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KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBERS 2001 and up
- PUBLICATION NUMBER:SEN00237-13
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Description
KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU HM300-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
COVER ........................................................................................................................... 1 00 Index and foreword............................................................................................................ 0 Index........................................................................................................................ 3 Composition of shop manual............................................................................................... 4 Table of contents........................................................................................................ 6 Foreword and general information............................................................................................. 17 Safety notice............................................................................................................ 18 How to read the shop manual.............................................................................................. 23 Explanation of terms for maintenance standard............................................................................ 25 Handling of electric equipment and hydraulic component................................................................... 27 Handling of connectors newly used for engines............................................................................ 36 How to read electric wire code........................................................................................... 39 Precautions when carrying out operation.................................................................................. 42 Method of disassembling and connecting push-pull type coupler............................................................ 45 Standard tightening torque table......................................................................................... 48 Conversion table......................................................................................................... 52 01 Specification................................................................................................................. 0 Specification and technical data............................................................................................. 59 Specification drawings................................................................................................... 60 Specifications........................................................................................................... 61 Weight table............................................................................................................. 64 Fuel, coolant and lubricants............................................................................................. 65 10 Structure, function and maintenance standard.................................................................................. 0 Engine and cooling system.................................................................................................... 69 Radiator, oil cooler, aftercooler........................................................................................ 70 Output shaft............................................................................................................. 71 Power train, Part 1.......................................................................................................... 75 Power train skeleton..................................................................................................... 76 Torque converter and transmission hydraulic piping....................................................................... 78 Brake cooling oil control valve (BCV).................................................................................... 80 Power train pump......................................................................................................... 81 Torque converter......................................................................................................... 84 Transmission............................................................................................................. 90 Transmission control valve............................................................................................... 118 ECMV..................................................................................................................... 119 Main relief, torque converter relief valve............................................................................... 126 Power train, Part 2.......................................................................................................... 129 Drive shaft.............................................................................................................. 130 Axle..................................................................................................................... 131 Differential............................................................................................................. 134 Limited slip differential................................................................................................ 140 Final drive.............................................................................................................. 144 Steering system.............................................................................................................. 151 Steering column.......................................................................................................... 152 Brake system................................................................................................................. 155 Brake piping............................................................................................................. 156 Brake valve.............................................................................................................. 158 Accumulator charge valve................................................................................................. 161 Accumulator.............................................................................................................. 165 Slack adjuster........................................................................................................... 166 Brake.................................................................................................................... 168 Proportional reducing valve.............................................................................................. 173 Brake system tank........................................................................................................ 174 Parking brake............................................................................................................ 176 Parking brake solenoid................................................................................................... 180 Undercarriage and frame...................................................................................................... 183 Suspension............................................................................................................... 184 Suspension cylinder...................................................................................................... 190 Oscillation hitch........................................................................................................ 192 Hydraulic system............................................................................................................. 197 Steering, hoist oil pressure piping diagram.............................................................................. 198 Dump body control........................................................................................................ 199 Hydraulic tank and filter................................................................................................ 200 Flow amp valve........................................................................................................... 201 Steering valve........................................................................................................... 204 Steering cylinder........................................................................................................ 