................................................................................................... 126 SUSPENSION SYSTEM............................................................................................................... 128 FRONT....................................................................................................................... 128 REAR........................................................................................................................ 130 SUSPENSION CYLINDER......................................................................................................... 134 OSCILLATION HITCH JOINT......................................................................................................... 136 STEERING, HOIST OIL PIPING DIAGRAM.............................................................................................. 139 DUMP BODY CONTROL............................................................................................................... 140 HYDRAULIC TANK AND FILTER....................................................................................................... 141 FLOW AMPLIFIER VALVE............................................................................................................ 142 STEERING VALVE.................................................................................................................. 145 HAND PUMP AND SLEEVE CONNECTION............................................................................................. 147 FUNCTION OF CENTER SPRING................................................................................................... 148 STEERING CYLINDER............................................................................................................... 149 HOIST VALVE..................................................................................................................... 150 HOIST VALVE AT HOLD POSITION................................................................................................ 152 HOIST VALVE AT RAISE POSITION............................................................................................... 153 HOIST VALVE AT FLOAT POSITION............................................................................................... 154 HOIST VALVE AT LOWER POSITION............................................................................................... 155 EPC VALVE....................................................................................................................... 156 PILOT CHECK VALVE............................................................................................................... 157 HOIST CYLINDER.................................................................................................................. 158 HYDRAULIC PUMP.................................................................................................................. 159 STEERING, HOIST + PILOT PUMP................................................................................................ 159 TRANSMISSION + FRONT BRAKE COOLING PUMP..................................................................................... 160 BRAKE COOLING + BRAKE PUMP.................................................................................................. 161 AUXILIARY STEERING PUMP..................................................................................................... 162 CAB TILT SYSTEM VIEW............................................................................................................ 163 AIR CONDITIONING SYSTEM VIEW.................................................................................................... 164 AIR CONDITIONER UNIT........................................................................................................ 165 RECEIVER DRYER.............................................................................................................. 166 CONDENSER................................................................................................................... 167 REFRIGERANT COMPRESSOR...................................................................................................... 168 MACHINE MONITOR SYSTEM.......................................................................................................... 169 NETWORK DATA................................................................................................................ 169 MACHINE MONITOR PANEL....................................................................................................... 172 OPTION SETTING CONNECTOR DIAGRAM............................................................................................ 174 ADJUSTING MACHINE MONITOR................................................................................................... 174 MACHINE MONITOR NORMAL DISPLAY FUNCTIONS.................................................................................... 175 SELF-DIAGNOSTIC FUNCTION WHEN OPERATING IGNITION SWITCH................................................................. 178 CHECK FUNCTION OF MONITOR LAMPS AND METERS.................................................................................. 179 SERVICE METER DISPLAY....................................................................................................... 179 ODOMETER.................................................................................................................... 179 SERVICE MODE................................................................................................................ 179 OPERATION METHOD............................................................................................................ 181 AUTOMATIC SHIFT CONTROL SYSTEM.................................................................................................. 182 TRANSMISSION CONTROLLER......................................................................................................... 184 SHIFT LEVER POSITION AND AUTOMATIC GEAR SHIFTING RANGE...................................................................... 187 GEAR SHIFTING CHARACTERISTICS........................................................................................... 187 AUTOMATIC GEAR SHIFTING GRAPH............................................................................................... 188 GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD........................................................................... 189 SHIFT HOLD FUNCTION..................................................................................................... 190 GEAR SHIFTING TIME DELAY................................................................................................ 190 SAFETY FUNCTIONS........................................................................................................ 190 SELF-DIAGNOSTIC FUNCTION................................................................................................ 191 EMERGENCY STEERING SYSTEM....................................................................................................... 192 SENSORS AND SWITCHES............................................................................................................ 193 ENGINE SPEED SENSOR......................................................................................................... 193 ACCELERATOR PEDAL SENSOR.................................................................................................... 193 ENGINE COOLANT / COOLING OIL TEMPERATURE SENSORS............................................................................ 195 STEERING OIL TEMPERATURE SENSOR............................................................................................. 195 FUEL LEVEL SENSOR........................................................................................................... 196 TILT SENSOR................................................................................................................. 197 AIR CLEANER CLOGGING SENSOR................................................................................................. 198 HYDRAULIC OIL LEVEL SENSOR.................................................................................................. 199 BODY POSITIONER SENSOR...................................................................................................... 200 RETARDER CONTROL SYSTEM......................................................................................................... 201 RETARDER CONTROLLER UNIT.................................................................................................... 202 RETARDER CONTROL FUNCTION................................................................................................... 206 HOIST CONTROL FUNCTION...................................................................................................... 208 DIFFERENTIAL LOCK CONTROL FUNCTION.......................................................................................... 210 BRAKE CONTROL SYSTEM (E-SPEC)................................................................................................... 212 BRAKE CONTROLLER (E-SPEC) UNIT.............................................................................................. 213 BRAKE CONTROL FUNCTION...................................................................................................... 217 HOIST CONTROL SYSTEM........................................................................................................ 218 DIFFERENTIAL LOCK CONTROL SYSTEM............................................................................................ 220 DUMP CONTROL LEVER.............................................................................................................. 222 20 TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................................... 227 STANDARD VALUE TABLE FOR ENGINE................................................................................................. 229 STANDARD VALUE TABLE FOR CHASSIS................................................................................................ 230 STANDARD VALUE TABLE FOR ELECTRICAL COMPONENTS.................................................................................. 234 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 248 ENGINE COMPONENTS............................................................................................................... 249 MEASURING EXHAUST SMOKE..................................................................................................... 249 MEASURING EXHAUST TEMPERATURE............................................................................................... 249 ADJUSTING VALVE CLEARANCE................................................................................................... 249 MEASURING COMPRESSION PRESSURE.............................................................................................. 249 MEASURING CRANKCASE PRESSURE................................................................................................ 249 MEASURING ENGINE OIL PRESSURE............................................................................................... 249 MEASURING BOOST PRESSURE.................................................................................................... 249 MEASURING FUEL PRESSURE..................................................................................................... 249 BLEEDING AIR FROM FUEL SYSTEM............................................................................................... 249 ADJUSTING ENGINE SPEED SENSOR................................................................................................... 250 ADJUSTING ALTERNATOR BELT................................................................................................... 252 TESTING TORQUE CONVERTER STALL SPEED............................................................................................ 253 POWER TRAIN OIL PRESSURES....................................................................................................... 254 MEASURING POWER TRAIN MAIN RELIEF PRESSURE.................................................................................. 255 MEASURING TORQUE CONVERTER INLET OIL PRESSURE............................................................................... 