Komatsu HM300-2 Dump Truck Shop Manual CEBM007700 PDF

Description

Komatsu HM300-2 Dump Truck Shop Manual CEBM007700 – PDF DOWNLOAD

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Komatsu HM300-2 Dump Truck Shop Manual CEBM007700 – PDF DOWNLOAD 

Language : English
Pages : 1375
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HM300-2 Dump Truck Shop Manual CEBM007700 – PDF DOWNLOAD 

SERIAL NUMBERS HM300-2 A11001 and up
ENGINE SAA6D125E-5

General precautions:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting work.

TABLE OF CONTENTS:

Komatsu HM300-2 Dump Truck Shop Manual CEBM007700 – PDF DOWNLOAD 

SERIAL NUMBERS HM300-2 A11001 and up
ENGINE SAA6D125E-5

00 INDEX AND FOREWORD 3
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 59
SPECIFICATION DRAWINGS 60
SPECIFICATIONS 61
WEIGHT TABLE 64
FUEL, COOLANT AND LUBRICANTS 65
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 69
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 DISCONNECT 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 363
STANDARD VALUE TABLE FOR ENGINE 364
STANDARD VALUE TABLE FOR CHASSIS 365
30 TESTING AND ADJUSTING 371
TESTING AND ADJUSTING, PART 1 371
TOOLS FOR TESTING, ADJUSTING, AND TROUBLE SHOOTING 373
TESTING ENGINE SPEED 377
TESTING INTAKE AIR PRESSURE (BOOST PRESSURE) 378
TESTING EXHAUST TEMPERATURE 379
TESTING EXHAUST GAS COLOR 381
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
TESTING AND ADJUSTING, PART 2 401
TESTING TORQUE CONVERTER STALL SPEED 403
TESTING POWER TRAIN OIL PRESSURE 404
ADJUSTING TRANSMISSION SPEED SENSOR 412
TESTING AND ADJUSTING BRAKE OIL PRESSURE 414
TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS 418
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 OF EMERGENCY RELEASE OF PARKING BRAKE 426
TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE 427
TESTING AND ADJUSTING SUSPENSION CYLINDER 429
METHOD OF TILTING CAB UP 433
TESTING AND ADJUSTING DUMP CIRCUIT OIL PRESSURE 435
ADJUSTING BODY POSITIONER SENSOR 438
PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT 439
HANDLING ENGINE CONTROLLER HIGH VOLTAGE 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 EQUIPMENT 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 509
FAILURE CODE TABLE AND FUSE LOCATIONS 509
FAILURE CODES TABLE 510
FUSE LOCATIONS 518
GENERAL INFORMATION ON TROUBLE SHOOTING 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: SLIPPPING) 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 PWOER 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 2 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] (PWOER SOURCE VOLTAGE TOO LOW) 715
FAILURE CODE [CA442] (PWOER SOURCE VOLTAGE TOO HIGH) 715
FAILURE CODE [CA449] (COMMON RAIL PRESSURE TOO HIGH 2 716
FAILURE CODE [CA451] (COMON RAIL PRESSURE SENSOR TO 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 VALE SERVO 1) 739
FAILURE CODE [CA1629] (ABNORMAL BYPASS VALVE SERVO 2) 740
TROUBLESHOOTING BY FAILURE CODE, PART 3 743
FAILURE CODE [CA1631] (BYPASS VALVE LFIT 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 LIFR 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 [DK53LB] (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 SICRUIT) 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 RPESSURE 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: MANFUNCTION) 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 CIDE [DXH0KB] (INTERAXLE DIFFERENTIAL LOCK PRESSURE CONTROL VALVE: SHORT CIRCUIT) 878
FAILURE CODE [DXH0KY] (INTER-AXLE DIFFERNETIAL 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: 888
FAILURE CODE [DXH3KA] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION) 892
FAILURE CODE [DXH3KB] (L0 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 OTUPUT 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 935
E-1 ENGINE DOES NOT START 936
E-2 AUTOMATIC PREHEATING DOES NOT OPERATE 939
E-3 MACHINE MONITOR DOES NOT DISPLAY ALL, WHEN STARTING SWITCH IS TURNED ON 942
E-4 MACHINE MONITOR DOES NOT OPERATE WHEN STARTING SWITCH IS OFF 944
E-5 ALARM BUZZER DOES NOT STOP SOUNDING 946
E-6 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLY 947
E-7 SELECTION OF DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGED 948
E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLY 952
E-9 AISS FUNCTION DOES NOT OPERATE PROPERLY 953
E-10 SEAT BELT CAUTION LAMP DOES NOT DISPLAY PROPERLY 954
E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZZARD LAMP) DOES NOT WORK PROPELY 955
E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLY 958
3-13 EMERGENCY STEERING DOES NOT OPERATE 965
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 971
CONTENTS OF TROUBLESHOOTING TABLE 973
H-1 MACHINE DOES NOT START 974
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS) 976
H-3 LOCKUP CANNOT BE CANCELLED 976
H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING 977
H-5 TRANSMISSION DOES NOT SHIFT UP 978