208 Hoist valve.............................................................................................................. 210 Dump control valve (EPC valve)........................................................................................... 216 Hoist cylinder........................................................................................................... 220 Hydraulic pump........................................................................................................... 221 Cab and its attachments...................................................................................................... 225 ROPS cab................................................................................................................. 226 Cab tilt................................................................................................................. 227 Air conditioner.......................................................................................................... 228 Rear view monitor........................................................................................................ 236 Controller related....................................................................................................... 239 Electrical system, Part 1.................................................................................................... 241 Machine monitor system................................................................................................... 242 Electrical system, Part 2.................................................................................................... 263 Automatic shift control system........................................................................................... 264 Retarder control system.................................................................................................. 296 Auto emergency steering system........................................................................................... 308 Battery disconnector switch.............................................................................................. 310 Dump control lever....................................................................................................... 312 Electrical system, Part 3.................................................................................................... 317 Payload meter (Card type)................................................................................................ 318 Electrical system, Part 4.................................................................................................... 351 Sensors, switches........................................................................................................ 352 KOMTRAX terminal system (If equipped).................................................................................... 360 20 Standard value table.......................................................................................................... 0 Standard service value table................................................................................................. 363 Standard value table for engine.......................................................................................... 364 Standard value table for chassis......................................................................................... 365 30 Testing and adjusting......................................................................................................... 0 Testing and adjusting, Part 1................................................................................................ 371 Tools for testing, adjusting, and troubleshooting........................................................................ 373 Sketches of special tools................................................................................................ 377 Testing engine speed..................................................................................................... 378 Testing intake air pressure (boostpressure).............................................................................. 379 Testing exhaust temperature.............................................................................................. 380 Testing exhaust gas color................................................................................................ 382 Adjusting valve clearance................................................................................................ 383 Testing compression pressure............................................................................................. 385 Testing blow-by pressure................................................................................................. 387 Testing engine oil pressure.............................................................................................. 388 Testing EGR valve and bypass valve drive oil pressure.................................................................... 389 Handling of fuel system devices.......................................................................................... 390 Releasing residual pressure from fuel system............................................................................. 390 Testing fuel pressure.................................................................................................... 391 Handling during cylinder cut-out operation............................................................................... 392 Handling during no injection cranking operation.......................................................................... 392 Testing fuel return and leak amount...................................................................................... 393 Bleeding air from fuel circuit........................................................................................... 396 Testing fuel circuit for leakage......................................................................................... 397 Testing and adjusting alternator belt tension............................................................................ 398 Testing and adjusting air conditioner compressor belt tension............................................................ 398 Adjusting the body mount................................................................................................. 398 Testing and adjusting, Part 2................................................................................................ 401 Testing torque converter stallspeed...................................................................................... 402 Testing power train oil pressure......................................................................................... 403 Adjusting transmission speed sensor...................................................................................... 411 Testing and adjusting brake oilpressure.................................................................................. 413 Testing of accumulator nitrogengas pressure and procedure forcharging accumulator withnitrogen gas....................... 417 Testing brake performance................................................................................................ 421 Bleeding air from brake circuit.......................................................................................... 422 Testing wear of wheel brake disc......................................................................................... 423 Testing wear of parking brake pad........................................................................................ 424 Method for emergency release ofparking brake............................................................................. 426 Testing and adjusting steeringcircuit oil pressure....................................................................... 427 Testing and adjusting suspensioncylinder................................................................................. 429 Method of tilting cab up................................................................................................. 433 Testing and adjusting dumpcircuit oil pressure........................................................................... 435 Adjusting body positioner sensor......................................................................................... 438 Procedure for adjusting length ofspring in body heating sphericaljoint................................................... 439 Handling engine controller highvoltage circuit........................................................................... 