255 MEASURING TORQUE CONVERTER OUTLET OIL PRESSURE.............................................................................. 255 MEASURING TORQUE CONVERTER LOCK-UP CLUTCH PRESSURE.......................................................................... 256 MEASURING TRANSMISSION LO CLUTCH PRESSURE................................................................................... 257 MEASURING TRANSMISSION HI CLUTCH PRESSURE................................................................................... 257 MEASURING TRANSMISSION 1ST CLUTCH PRESSURE.................................................................................. 257 MEASURING TRANSMISSION 2ND CLUTCH PRESSURE.................................................................................. 258 MEASURING TRANSMISSION 3RD CLUTCH PRESSURE.................................................................................. 258 MEASURING TRANSMISSION R CLUTCH PRESSURE.................................................................................... 259 MEASURING INTER-AXLE DIFFERENTIAL LOCK CLUTCH PRESSURE...................................................................... 259 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................. 260 BRAKE OIL PRESSURE.............................................................................................................. 262 MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 262 MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP........................................................................... 262 MEASURING ACTUATION PRESSURE ON PARKING BRAKE............................................................................... 263 MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID...................................................................... 264 ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE.......................................................................... 265 TESTING BRAKE PERFORMANCE....................................................................................................... 266 TESTING BRAKING PERFORMANCE OF FOOT BRAKE................................................................................... 266 TESTING BRAKING PERFORMANCE OF RETARDER BRAKE............................................................................... 266 TESTING PARKING BRAKE BRAKING PERFORMANCE................................................................................... 267 TESTING OVERRUN PROTECTION BRAKING PERFORMANCE.............................................................................. 267 BLEEDING AIR FROM BRAKE CIRCUIT................................................................................................. 268 BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE..................................................................... 268 BLEEDING AIR FROM WHEEL BRAKE............................................................................................... 269 BLEEDING AIR FROM PARKING BRAKE CIRCUIT..................................................................................... 269 CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD................................................................................. 270 CHECKING BRAKE DISC......................................................................................................... 270 CHECKING BRAKE PAD.......................................................................................................... 271 ADJUSTING PAD CLEARANCE..................................................................................................... 272 RELEASING EMERGENCY PARKING BRAKE............................................................................................... 273 STEERING CIRCUIT PRESSURE....................................................................................................... 273 MEASURING STEERING RELIEF OIL PRESSURE...................................................................................... 273 ADJUSTING STEERING RELIEF OIL PRESSURE...................................................................................... 274 SUSPENSION CYLINDER............................................................................................................. 275 CHECKING CYLINDER LENGTH.................................................................................................... 275 RELEASING NITROGEN GAS...................................................................................................... 275 ADJUSTING OIL LEVEL......................................................................................................... 276 CHARGING WITH NITROGEN GAS.................................................................................................. 277 ADJUSTING CYLINDER LENGTH................................................................................................... 278 TILTING THE CAB................................................................................................................. 279 PREPARATORY WORK............................................................................................................ 279 TILTING CAB UP.............................................................................................................. 279 USING EXTERNAL CRANE........................................................................................................ 280 HOLDING CAB IN POSITION..................................................................................................... 280 LOWERING CAB DOWN........................................................................................................... 280 DUMP CIRCUIT PRESSURE........................................................................................................... 281 TESTING DUMP MAIN RELIEF OIL PRESSURE....................................................................................... 281 ADJUSTING DUMP MAIN RELIEF OIL PRESSURE..................................................................................... 282 MEASURING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 282 ADJUSTING DUMP PILOT RELIEF OIL PRESSURE.................................................................................... 283 BODY POSITIONER SENSOR.......................................................................................................... 284 CHECKING SENSOR OUTPUT/INPUT VOLTAGE........................................................................................ 284 ADJUSTING LINK LENGTH....................................................................................................... 284 CALIBRATING SYSTEM.......................................................................................................... 285 HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT................................................................................. 286 TRANSMISSION CONTROLLER......................................................................................................... 287 SETTING ROTARY SWITCH....................................................................................................... 287 ADJUSTING TRANSMISSION...................................................................................................... 287 ESCAPE METHOD FOR ELECTRICAL SYSTEM............................................................................................. 288 MACHINE MONITOR................................................................................................................. 292 FUNCTIONS OF MACHINE MONITOR.................................................................................................... 296 NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR......................................................................... 296 FLOW OF MODES AND FUNCTIONs................................................................................................. 297 OPERATION AND DISPLAYS FOR OPERATOR MODE.................................................................................... 299 SWITCHING TO SERVICE MODE AND SCREEN DISPLAY................................................................................ 307 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................... 328 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 330 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....................................................................................... 331 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.............................................................................. 331 HANDLING ELECTRONIC CONTROL UNIT............................................................................................ 336 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS................................................................. 337 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT........................................................................ 338 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 340 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................... 341 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.............................................................................. 342 TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS............................................................................... 344 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................... 346 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................... 354 T-ADAPTER TABLE................................................................................................................. 379 CONNECTOR LAYOUT DRAWING........................................................................................................ 382 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 391 ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM........................................................................................... 397 CONTENT OF CODE DISPLAY (1)..................................................................................................... 400 CONTENT OF CODE DISPLAY (2)..................................................................................................... 402 CONTENT OF CODE DISPLAY (3)..................................................................................................... 404 CONTENT OF CODE DISPLAY (4)..................................................................................................... 406 CONTENT OF CODE DISPLAY (5)..................................................................................................... 408 CONTENT OF CODE DISPLAY (6)..................................................................................................... 410 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 412 (ENG-1) FAILURE CODE [A000N1]................................................................................................... 414 ENGINE OVERSPEEDS (N1)...................................................................................................... 414 (ENG-2) FAILURE CODE [A570NX]................................................................................................... 415 ENGINE OIL FILTER CLOG SENSOR SYSTEM........................................................................................ 415 (ENG-3) FAILURE CODE [AD00L2]................................................................................................... 416 COMMON RAIL HIGHER THAN SET VALUE........................................................................................... 416 (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3].................................................................................. 417 COMMON RAIL PRESSURE HIGH OR LOW............................................................................................ 417 (ENG-6) FAILURE CODE [AD10MA]............................................................................................... 419 (ENG-7) FAILURE CODE [AD10MB]............................................................................................... 419 (ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB].................................................................................. 