H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING 979
H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR 981
H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 982
H-9 TORQUE CONVERTER OIL PRESSURE IS LOW 983
H-10 FRONT BRAKE IS INEFFECTIVE 984
H-11 CENTER BRAKE IS INEFFECTIVE 985
H-12 STEERING WHEEL IS HEAVY 986
H-13 STEERING WHEEL DOES NOT WORK 987
H-14 STEERING SHEEL VIBRATES 988
H-15 DUMP BODY LIFTING SPEED IS SLOW 989
H-16 DUMP BODY DOES NOT WORK 990
H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY 991
TROUBLESHOOTING OF ENGINE (S-MODE) 993
HOW TO USE A TROUBLESHOOTING CHART 995
S-1 ENGINE IS HARD TO START 998
S-2 ENGINE DOES NOT START 1000
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 1004
S-4 ENGINE STOPS DURING OPERATIONS 1005
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 1006
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1007
S-7 EXHAUST GAS COLOR IS BLACK (INCOMPLETE COMPUSTION) 1008
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS COLOR IS BLUE) 1010
S-9 OIL GETS CONTAMINATED PREMATURELY 1011
S-10 FUEL CONSUMPTION IS EXCESSIVE 1012
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1013
S-12 OIL PRESSURE DROPS 1014
S-13 OIL LEVEL RISES (COOLANT OR FUEL MIXES) 1016
S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT) 1018
S-15 ABNORMAL NOISE 1019
S-16 VIBRATION IS EXCESSIVE 1020
50 DISASSEMBLY AND ASSEMBLY 1023
HOW TO READ THIS MANUAL 1024
LIST OF ADHESIVES 1026
SPECIAL TOOL LIST 1029
SKETCHES OF SPECIAL TOOLS 1034
ENGINE AND COOLING SYSTEM, PART 1 1049
REMOVAL AND INSTALLATION O FFUEL SUPPLY PUMP ASSEMBLY 1050
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY 1055
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1060
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 1073
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 1075
ENGINE AND COOLING SYSTEM, PART 2 1081
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1082
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY 1090
REMOVAL AND INSTALLATION OF COOLING ASSEMBLY 1092
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY 1095
DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY 1100
POWER TRAIN, PART 1 1105
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 1106
DISCONNECTION AND CONNECTION OF DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY 1112
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY 1114
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 1129
POWER TRAIN, PART 2 1137
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY 1138
POWER TRAIN, PART 3 1181
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY 1182
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY 1186
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY 1204
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
DISASEMBLY 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 INSTSALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY 1264
REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY 1266
REMOVAL AND INSTALLATION OF EQUILIZER BAR 1267
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY 1269
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY 1279
HYDRAULIC SYSTEM 1287
REMOVAL AND INSTALLATION OF FLOW AMP VALVE 1288
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY 1290
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY 1293
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY 1297
BODY 1303
REMOVAL AND INSTALLATION OF BODY ASSEMBLY 1304
CAB AND ITS ATTACHMENTS 1307
REMOVAL AND INSTALLATION OF OPERATO’S CAB 1308
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) 1313
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY (IF EQUIPPED) 1320
ELECTRICAL SYSTEM 1331
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 1332
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER 1337
REMOVAL AND INSTALLATION OF RETARDER CONTROLLER 1339
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY 1341
90 DIAGRAMS AND DRAWINGS 1343
HYDRAULIC DIAGRAMS AND DRAWINGS 1343
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM 1345
BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM 1347
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1349
BRAKE 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 : PREVIOUS DESIGN) 1357
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4) (SERIAL NP : NEW DESIGN) 1359
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO : PREVIOUS DESIGN) 1361
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO : NEW DESIGN) 1363
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (4/4) 1365
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3) 1367
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3) 1369
ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3) 1371
ELECTRICAL CIRCUIT DIAGRAM FOR PAYLOAD METER 1373
CONNECTORS TABLE AND ARRANGEMENT DRAWING 1375

S.V 15/12/24