439 Adjusting transmission controller........................................................................................ 440 Method for emergency escape at electrical system failure................................................................. 441 Testing and adjusting, Part 3................................................................................................ 447 Setting and adjusting various equipments................................................................................. 448 Special function of machine monitor (EMMS)............................................................................... 460 How to start operation of KOMTRAX terminal............................................................................... 497 Lamp display of KOMTRAX terminal......................................................................................... 502 Pm Clinic check sheet.................................................................................................... 505 40 Troubleshooting............................................................................................................... 0 Failure code table and fuse locations........................................................................................ 509 Failure codes table...................................................................................................... 510 Fuse locations........................................................................................................... 518 General information on troubleshooting....................................................................................... 525 Points to remember when troubleshooting.................................................................................. 526 Sequence of events in troubleshooting.................................................................................... 527 Checks before troubleshooting............................................................................................ 528 Classification and procedures for troubleshooting........................................................................ 529 Information in troubleshooting table..................................................................................... 530 Connection table for connector pin numbers............................................................................... 532 T-branch box and T-branch adapter table.................................................................................. 568 Troubleshooting by failure code, Part 1...................................................................................... 573 Failure code [1500L0] (Dual engagement).................................................................................. 575 Failure code [15B0NX] (Transmission oil filter: Clogged)................................................................. 576 Failure code [15F0KM] (R → F shifting abuse 1: Operational error or incorrect setting)................................... 578 Failure code [15F0MB] (R → F shifting abuse 2: Functional deterioration)................................................. 578 Failure code [15F7KM] (forward clutch disc abuse)........................................................................ 579 Failure code [15G0MW] (R clutch: Slipping)............................................................................... 580 Failure code [15G7KM] (reverse clutch disc abuse)........................................................................ 582 Failure code [15H0MW] (Hi clutch: Slipping).............................................................................. 583 Failure code [15J0MW] (Lo clutch: Slipping).............................................................................. 586 Failure code [15K0MW] (1st clutch: Slipping)............................................................................. 588 Failure code [15L0MW] (2nd clutch: Slipping)............................................................................. 590 Failure code [15M0MW] (3rd clutch: Slipping)............................................................................. 592 Failure code [15SBL1] (R clutch solenoid: Fill signal is ON when command current is OFF.)................................ 594 Failure code [15SBMA] (R clutch solenoid: Malfunction)................................................................... 598 Failure code [15SCL1] (Hi clutch solenoid: Fill signal is ON when command current is OFF.)............................... 600 Failure code [15SCMA] (Hi clutch solenoid: Malfunction).................................................................. 604 Failure code [15SDL1] (Lo clutch solenoid: Fill signal is ON when command current is OFF.)............................... 606 Failure code [15SDMA] (Lo clutch solenoid: Malfunction).................................................................. 608 Failure code [15SEL1] (1st clutch solenoid: Fill signal is ON when command current is OFF)............................... 612 Failure code [15SEMA] (1st clutch solenoid: Malfunction)................................................................. 616 Failure code [15SFL1] (2nd clutch solenoid: Fill signal is ON when command current is OFF.).............................. 618 Failure code [15SFMA] (2nd clutch solenoid: Malfunction)................................................................. 622 Failure code [15SGL1] (3rd clutch solenoid: Fill signal is ON when command current is OFF.).............................. 624 Failure code [15SGMA] (3rd clutch solenoid: Malfunction)................................................................. 628 Failure code [15SJMA] (Lockup clutch solenoid: Malfunction).............................................................. 630 Failure code [15SKMA] (Inter-axle differential lockup pressure control valve: Malfunction)............................... 632 Failure code [2F00KM] (Parking brake: Error in operation or setting)..................................................... 634 Failure code [2G42ZG] (Front accumulator: Oil pressure too low).......................................................... 636 Failure code [2G43ZG] (Rear accumulator: Oil pressure too low)........................................................... 636 Failure code [989A00] (Engine over run prevention command signal: Operating)............................................. 637 Failure code [989D00] (Rear section tipping over alarm: Alarm is activated.)............................................. 637 Failure code [AA10NX] (Air cleaner element: Clogged)..................................................................... 638 Failure code [AB00MA] (Alternator: Malfunction).......................................................................... 640 Failure code [B@BAZG] Lowering of engine oil pressure.................................................................... 641 Failure code [B@BAZK] (Engine oil : Level too low)....................................................................... 642 Failure code [B@BCNS] (Engine: Overheat)................................................................................. 643 Failure code [B@BCZK] (Radiator coolant: Level too low).................................................................. 644 Failure code [B@BFZK] (Fuel level: Level too low)........................................................................ 645 Failure code [B@C6NS] (Front brake oil: Overheat)........................................................................ 646 Failure code [B@C8NS] (Center brake oil: Overheat)....................................................................... 646 Failure code [B@CENS] (Torque converter: Overheat)....................................................................... 647 Failure code [B@HAZK] (Hydraulic tank oil: Level too low)................................................................ 648 Failure code [B@JANS] (Steering oil: Overheat)........................................................................... 649 Troubleshooting by failure code, Part 2...................................................................................... 651 Failure code [CA111] (Abnormality in engine controller).................................................................. 653 Failure code [CA115] (Abnormal engine Ne and Bkup sensors)............................................................... 654 Failure code [CA122] (Charge pressure sensor too high)................................................................... 