420 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM............................................................................... 420 (ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB]................................................................................ 422 OPEN OR SHORT IN FUEL SUPPLY PUMP PVC2 SYSTEM............................................................................... 422 (ENG-12) FAILURE CODE [ADA1KA].................................................................................................. 423 OPEN IN NO. 1 INJECTOR SOLENOID VALVE....................................................................................... 423 (ENG-13) FAILURE CODE [ADZKKB].................................................................................................. 424 SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE........................................................................ 424 (ENG-14) FAILURE CODE [ADB1KA].................................................................................................. 428 OPEN IN NO. 2 INJECTOR SOLENOID VALVE....................................................................................... 428 (ENG-15) FAILURE CODE [ADC1KA].................................................................................................. 430 OPEN IN NO. 3 INJECTOR SOLENOID VALVE....................................................................................... 430 (ENG-16) FAILURE CODE [ADD1KA].................................................................................................. 432 OPEN IN NO. 4 INJECTOR SOLENOID VALVE....................................................................................... 432 (ENG-17) FAILURE CODE [ADDZKB].................................................................................................. 434 SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE........................................................................ 434 (ENG-18) FAILURE CODE [ADE1KA].................................................................................................. 438 OPEN IN NO. 5 INJECTOR SOLENOID VALVE....................................................................................... 438 (ENG-19) FAILURE CODE [ADF1KA].................................................................................................. 440 OPEN IN NO. 6 INJECTOR SOLENOID VALVE....................................................................................... 440 (ENG-20) FAILURE CODE [B@BAZG].................................................................................................. 442 ENGINE OIL PRESSURE DROP (ZG)............................................................................................... 442 (ENG-21) FAILURE CODE [B@BAZK].................................................................................................. 444 ENGINE OIL LEVEL DROP (ZK).................................................................................................. 444 (ENG-22) FAILURE CODE [B@BCNS].................................................................................................. 446 COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)....................................................................... 446 (ENG-23) FAILURE CODE [D181KZ].................................................................................................. 448 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)........................................................................ 448 (ENG-24) FAILURE CODE [D182KZ].................................................................................................. 450 OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)........................................................................ 450 (ENG-25) FAILURE CODE [D1D0KB].................................................................................................. 452 SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)............................................................................. 452 (ENG-26) FAILURE CODE [D5ZAKX].................................................................................................. 454 ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX).............................................................................. 454 (ENG-27) FAILURE CODE [DB20KT].................................................................................................. 456 CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW................................................................................. 456 (ENG-28) FAILURE CODE [DB22KK].................................................................................................. 458 DROP IN VOLTAGE LOAD POWER SUPPLY (KK)...................................................................................... 458 (ENG-29) FAILURE CODE [DB29KQ].................................................................................................. 460 NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING HARNESS (KQ).......................................... 460 (ENG-30) FAILURE CODE [DB2AMA].................................................................................................. 462 “Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA).................................................................. 462 (ENG-31) FAILURE CODE [KK11KB].................................................................................................. 463 TROUBLE IN INPUT OF ignition switch C (KB).................................................................................. 463 (ENG-32) FAILURE CODE [DDA1L5].................................................................................................. 464 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)....................................................................... 464 (ENG-33) FAILURE CODE [DDE2L6].................................................................................................. 466 ENGINE OIL PRESSURE DROP (L6)............................................................................................... 466 (ENG-34) FAILURE CODE [DGE2KX].................................................................................................. 468 COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)......................................................................... 468 (ENG-35) FAILURE CODE [DGE3LC].................................................................................................. 469 COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6).......................................................................... 469 (ENG-36) FAILURE CODE [DGE4KX].................................................................................................. 470 TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX).............................................................................. 470 (ENG-37) FAILURE CODE [DH30KX].................................................................................................. 471 TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)................................................................................ 471 (ENG-38) FAILURE CODE [DH40KX].................................................................................................. 472 TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)..................................................................... 472 (ENG-39) FAILURE CODE [DK10KX].................................................................................................. 474 TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)....................................................................... 474 (ENG-40) FAILURE CODE [DLE3LC].................................................................................................. 476 TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM.................................................................................... 476 (ENG-41) FAILURE CODE [DLE1LC].................................................................................................. 477 TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)................................................................................ 477 (ENG-42) NO FAILURE CODE DISPLAYED.............................................................................................. 478 ENGINE DOES NOT CRANK....................................................................................................... 478 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 486 TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM.......................................................................................... 492 CONTENT OF CODE DISPLAY (1)..................................................................................................... 498 CONTENT OF CODE DISPLAY (2)..................................................................................................... 500 CONTENT OF CODE DISPLAY (3)..................................................................................................... 502 CONTENT OF CODE DISPLAY (4)..................................................................................................... 504 CONTENT OF CODE DISPLAY (5)..................................................................................................... 506 CONTENT OF CODE DISPLAY (6)..................................................................................................... 508 CONTENT OF CODE DISPLAY (7)..................................................................................................... 510 CONTENT OF CODE DISPLAY (8)..................................................................................................... 512 CONTENT OF CODE DISPLAY (9)..................................................................................................... 514 CONTENT OF CODE DISPLAY (10).................................................................................................... 516 CONTENT OF CODE DISPLAY (11).................................................................................................... 518 CONTENT OF CODE DISPLAY (12).................................................................................................... 520 CONTENT OF CODE DISPLAY (13).................................................................................................... 522 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 524 (TM-1) FAILURE CODE [1380MW].................................................................................................... 526 LOCK-UP CLUTCH SLIPPING (MW)................................................................................................ 526 (TM-2) FAILURE CODE [1500LO].................................................................................................... 528 TRANSMISSION CLUTCH (LO).................................................................................................... 528 (TM-3) FAILURE CODE [15BONX].................................................................................................... 530 TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)................................................................. 530 (TM-4) FAILURE CODE [15GOMW].................................................................................................... 532 “R” CLUTCH SLIPPING (MW).................................................................................................... 532 (TM-5) FAILURE CODE [15HOMW].................................................................................................... 534 “HI” CLUTCH SLIPPING (MW)................................................................................................... 534 (TM-6) FAILURE CODE [15JOMW].................................................................................................... 536 “LO” CLUTCH SLIPPING (MW)................................................................................................... 536 (TM-7) FAILURE CODE [15KOMW].................................................................................................... 538 1ST CLUTCH SLIPPING (MW).................................................................................................... 538 (TM-8) FAILURE CODE [15LOMW].................................................................................................... 540 2ND CLUTCH SLIPPING (MW).................................................................................................... 