656 Failure code [CA123] (Charge pressure sensor too low).................................................................... 658 Failure code [CA131] (Throttle sensor tool high)......................................................................... 660 Failure code [CA132] (Throttle sensor tool low).......................................................................... 662 Failure code [CA135] (Oil pressure sensor too high)...................................................................... 664 Failure code [CA141] (Oil pressure sensor too low)....................................................................... 666 Failure code [CA144] (Coolant temperature sensor too high)............................................................... 668 Failure code [CA145] (Coolant temperature sensor too low)................................................................ 670 Failure code [CA153] (Charge temperature sensor too high)................................................................ 672 Failure code [CA154] (Charge temperature sensor too low)................................................................. 674 Failure code [CA187] (Sensor power source 2 too low)..................................................................... 674 Failure code [CA221] (Atmospheric sensor too high)....................................................................... 676 Failure code [CA222] (Atmospheric sensor too low)........................................................................ 678 Failure code [CA227] (Sensor power source 2 too high).................................................................... 680 Failure code [CA234] (Engine over speed)................................................................................. 682 Failure code [CA238] (Abnormal power source for Ne speed sensor)......................................................... 684 Failure code [CA263] (Fuel temperature sensor too high).................................................................. 686 Failure code [CA265] (Fuel temperature sensor too low)................................................................... 688 Failure code [CA271] (PCV1 short circuit)................................................................................ 689 Failure code [CA272] (PCV1 disconnection)................................................................................ 690 Failure code [CA273] (PCV2 short circuit)................................................................................ 691 Failure code [CA274] (PCV2 disconnection)................................................................................ 692 Failure code [CA322] Disconnection or short circuit in injector #1 (L#1)................................................. 694 Failure code [CA323] Disconnection or short circuit in injector #5 (L#5)................................................. 696 Failure code [CA324] Disconnection or short circuit in injector #3 (L#3)................................................. 698 Failure code [CA325] Disconnection or short circuit in injector #6 (L#6)................................................. 700 Failure code [CA331] Disconnection or short circuit in injector #2 (L#2)................................................. 702 Failure code [CA332] Disconnection or short circuit in injector #4 (L#4)................................................. 704 Failure code [CA342] (Abnormal engine controller data consistency)....................................................... 706 Failure code [CA351] (Abnormal injector drive circuit)................................................................... 707 Failure code [CA352] (Sensor power source 1 too low)..................................................................... 708 Failure code [CA386] (Sensor power source 1 too high).................................................................... 710 Failure code [CA431] (Abnormal idle validation switch)................................................................... 712 Failure code [CA432] (Abnormal process with idle validation switch)...................................................... 714 Failure code [CA441] (Power source voltage too low)...................................................................... 715 Failure code [CA442] (Power source voltage too high)..................................................................... 715 Failure code [CA449] (Common rail pressure too high 2)................................................................... 716 Failure code [CA451] (Common rail pressure sensor too high).............................................................. 718 Failure code [CA452] (Common rail pressure sensor too low)............................................................... 720 Failure code [CA553] (Common rail pressure too high 1)................................................................... 720 Failure code [CA554] (In-range error of common rail pressure sensor)..................................................... 721 Failure code [CA559] (Loss of pressure feed from supply pump 1).......................................................... 722 Failure code [CA689] (Abnormal engine Ne speed sensor)................................................................... 726 Failure code [CA697] (Engine controller inside temperature sensor too high).............................................. 728 Failure code [CA698] (Engine controller inside temperature sensor too low)............................................... 728 Failure code [CA731] (Abnormal engine Bkup speed sensor phase)........................................................... 729 Failure code [CA757] (Loss of all engine controller data)................................................................ 729 Failure code [CA778] (Abnormal engine Bkup speed sensor)................................................................. 730 Failure code [CA1117] (Loss of partial engine controller data)........................................................... 732 Failure code [CA1228] (Abnormal EGR valve servo 1)....................................................................... 733 Failure code [CA1625] (Abnormal EGR valve servo 2)....................................................................... 734 Failure code [CA1626] (Short circuit of bypass valve solenoid drive)..................................................... 736 Failure code [CA1627] (Disconnection in bypass valve solenoid drive)..................................................... 738 Failure code [CA1628] (Abnormal bypass valve servo 1).................................................................... 739 Failure code [CA1629] (Abnormal bypass valve servo 2).................................................................... 740 Troubleshooting by failure code, Part 3...................................................................................... 743 Failure code [CA1631] (Bypass valve lift sensor too high)................................................................ 746 Failure code [CA1632] (Bypass valve lift sensor too low)................................................................. 748 Failure code [CA1633] (Abnormal KOMNET).................................................................................. 750 Failure code [CA1642] (EGR inlet pressure sensor too low)................................................................ 752 Failure code [CA1653] (EGR inlet pressure sensor too high)............................................................... 754 Failure code [CA2185] (Throttle sensor power source too high)............................................................ 756 Failure code [CA2186] (Throttle sensor power source too low)............................................................. 758 Failure code [CA2249] (Loss of pressure feed from supply pump 2)......................................................... 758 Failure code [CA2271] (EGR valve lift sensor too high)................................................................... 760 Failure code [CA2272] (EGR valve lift sensor too low).................................................................... 762 Failure code [CA2351] (EGR valve solenoid drive short circuit)........................................................... 764 Failure code [CA2352] (EGR valve solenoid drive disconnection)........................................................... 766 Failure code [CA2555] (Intake air heater relay disconnection)............................................................ 766 Failure code [CA2556] (Intake air heater relay short circuit)............................................................ 