540 (TM-9) FAILURE CODE [15MOMW].................................................................................................... 542 3RD CLUTCH SLIPPING (MW).................................................................................................... 542 (TM-10) FAILURE CODE [15SBL1]................................................................................................... 544 ECMV FOR “R” CLUTCH NOT DISENGAGING (L1).................................................................................... 544 (TM-11) FAILURE CODE [15SBMA]................................................................................................... 546 ECMV FOR “R” CLUTCH NOT ENGAGING (MA)....................................................................................... 546 (TM-12) FAILURE CODE [15SCL1]................................................................................................... 548 ECMV “HI” CLUTCH NOT DISENGAGING (L1)....................................................................................... 548 (TM-13) FAILURE CODE [15SCMA]................................................................................................... 550 ECMV “HI” CLUTCH NOT DISENGAGING (MA)....................................................................................... 550 (TM-14) FAILURE CODE [15SDL1]................................................................................................... 552 ECMV “LO” CLUTCH NOT DISENGAGING (L1)....................................................................................... 552 (TM-15) FAILURE CODE [15SDMA]................................................................................................... 554 ECMV “LO” CLUTCH NOT ENGAGING (MA).......................................................................................... 554 (TM-16) FAILURE CODE [15SEL1]................................................................................................... 556 ECMV “1ST” CLUTCH NOT DISENGAGING (L1)...................................................................................... 556 (TM-17) FAILURE CODE [15SEMA]................................................................................................... 558 ECMV “1ST” CLUTCH NOT ENGAGING (MA)......................................................................................... 558 (TM-18) FAILURE CODE [15SFL1]................................................................................................... 560 ECMV “2ND” CLUTCH NOT DISENGAGING (L1)...................................................................................... 560 (TM-19) FAILURE CODE [15SFMA]................................................................................................... 562 ECMV “2ND” CLUTCH NOT ENGAGING (MA)......................................................................................... 562 (TM-20) FAILURE CODE [15SGL1]................................................................................................... 564 ECMV “3RD” CLUTCH NOT DISENGAGING (L1)...................................................................................... 564 (TM-21) FAILURE CODE [15SGMA]................................................................................................... 566 ECMV “3RD” CLUTCH NOT ENGAGING (MA)......................................................................................... 566 (TM-22) FAILURE CODE [15SJL1]................................................................................................... 568 ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1).................................................................................. 568 (TM-23) FAILURE CODE [15SJMA]................................................................................................... 570 ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA)..................................................................................... 570 (TM-24) FAILURE CODE [15SKL1]................................................................................................... 572 ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1)............................................................................... 572 (TM-25) FAILURE CODE [15SKMA]................................................................................................... 574 ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA).................................................................................. 574 (TM-26) FAILURE CODE [2B61MW]................................................................................................... 576 ECMV “INTER-AXLE” CLUTCH SLIPPING (MW)...................................................................................... 576 (TM-27) FAILURE CODE [2F00KM]................................................................................................... 578 PARKING BRAKE SYSTEM INDICATING FAILURE (KM)................................................................................ 578 (TM-28) FAILURE CODE [6014NX]................................................................................................... 580 HYDRAULIC TANK FILTER CLOGGED (NX).......................................................................................... 580 (TM-29) FAILURE CODE [989A00]................................................................................................... 582 POSSIBLE ENGINE OVER SPEED CONDITION (00)................................................................................... 582 (TM-30) FAILURE CODE [989AKZ]................................................................................................... 584 OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ)...................................................................... 584 (TM-31)FAILURE CODE [989D00].................................................................................................... 586 REAR OVERTURN SIGNAL OUT OF RANGE (00)...................................................................................... 586 (TM-32)FAILURE CODE [AA10NX].................................................................................................... 588 AIR CLEANER CLOG INDICATION (NX)............................................................................................ 588 (TM-33) FAILURE CODE [AB00MA]................................................................................................... 590 ALTERNATOR NOT CHARGING PROPERLY (MA)....................................................................................... 590 (TM-34) FAILURE CODE [B@BCZK]................................................................................................... 592 COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)......................................................................... 592 (TM-35) FAILURE CODE [B@HAZK]................................................................................................... 594 LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)................................................................................. 594 (TM-36) FAILURE CODE [B@JANS]................................................................................................... 595 STEERING OIL OVERHEAT CONDITION INDICATED (ZK).............................................................................. 595 (TM-37) FAILURE CODE [D1B0KZ]................................................................................................... 596 POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)................................................................ 596 (TM-38) FAILURE CODE [D5ZBKX]................................................................................................... 598 DIFFERENTIAL LOCK CIRCUIT SIGNAL INCORRECT (KX)............................................................................. 598 (TM-39) FAILURE CODE [D5ZCKZ]................................................................................................... 600 OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ).......................................................................... 600 (TM-40) FAILURE CODE [DF10KA]................................................................................................... 602 FORCED NEUTRAL DEMAND SIGNAL (L4)........................................................................................... 602 (TM-41) FAILURE CODE [D5ZEKX]................................................................................................... 604 ENGINE LOAD SIGNAL OUT OF RANGE (KX)........................................................................................ 604 (TM-42) FAILURE CODE [DAQ0KK]................................................................................................... 606 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 606 (TM-43) FAILURE CODE [DAQ1KK]................................................................................................... 608 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 608 (TM-44) FAILURE CODE [DAQ2KK]................................................................................................... 610 POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK).................................................................. 610 (TM-45) FAILURE CODE [DAQ3KK]................................................................................................... 612 TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)........................................................................... 612 (TM-46) FAILURE CODE [DAQ5KP]................................................................................................... 614 TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)............................................................................ 614 (TM-47) FAILURE CODE [DAQ9KM]................................................................................................... 616 MISTAKEN OPERATION SETTING (KP)............................................................................................. 616 (TM-48) FAILURE CODE [DAQ9KM]................................................................................................... 617 NO MATCH IN MODEL SELECTION SIGNAL (KP)..................................................................................... 617 (TM-49) FAILURE CODE [DAQAKQ]................................................................................................... 618 TRANSMISSION CONTROLLER ROTARY SWITCH....................................................................................... 618 (TM-50) FAILURE CODE [DAQSMA]................................................................................................... 618 TRANSMISSION FUNCTION INOPERABLE............................................................................................ 618 (TM-51) FAILURE CODE [DDTFKA]................................................................................................... 620 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA).................................................................... 620 (TM-52) FAILURE CODE [DDTFKA]................................................................................................... 622 “LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA).................................................................... 622 (TM-53) FAILURE CODE [DDTHKA]................................................................................................... 624 “HI” CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 624 (TM-54) FAILURE CODE [DDTJKA]................................................................................................... 626 “LO” CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 626 (TM-55) FAILURE CODE [DDTKKA]................................................................................................... 628 1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 628 (TM-56) FAILURE CODE [DDTLKA]................................................................................................... 630 2ND CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 630 (TM-57) FAILURE CODE [DDTMKA]................................................................................................... 632 3RD CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 632 (TM-58) FAILURE CODE [DDTNKA]................................................................................................... 634 “R” CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 634 (TM-59) FAILURE CODE [DF10KA]................................................................................................... 636 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)...................................................................... 636 (TM-60) FAILURE CODE [DF10KB]................................................................................................... 638 POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)...................................................................... 638 (TM-61) FAILURE CODE [DGF1KX]................................................................................................... 640 TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)....................................................................... 640 (TM-63) FAILURE CODE [DGR3L8]................................................................................................... 642 CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)....................................................................... 642 (TM-64) FAILURE CODE [DGR4L8]................................................................................................... 644 FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)........................................................................ 644 (TM-65) FAILURE CODE [DGT1LX]................................................................................................... 646 TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)....................................................................... 646 (TM-66) FAILURE CODE [DHT5KX]................................................................................................... 648 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX)...................................................................... 648 (TM-67) FAILURE CODE [DHT5L6]................................................................................................... 650 TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6)...................................................................... 650 (TM-68) FAILURE CODE [DJF1KA]................................................................................................... 652 FUEL LEVEL SENSOR OUT OF RANGE (L6)......................................................................................... 652 (TM-69) FAILURE CODE [DK11KX]................................................................................................... 654 THROTTLE ANGLE SENSOR OUT OF RANGE (KX)..................................................................................... 654 (TM-70) FAILURE CODE [DLE2KA]................................................................................................... 656 ENGINE SPEED SENSOR OPEN OR SHORTED (KA).................................................................................... 656 (TM-71) FAILURE CODE [DLE2LC]................................................................................................... 657 ENGINE SPEED SENSOR OPEN OR SHORTED (LC).................................................................................... 657 (TM-72) FAILURE CODE [DLF1KA]................................................................................................... 658 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA).................................................................. 658 (TM-73) FAILURE CODE [DLF1LC]................................................................................................... 659 TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC).................................................................. 659 (TM-74) FAILURE CODE [DLF2KA]................................................................................................... 660 TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA)........................................................... 660 (TM-75) FAILURE CODE [DLF2LC]................................................................................................... 661 TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC)........................................................... 661 (TM-76) FAILURE CODE [DLT3KA]................................................................................................... 662 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)................................................................. 662 (TM-77) FAILURE CODE [DLT3LC]................................................................................................... 664 TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)................................................................. 664 (TM-78) FAILURE CODE [DXH0KA]................................................................................................... 666 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA).................................................................... 666 (TM-79) FAILURE CODE [DXH0KB]................................................................................................... 668 INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB).................................................................... 668 (TM-80) FAILURE CODE [DXH1KA]................................................................................................... 670 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 670 (TM-81) FAILURE CODE [DXH1KB]................................................................................................... 672 LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 672 (TM-82) FAILURE CODE [DXH2KA]................................................................................................... 674 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)..................................................................................... 674 (TM-83) FAILURE CODE [DXH2KB]................................................................................................... 676 HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)..................................................................................... 676 (TM-84) FAILURE CODE [DXH3KA]................................................................................................... 678 LOW CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 678 (TM-85) FAILURE CODE [DXH3KB]................................................................................................... 680 LOW CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 680 (TM-86) FAILURE CODE [DXH4KA]................................................................................................... 682 1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 682 (TM-87) FAILURE CODE [DXH4KB]................................................................................................... 684 1ST CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 684 (TM-88) FAILURE CODE [DXH5KA]................................................................................................... 686 2ND CLUTCH SYSTEM OPEN OR SHORTED (KA)...................................................................................... 686 (TM-89) FAILURE CODE [DXH5KB]................................................................................................... 688 2ND CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 688 (TM-90) FAILURE CODE [DXH6KA]................................................................................................... 690 3RD CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 690 (TM-91) FAILURE CODE [DXH6KB]................................................................................................... 692 3RD CLUTCH SYSTEM OPEN OR SHORTED (KB)...................................................................................... 692 (TM-92) FAILURE CODE [DXH7KA]................................................................................................... 694 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA).................................................................................. 694 (TM-93) FAILURE CODE [DXH7KB]................................................................................................... 696 REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB).................................................................................. 696 (TM-94) NO FAILURE CODE DISPLAYED............................................................................................... 698 BACK-UP LIGHTS AND ALARM DO NOT OPERATE..................................................................................... 698 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 704 BK CONTROL SYSTEM CIRCUIT DIAGRAM............................................................................................... 710 CONTENT OF CODE DISPLAY (1)..................................................................................................... 716 CONTENT OF CODE DISPLAY (2)..................................................................................................... 718 CONTENT OF CODE DISPLAY (3)..................................................................................................... 720 CONTENT OF CODE DISPLAY (4)..................................................................................................... 722 CONTENT OF CODE DISPLAY (5)..................................................................................................... 724 CONTENT OF CODE DISPLAY (6)..................................................................................................... 726 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 728 (BK-1) FAILURE CODE [2G42ZG].................................................................................................... 730 ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG).............................................................................. 730 (BK-2) FAILURE CODE [2G43ZG].................................................................................................... 731 ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)............................................................................... 731 (BK-3) FAILURE CODE [D1C0KZ].................................................................................................... 732 OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)................................................................................... 732 (BK-4) FAILURE CODE [D5ZFKZ].................................................................................................... 734 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)......................................................................................... 734 (BK-5) FAILURE CODE [D5ZGKZ].................................................................................................... 736 NEUTRAL SIGNAL OPEN OR SHORTED (KZ)......................................................................................... 736 (BK-6) FAILURE CODE [DB10KK].................................................................................................... 738 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 738 (BK-7) FAILURE CODE [DB11KK].................................................................................................... 740 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 740 (BK-8) FAILURE CODE [DB12KK].................................................................................................... 742 VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)................................................................................ 742 (BK-9) FAILURE CODE [DB13KK].................................................................................................... 744 DROP IN VOLTAGE FOR RETARDER SYSTEM (KK).................................................................................... 744 (BK-10) FAILURE CODE [DB19KM]................................................................................................... 746 MISTAKEN OPERATION OF RETARDER CONTROLLER (KM).............................................................................. 746 (BK-11) FAILURE CODE [DB1SKQ]................................................................................................... 747 RETARDER CONTROL S-NET LINE MISMATCHED (KQ)................................................................................. 