768 Failure code [DAF9KM] (Machine monitor connector: Error in operation or setting)......................................... 770 Failure code [DAFRKR] (Abnormal CAN communication (machine monitor): Abnormal communication)............................. 772 Failure code [DAQ0KK] (Transmission controller: Power source voltage too low)............................................ 774 Failure code [DAQ0KT] (Transmission nonvolatile memory: Abnormality in controller)....................................... 776 Failure code [DAQ2KK] (Transmission controller solenoid power source: Voltage too low)................................... 777 Failure code [DAQRKR] (COMMUNICATION LOST: Defective communication)...................................................... 778 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).............................................. 780 Failure code [DB10KT] (Retarder controller nonvolatile memory: Abnormality in controller)................................ 780 Failure code [DB12KK] (Retarder controller solenoid power source: Power source voltage too low).......................... 781 Failure code [DB13KK] (Retarder controller battery direct power source: Power source voltage too low).................... 782 Failure code [DB19KQ] (Retarder controller model select signal: Inconsistent model selection signal)..................... 783 Failure code [DB1QMA] (Retarder controller option setting: Malfunction).................................................. 783 Failure code [DB1RKR] (CAN communication (retarder controller): Communication disabled).................................. 784 Failure code [DB2RKR] (CAN communication (engine controller): Communication disabled).................................... 786 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal.......................................... 788 Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)......................................................... 790 Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection )........................................................ 792 Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)........................................................ 794 Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)........................................................ 795 Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)........................................................ 796 Failure code [DDTNKA] (Fill switch for R clutch: Disconnection).......................................................... 797 Failure code [DF10KA] (Gear shift lever: Disconnection).................................................................. 798 Failure code [DF10KB] (Gear shift lever: Short circuit).................................................................. 801 Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)................................... 804 Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit).............................. 806 Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)................................. 808 Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)............................... 810 Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals).................................. 812 Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)....................................... 814 Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)............................... 816 Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range).................................. 818 Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop).............. 820 Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)................................. 822 Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range).................................. 824 Failure code [DJF1KA] (Fuel level sensor: Disconnection)................................................................. 826 Failure code [DK51L5] (Retarder lever potentiometer : Potentiometer signal is inconsistent with switch signal)........... 828 Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range).................................... 830 Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)................................... 832 Failure code [DK54KX] (Body positioner sensor: Input signal out of range)................................................ 834 Troubleshooting by failure code, Part 4...................................................................................... 837 Failure code [DKH0KX] (Inclination sensor: Inclination out of range)..................................................... 840 Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)............................................. 842 Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)........................ 843 Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)...................................... 844 Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal).......................... 845 Failure code [DLF4KA] (Differential speed sensor: Disconnection)......................................................... 846 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)............................................ 847 Failure code [DV00KB] (Alarm buzzer output: Short circuit)............................................................... 848 Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit).................................. 850 Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)............................... 852 Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)............................. 854 Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)............................ 856 Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)......................... 858 Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)........... 860 Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit).......................... 861 Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)..... 862 Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)............................ 864 Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)........................ 866 Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection).......... 868 Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)......................... 869 Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line).... 870 Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)........................... 872 Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection).................................................... 874 Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit).................................................... 875 Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)............................... 876 Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)............................... 877 Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)............................... 878 Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)........ 879 Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)............................................. 880 Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)............................................. 881 Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)........................ 882 Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)................................................. 884 Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)................................................. 886 Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)............................ 888 Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)................................................. 892 Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)................................................. 894 Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)............................ 896 Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)................................................ 900 Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)................................................ 902 Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)........................... 904 Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)................................................ 908 Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)................................................ 910 Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)........................... 912 Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)................................................ 916 Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)................................................ 