747 (BK-12) FAILURE CODE [DHU2KX]................................................................................................... 748 ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)..................................................................... 748 (BK-13) FAILURE CODE [DHU3KX]................................................................................................... 750 ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX)...................................................................... 750 (BK-14) FAILURE CODE [DK51L5]................................................................................................... 752 TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)......................................................................... 752 (BK-15) FAILURE CODE [DK52KX]................................................................................................... 754 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)................................................................................... 754 (BK-16) FAILURE CODE [DK53L8]................................................................................................... 756 DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)................................................................................... 756 (BK-17) FAILURE CODE [DK54KX]................................................................................................... 758 BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)............................................................................... 758 (BK-18) FAILURE CODE [DLF4KA]................................................................................................... 760 TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA)................................................................ 760 (BK-19) FAILURE CODE [DLT3KA]................................................................................................... 762 TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA)................................................................ 762 (BK-20) FAILURE CODE [DW71KZ]................................................................................................... 764 EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)................................................................................. 764 (BK-21) FAILURE CODE [DK72KX]................................................................................................... 766 DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)................................................................................... 766 (BK-22) FAILURE CODE [DW73KZ]................................................................................................... 768 DUMP SELECTOR VALVE OPEN OR SHORTED (KZ).................................................................................... 768 (BK-23) FAILURE CODE [DX11KA]................................................................................................... 770 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA).................................................................. 770 (BK-24) FAILURE CODE [DX11KB]................................................................................................... 771 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB).................................................................. 771 (BK-25) FAILURE CODE [DX11KY]................................................................................................... 772 REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY).................................................................. 772 (BK-26) FAILURE CODE [DX12KA]................................................................................................... 773 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)................................................................. 773 (BK-27) FAILURE CODE [DX12KB]................................................................................................... 774 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)................................................................. 774 (BK-28) FAILURE CODE [DX12KY]................................................................................................... 775 FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)................................................................. 775 (BK-29) FAILURE CODE [DX13KA]................................................................................................... 776 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)................................................................................ 776 (BK-30) FAILURE CODE [DX13KB]................................................................................................... 778 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)................................................................................ 778 (BK-31) FAILURE CODE [DX13KY]................................................................................................... 780 DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)................................................................................ 780 (BK-32) NO FAILURE CODE DISPLAYED............................................................................................... 782 PARKING BRAKE SYSTEM FAILURE................................................................................................ 782 CONNECTOR ARRANGEMENT AND LOCATIONS............................................................................................. 788 MON CONTROL SYSTEM CIRCUIT DIAGRAM.............................................................................................. 794 CONTENT OF CODE DISPLAY (1)..................................................................................................... 798 INFORMATION CONTAINED IN TESTING PROCEDURES..................................................................................... 801 (MON-1) FAILURE CODE [B@C6NS]................................................................................................... 803 FRONT BRAKE OIL OVERHEAT CONDITION (NS)..................................................................................... 803 (MON-2) FAILURE CODE [B@C8NS]................................................................................................... 804 CENTER BRAKE OIL OVERHEAT CONDITION (NS).................................................................................... 804 (MON-3) FAILURE CODE [B@CENS]................................................................................................... 805 TORQUE CONVERTER OIL is in OVERHEAT CONDITION (NS).......................................................................... 805 (MON-4) FAILURE CODE [DAF0KM]................................................................................................... 806 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)......................................................................... 806 (MON-5) FAILURE CODE [DAF9KM]................................................................................................... 808 MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)......................................................................... 808 (MON-6) FAILURE CODE [DAFSKQ]................................................................................................... 809 MODEL SELECTION DOES NOT MATCH (KQ)......................................................................................... 809 (MON-7) FAILURE CODE [DAQSKR]................................................................................................... 810 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 810 (MON-8) FAILURE CODE [DB1SKR]................................................................................................... 812 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 812 (MON-9) FAILURE CODE [DB2SKR]................................................................................................... 814 DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)........................................................................ 814 (MON-10) FAILURE CODE [DV00KB].................................................................................................. 816 DEFECTIVE ALARM BUZZER (KB)................................................................................................. 816 (MON-11) NO FAILURE CODE DISPLAYED.............................................................................................. 818 WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL................................................................. 818 (MON-12) NO FAILURE CODE DISPLAYED.............................................................................................. 820 WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL................................................................ 820 (MON-13) NO FAILURE CODE DISPLAYED.............................................................................................. 822 ALARM BUZZER DOES NOT SOUND................................................................................................. 822 (MON-14) NO FAILURE CODE DISPLAYED.............................................................................................. 824 INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL................................................................... 824 (MON-15) NO FAILURE CODE DISPLAYED.............................................................................................. 825 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED...................................................................... 825 (MON-16) NO FAILURE CODE DISPLAYED.............................................................................................. 826 MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE..................................................................... 826 (MON-17) NO FAILURE CODE DISPLAYED.............................................................................................. 828 POWER MODE SWITCH DOES NOT WORK PROPERLY.................................................................................... 828 (MON-18) NO FAILURE CODE DISPLAYED.............................................................................................. 829 AISS FUNCTION DOES NOT WORK PROPERLY........................................................................................ 829 (MON-19) NO FAILURE CODE DISPLAYED.............................................................................................. 830 EXHAUST BRAKE DOES NOT WORK PROPERLY........................................................................................ 830 (MON-20) NO FAILURE CODE DISPLAYED.............................................................................................. 832 SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY............................................................................... 832 (MON-21) NO FAILURE CODE DISPLAYED.............................................................................................. 833 SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY................................................................................. 833 (MON-22) NO FAILURE CODE DISPLAYED.............................................................................................. 836 HEAD AND TAIL LAMPS DO NOT WORK PROPERLY.................................................................................... 836 (H-1)........................................................................................................................... 840 THE MACHINE DOES NOT MOVE................................................................................................... 840 (H-2) AND (H-3)................................................................................................................. 841 MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKY)........................................................................ 841 LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING).................................................................. 841 (H-4) AND (H-5)................................................................................................................. 