918 Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)........................... 920 Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection).................................................. 924 Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit).................................................. 926 Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)............................. 928 Troubleshooting of electrical system (E-mode)................................................................................ 933 Information in troubleshooting table..................................................................................... 934 E-1 Engine does not start................................................................................................ 935 E-2 Automatic preheating does not operate................................................................................ 938 E-3 Machine monitor does not display all, when starting switch is turned ON.............................................. 941 E-4 Machine monitor does not operate when starting switch is OFF......................................................... 943 E-5 Alarm buzzer does not stop sounding.................................................................................. 945 E-6 Gauges of machine monitor, caution lamps or character display section do not display properly........................ 946 E-7 Selection of display in character display section cannot be changed.................................................. 947 E-8 Power mode selecting function does not operate properly.............................................................. 951 E-9 AISS function does not operate properly.............................................................................. 952 E-10 Seat belt caution lamp does not display properly.................................................................... 953 E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly............................................... 954 E-12 Night illumination (lighting) does not work properly................................................................ 957 E-13 Emergency steering does not operate................................................................................. 964 E-14 Air conditioner does not operate normally........................................................................... 968 Troubleshooting of hydraulic and mechanical system (H-mode).................................................................. 975 Contents of troubleshooting table........................................................................................ 977 H-1 Machine does not start............................................................................................... 978 H-2 Machine does not travel smoothly (machine jerks)..................................................................... 980 H-3 Lockup cannot be cancelled........................................................................................... 980 H-4 Excessive shock when starting or shifting............................................................................ 981 H-5 Transmission does not shift up....................................................................................... 982 H-6 Machine lacks power or speed when traveling.......................................................................... 983 H-7 Time lag is excessive when starting or shifting gear................................................................. 985 H-8 Torque converter oil temperature is high............................................................................. 986 H-9 Torque converter oil pressure is low................................................................................. 987 H-10 Front brake is ineffective.......................................................................................... 988 H-11 Center brake is ineffective......................................................................................... 989 H-12 Steering wheel is heavy............................................................................................. 990 H-13 Steering wheel does not work........................................................................................ 991 H-14 Steering wheel vibrates............................................................................................. 992 H-15 Dump body lifting speed is slow..................................................................................... 993 H-16 Dump body does not work............................................................................................. 994 H-17 Excessive hydraulic drift of dump body.............................................................................. 995 Troubleshooting of engine (S-mode)........................................................................................... 997 How to use a troubleshooting chart....................................................................................... 999 S-1 Engine is hard to start..............................................................................................1002 S-2 Engine does not start................................................................................................1004 S-3 Engine does not pick up smoothly.....................................................................................1008 S-4 Engine stops during operations.......................................................................................1009 S-5 Engine does not rotate smoothly......................................................................................1010 S-6 Engine lacks output (or lacks power).................................................................................1011 S-7 Exhaust gas color is black (incomplete combustion)...................................................................1012 S-8 Oil consumption is excessive (or exhaust gas color is blue)..........................................................1014 S-9 Oil gets contaminated prematurely....................................................................................1015 S-10 Fuel consumption is excessive.......................................................................................1016 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...............................................1017 S-12 Oil pressure drops..................................................................................................1018 S-13 Oil level rises (coolant or fuel mixes).............................................................................1020 S-14 Coolant temperature rises too high (overheat).......................................................................1022 S-15 Abnormal noise comes out............................................................................................1023 S-16 Vibration is excessive..............................................................................................1024 50 Disassembly and assembly...................................................................................................... 0 General information on disassembly and assembly..............................................................................1027 How to read this manual..................................................................................................1028 Coating materials list...................................................................................................1030 Special tool list........................................................................................................1033 Sketches of special tools................................................................................................1037 Engine and cooling system, Part 1............................................................................................1051 Removal and installation of fuel supply pump assembly....................................................................1052 Removal and installation of fuel injector assembly.......................................................................1057 Removal and installation of cylinder head assembly.......................................................................1062 Removal and installation of engine front seal............................................................................1075 Removal and installation of engine rear seal.............................................................................1077 Engine and cooling system, Part 