842 EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS..................................................................... 842 TRANSMISSION WILL NOT UP SHIFT GEAR RANGE................................................................................... 842 (H-6)........................................................................................................................... 843 MACHINE LACKS POWER OR SPEED WHEN TRAVELING................................................................................. 843 (H-6)........................................................................................................................... 844 ABNORMAL OPERATION AT SOME SPEED RANGES..................................................................................... 844 (H-6)........................................................................................................................... 845 TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE.................................................................................... 845 (H-7)........................................................................................................................... 846 TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES................................................................... 846 (H-8)........................................................................................................................... 847 TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)..................................................................... 847 (H-9)........................................................................................................................... 848 TORQUE CONVERTER OIL PRESSURE LOW........................................................................................... 848 (H-10).......................................................................................................................... 849 FRONT BRAKE IS INEFFECTIVE OR INEFFECTIVE ON ONE SIDE ONLY.................................................................. 849 (H-11).......................................................................................................................... 850 CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE............................................................... 850 (H-12).......................................................................................................................... 851 STEERING EFFORT SEAMS HEAVY................................................................................................. 851 (H-13).......................................................................................................................... 852 STEERING SYSTEM DOES NOT OPERATE............................................................................................ 852 (H-14).......................................................................................................................... 853 STEERING WHEEL VIBRATES..................................................................................................... 853 (H-15).......................................................................................................................... 854 DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER.............................................................................. 854 (H-16).......................................................................................................................... 855 DUMP OPERATIONS DO NOT WORK................................................................................................. 855 (H-17).......................................................................................................................... 856 EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY...................................................................................... 856 HYDRAULIC POWER TRAIN CIRCUIT DIAGRAM........................................................................................... 857 STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM.................................................................................... 858 USING TROUBLESHOOTING CHARTS.................................................................................................... 860 S-7 Exhaust gas is black (incomplete combustion)............................................................................ 862 (S-1) STARTING PERFORMANCE IS POOR.............................................................................................. 864 (S-2) ENGINE DOES NOT CRANK..................................................................................................... 865 (1) ENGINE DOES NOT TURN.................................................................................................... 865 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT OF STACK (FUEL IS NOT BEING INJECTED)....................................... 866 (3) EXHAUST SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..................................... 867 (S-3) ENGINE RPM DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).................................................................. 868 (S-4) ENGINE STOPS DURING OPERATIONS............................................................................................ 869 (S-5) ENGINE DOES NOT RUN SMOOTHLY (HUNTING).................................................................................... 870 (S-6) ENGINE LACKS OUTPUT (OR LACKS POWER)...................................................................................... 871 (S-7) EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................ 872 (S-8) OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................................... 873 (S-9) OIL BECOMES CONTAMINATED QUICKLY.......................................................................................... 874 (S-10) FUEL CONSUMPTION IS EXCESSIVE............................................................................................ 875 (S-11) OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR LEVEL GOES DOWN............................................................ 876 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................... 877 (S-13) OIL LEVEL RISES (COOLANT, FUEL IN OIL)................................................................................... 878 (S-14) COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................................................... 879 (S-15) ABNORMAL NOISE IS HEARD.................................................................................................. 880 (S-16) VIBRATION IS EXCESSIVE................................................................................................... 881 30 DISASSEMBLY AND ASSEMBLY......................................................................................................... 883 HOW TO USE MANUAL............................................................................................................... 887 Removal and Installation of Assemblies...................................................................................... 887 Disassembly and Assembly of Assemblies...................................................................................... 889 PRECAUTIONS WHEN CARRYING OUT REPAIR OPERATION.................................................................................. 891 SPECIAL TOOL LIST............................................................................................................... 894 SKETCHES OF SPECIAL TOOLS....................................................................................................... 898 CONNECTOR REPAIR PROCEDURES..................................................................................................... 910 Stripping Insulation........................................................................................................ 910 Wire Inspection............................................................................................................. 910 Contact Terminal Removal (HD30 Type)........................................................................................ 911 Crimping Contact Terminal (HD30 Type)....................................................................................... 912 Insertion Of Contact Terminal (HD30 Type)................................................................................... 913 Contact Terminal Removal (DT Type).......................................................................................... 914 Crimping Contact Terminal (DT Type)......................................................................................... 915 Insertion Of Contact Terminal (DT Type)..................................................................................... 916 ENGINE.......................................................................................................................... 917 REMOVAL..................................................................................................................... 917 INSTALLATION................................................................................................................ 922 RADIATOR........................................................................................................................ 924 REMOVAL..................................................................................................................... 924 INSTALLATION................................................................................................................ 926 OUTPUT SHAFT SYSTEM............................................................................................................. 927 REMOVAL..................................................................................................................... 927 INSTALLATION................................................................................................................ 929 DISASSEMBLY................................................................................................................. 931 ASSEMBLY.................................................................................................................... 933 TRANSMISSION AND FRONT DIFFERENTIAL............................................................................................. 935 REMOVAL..................................................................................................................... 935 INSTALLATION................................................................................................................ 941 SEPARATING FRONT DIFFERENTIAL FROM TRANSMISSION............................................................................. 944 REMOVAL................................................................................................................. 944 INSTALLATION............................................................................................................ 945 TORQUE CONVERTER............................................................................................................ 946 DISASSEMBLY............................................................................................................. 946 ASSEMBLY................................................................................................................ 950 TRANSMISSION................................................................................................................ 956 DISASSEMBLY............................................................................................................. 956 ASSEMBLY................................................................................................................ 981 FRONT DIFFERENTIAL..........................................................................................................1011 DISASSEMBLY.............................................................................................................1011 ASSEMBLY................................................................................................................1017 CENTER AXLE AND DIFFERENTIAL....................................................................................................1029 AXLE ASSEMBLY...............................................................................................................1029 REMOVAL.................................................................................................................1029 INSTALLATION............................................................................................................1031 DIFFERENTIAL................................................................................................................1032 REMOVAL.................................................................................................................1032 INSTALLATION............................................................................................................1034 DISASSEMBLY.............................................................................................................1037 ASSEMBLY................................................................................................................1044 REAR AXLE AND DIFFERENTIAL......................................................................................................1058 AXLE ASSEMBLY...............................................................................................................1058 REMOVAL.................................................................................................................1058 INSTALLATION............................................................................................................1060 DIFFERENTIAL ASSEMBLY.......................................................................................................1061 REMOVAL.................................................................................................................1061 INSTALLATION............................................................................................................1063 DISASSEMBLY.............................................................................................................1064 ASSEMBLY................................................................................................................1069 FRONT FINAL DRIVE AND BRAKE ASSEMBLY............................................................................................1080 REMOVAL.....................................................................................................................1080 INSTALLATION................................................................................................................1082 DISASSEMBLY.................................................................................................................1083 ASSEMBLY....................................................................................................................1089 CENTER FINAL DRIVE AND BRAKE ASSEMBLY...........................................................................................1097 REMOVAL.....................................................................................................................1097 INSTALLATION................................................................................................................1099 DISASSEMBLY.................................................................................................................1100 ASSEMBLY....................................................................................................................1103 REAR FINAL DRIVE AND BRAKE ASSEMBLY.............................................................................................1110 REMOVAL.....................................................................................................................1110 INSTALLATION................................................................................................................1111 DISASSEMBLY.................................................................................................................1112 ASSEMBLY....................................................................................................................1114 SUSPENSION SYSTEM...............................................................................................................1119 FRONT SUSPENSION............................................................................................................1119 REMOVAL.................................................................................................................1119 INSTALLATION............................................................................................................1121 REAR SUSPENSION.............................................................................................................1122 REMOVAL.................................................................................................................1122 INSTALLATION............................................................................................................1122 EQUALIZER BEAM..............................................................................................................1123 REMOVAL.................................................................................................................1123 INSTALLATION............................................................................................................1125 HITCH FRAME SYSTEM..............................................................................................................1126 REMOVAL.....................................................................................................................1126 INSTALLATION................................................................................................................1133 DISASSEMBLY.................................................................................................................1137 ASSEMBLY....................................................................................................................1139 ORBITAL STEERING UNIT...........................................................................................................1144 UNIT BREAKDOWN VIEW.........................................................................................................1144 DISASSEMBLY.................................................................................................................1146 ASSEMBLY....................................................................................................................1149 FLOW AMP VALVE..................................................................................................................1155 REMOVAL.....................................................................................................................1155 INSTALLATION................................................................................................................1156 HOIST VALVE.....................................................................................................................1157 REMOVAL.....................................................................................................................1157 INSTALLATION................................................................................................................1158 HYDRAULIC CYLINDER..............................................................................................................1159 STEERING CYLINDER...........................................................................................................1159 DISASSEMBLY.............................................................................................................1159 ASSEMBLY................................................................................................................1161 HOIST CYLINDER..............................................................................................................1164 DISASSEMBLY.............................................................................................................1164 ASSEMBLY................................................................................................................1166 TRUCK BODY ASSEMBLY.............................................................................................................1170 REMOVAL.....................................................................................................................1170 INSTALLATION................................................................................................................1171 OPERATOR’S SEAT.................................................................................................................1172 DISASSEMBLY.................................................................................................................1172 ASSEMBLY....................................................................................................................1179 90 DIAGRAMS AND SCHEMATICS..........................................................................................................1185 CAB.............................................................................................................................1187 CLIMATE CONTROL SYSTEM......................................................................................................1187 CAB HARNESS INSIDE OF CAB AND ENGINE CONTROLLER.............................................................................1189 CAB HARNESS TO OUTSIDE OF CAB AND ENGINE CONTROLLER.........................................................................1191 LIGHTING WIPER AND RELAY BANK...............................................................................................1193 RELAY AND SWITCH CIRCUITS...................................................................................................1195 MODE SWITCHES, INDICATORS AND ELECTRICAL MOTOR SYSTEMS......................................................................1197 DISPLAY PANEL, RADIO SPEAKERS AND WORK LAMPS................................................................................1199 DIFFERENTIAL LOCK, HOIST LEVER, DISPLAY PANEL AND LEVER KICK-OUT............................................................1201 RETARDER SYSTEM.............................................................................................................1203 RETARDER SYSTEM, RADIO, IGNITION SWITCH AND AUXILIARY STEERING..............................................................1205 TRANSMISSION CONTROLLER, CONSOLE HARNESS AND ACCELERATOR PEDAL..............................................................1207 TRANSMISSION CONTROLLER.....................................................................................................1209 TO HARNESS OUTSIDE OF CAB...................................................................................................1211 TO HARNESS OUTSIDE OF CAB AND TO ENGINE.....................................................................................1213 CHASSIS.........................................................................................................................1215 SIGNAL LAMPS, PRESSURE SWITCH AND TO HARNESS INSIDE OD CAB..................................................................1215 TO MAIN HARNESS OF INSIDE CAB AND FRONT LAMPS...............................................................................1217 TO MAIN HARNESS OF INSIDE CAB, HORN AND FRONT LAMPS.........................................................................1219 CHASSIS SENSORS, SWITCHES AND JOINT CONNECTIONS.............................................................................1221 CHASSIS SENSOR SYSTEMS......................................................................................................1223 CONNECTORS OUTSIDE OF CAB...................................................................................................1225 ALTERNATOR, DIFFERENTIAL LOCK, EXHAUST BRAKE, BRAKE WEAR INDICATOR AND TAIL LAMPS...........................................1227 DIFFERENTIAL LOCK, FUEL INJECTORS, FUEL LEVEL SENSOR AND PRE-HEAT SYSTEM....................................................1229 BATTERY BOX, ENGINE SENSORS AND INCLINATION SENSOR..........................................................................1231 TRANSMISSION SELECTOR SYSTEM................................................................................................1233 BRAKE HYDRAULIC CIRCUIT DIAGRAM.............................................................................................1235
KOMATSU HM300-1L ARTICULATED TRUCK SHOP MANUAL CEBM015200 – PDF DOWNLOAD:
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Eduardo Cairo –