2............................................................................................1083 Removal and installation of engine assembly..............................................................................1084 Removal and installation of radiator assembly............................................................................1092 Removal and installation of cooling assembly.............................................................................1094 Removal and installation of output shaft assembly........................................................................1097 Disassembly and assembly of output shaft assembly........................................................................1102 Power train, Part 1..........................................................................................................1107 Removal and installation of transmission and front differential assembly.................................................1108 Disconnection and connection of front differential assembly and transmission assembly....................................1114 Disassembly and assembly of front differential assembly..................................................................1116 Disassembly and assembly of torque converter assembly....................................................................1131 Power train, Part 2..........................................................................................................1139 Disassembly and assembly of transmission assembly........................................................................1140 Power train, Part 3..........................................................................................................1183 Removal and installation of center differential assembly.................................................................1184 Disassembly and assembly of center differential assembly.................................................................1188 Removal and installation of rear differential assembly...................................................................1205 Disassembly and assembly of rear differential assembly...................................................................1207 Power train, Part 4..........................................................................................................1223 Removal and installation of front final drive and brake assembly.........................................................1224 Disassembly and assembly of front final drive and brake assembly.........................................................1227 Removal and installation of center final drive and brake assembly........................................................1237 Disassembly and assembly of center final drive and brake assembly........................................................1239 Power train, Part 5..........................................................................................................1249 Disassembly and assembly of rear final drive assembly....................................................................1250 Removal and installation of center axle assembly.........................................................................1257 Removal and installation of rear axle assembly...........................................................................1260 Undercarriage and frame......................................................................................................1263 Removal and installation of front suspension cylinder assembly...........................................................1264 Removal and installation of rear suspension cylinder assembly............................................................1266 Disassembly and assembly of front and rear suspension cylinder assembly..................................................1267 Removal and installation of equalizer bar................................................................................1269 Removal and installation of hitch frame assembly.........................................................................1271 Disassembly and assembly of hitch frame assembly.........................................................................1281 Hydraulic system.............................................................................................................1289 Removal and installation of flow amp valve...............................................................................1290 Removal and installation of hoist valve assembly.........................................................................1292 Disassembly and assembly of steering cylinder assembly...................................................................1295 Disassembly and assembly of hoist cylinder assembly......................................................................1299 Body.........................................................................................................................1305 Removal and installation of body assembly................................................................................1306 Cab and its attachments......................................................................................................1309 Removal and installation of operator’s cab...............................................................................1310 Removal and installation of operator’s cab glass (Stuck glass)...........................................................1315 Disassembly and assembly of operator’s seat assembly (If equipped).......................................................1322 Electrical system............................................................................................................1333 Removal and installation of air conditioner unit assembly................................................................1334 Removal and installation of engine controller............................................................................1339 Removal and installation of retarder controller..........................................................................1341 Removal and installation of transmission controller assembly.............................................................1343 90 Diagrams and drawings......................................................................................................... 0 Hydraulic diagrams and drawings..............................................................................................1345 Power train hydraulic circuit diagram....................................................................................1347 Steering and hoist hydraulic circuit diagram.............................................................................1348 Brake hydraulic circuit diagram..........................................................................................1350 Brake cooling hydraulic circuit diagram..................................................................................1351 Electrical diagrams and drawings.............................................................................................1353 Electrical circuit diagram for inside cab (1/4)..........................................................................1355 Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 - 2241)................................................1356 Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)................................................1357 Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 - 2241)................................................1358 Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)................................................1359 Electrical circuit diagram for inside cab (4/4)..........................................................................1360 Electrical circuit diagram for outside cab (1/3).........................................................................1361 Electrical circuit diagram for outside cab (2/3).........................................................................1362 Electrical circuit diagram for outside cab (3/3).........................................................................1363 Electrical circuit diagram for payload meter.............................................................................1364 Connectors table and arrangement drawing.................................................................................1365 SEN00694-02-MA4.pdf.............................................................................................................. 0
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