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KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:3001 and up) – PDF Download
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- KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:3001 and up
- PUBLICATION NUMBER:SEN05629-04
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Description
KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:3001 and up)
KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:3001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:3001 and up)
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams
TABLE OF CONTENTS:
KOMATSU HM300-3 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL (SN:3001 and up)
Cover..................................................................................................................... 1 00 Index and foreword .................................................................................................... 3 Index ................................................................................................................ 4 Foreword, safety and general information ............................................................................. 19 Important safety notice .......................................................................................... 19 How to read the shop manual ...................................................................................... 26 Explanation of terms for maintenance standard .................................................................... 28 Handling equipment of fuel system devices ........................................................................ 30 Handling of intake system parts .................................................................................. 31 Handling of hydraulic equipment .................................................................................. 32 Method of disconnecting and connecting of push-pull type coupler ................................................. 34 Handling of electrical equipment ................................................................................. 37 How to read electric wire code ................................................................................... 45 Precautions when performing operation ............................................................................ 48 Practical use of KOMTRAX ......................................................................................... 53 Standard tightening torque table ................................................................................. 54 List of abbreviation ............................................................................................. 60 Conversion table ................................................................................................. 65 01 Specification ......................................................................................................... 71 Table of contents .................................................................................................... 72 Specifications ....................................................................................................... 73 Specification drawing ............................................................................................ 73 Specifications ................................................................................................... 75 Weight table ..................................................................................................... 81 Table of fuel, coolant, and lubricants ........................................................................... 82 10 Structure and function ................................................................................................ 85 Table of contents .................................................................................................... 86 Engine and cooling system ............................................................................................ 88 Engine related parts ............................................................................................. 88 Output shaft ..................................................................................................... 90 KVGT ............................................................................................................. 91 EGR system piping drawing ........................................................................................ 97 EGR system circuit diagram ....................................................................................... 99 EGR valve ........................................................................................................ 101 EGR cooler ....................................................................................................... 103 KCCV layout drawing .............................................................................................. 105 KCCV ventilator .................................................................................................. 107 KDPF ............................................................................................................. 109 Cooling system ................................................................................................... 115 Radiator fan pump ................................................................................................ 117 Aftercooler fan motor ............................................................................................ 127 Radiator fan motor ............................................................................................... 138 Oil cooler bypass valve .......................................................................................... 144 Power train .......................................................................................................... 145 Power train system ............................................................................................... 145 Drive shaft ...................................................................................................... 147 Torque converter and transmission hydraulic piping ............................................................... 148 Torque converter ................................................................................................. 150 Transmission ..................................................................................................... 156 Transmission control valve ....................................................................................... 180 Forward and reverse clutch ECMV and gear speed clutch ECMV ....................................................... 183 Lockup clutch ECMV ............................................................................................... 190 Differential lock clutch ECMV .................................................................................... 194 Main relief valve, torque converter relief valve, and main flow selector valve ................................... 198 Axle ............................................................................................................. 204 Differential ..................................................................................................... 207 Final drive ...................................................................................................... 211 Steering system ...................................................................................................... 214 Layout of steering devices ....................................................................................... 214 Steering column .................................................................................................. 215 Flow amplifier valve ............................................................................................. 216 Steering valve ................................................................................................... 220 Emergency steering pump .......................................................................................... 225 Brake system ......................................................................................................... 227 Layout of brake parts ............................................................................................ 227 Parking brake solenoid and accumulator charge valve .............................................................. 229 Accumulator ...................................................................................................... 235 Shut off solenoid valve .......................................................................................... 236 Brake valve ...................................................................................................... 237 Proportional pressure reducing valve ............................................................................. 242 Slack adjuster ................................................................................................... 244 Brake ............................................................................................................ 248 Brake system tank ................................................................................................ 251 Parking brake .................................................................................................... 252 Undercarriage and frame .............................................................................................. 255 Suspension ....................................................................................................... 255 Suspension cylinder .............................................................................................. 261 Oscillation hitch ................................................................................................ 263 Hydraulic system ..................................................................................................... 265 Hydraulic component layout ....................................................................................... 265 Dump body control ................................................................................................ 266 Hydraulic tank ................................................................................................... 267 Steering and hoist control pump .................................................................................. 268 Hoist valve ...................................................................................................... 280 Steering pump selector solenoid valve ............................................................................ 286 Hoist and radiator fan direction selector solenoid valve ......................................................... 287 Dump EPC valve ................................................................................................... 288 Brake cooling oil control valve .................................................................................. 290 Front brake cooling relief valve ................................................................................. 291 Cab and its attachments .............................................................................................. 292 ROPS cab ......................................................................................................... 292 Cab tilt ......................................................................................................... 293 Electrical system .................................................................................................... 294 Electrical control system ........................................................................................ 294 Machine monitor system ........................................................................................... 320 Rear view monitor system ......................................................................................... 344 KOMTRAX system ................................................................................................... 348 System component parts ........................................................................................... 352 Sensor ........................................................................................................... 372 20 Standard value tables ................................................................................................. 409 Table of contents .................................................................................................... 410 Standard service value table ......................................................................................... 411 Standard value table for engine .................................................................................. 411 Standard value table for machine ................................................................................. 413 30 Testing and adjusting ................................................................................................. 421 Table of contents .................................................................................................... 422 Related information on testing and adjusting ......................................................................... 424 Tools for testing and adjusting .................................................................................. 424 Sketch of tools for testing and adjusting ........................................................................ 430 Engine and cooling system ............................................................................................ 433 Testing engine speed ............................................................................................. 433 Testing boost pressure ........................................................................................... 434 Testing exhaust gas temperature .................................................................................. 436 Testing exhaust gas color ........................................................................................ 438 Testing and adjusting valve clearance ............................................................................ 440 Testing compression pressure ..................................................................................... 442 Testing blowby pressure .......................................................................................... 445 Testing engine oil pressure ...................................................................................... 447 Testing EGR valve and KVGT driving oil pressure .................................................................. 448 Testing fuel pressure ............................................................................................ 449 Handling cylinder cutout mode operation .......................................................................... 450 Handling no‐injection cranking operation ......................................................................... 451 Testing fuel return rate and leakage ............................................................................. 452 Bleeding air from fuel system .................................................................................... 455 Testing fuel circuit for leakage ................................................................................. 457 Checking and adjusting air conditioner compressor belt tension ................................................... 458 Replacing alternator belt ........................................................................................ 459 Procedures for cleaning fuel doser ............................................................................... 460 Writing compensation values at replacement of injector and engine controller ..................................... 463 Power train .......................................................................................................... 467 Testing torque converter stall speed ............................................................................. 467 Testing power train oil pressure ................................................................................. 469 Adjusting transmission speed sensor .............................................................................. 479 Adjusting transmission controller ................................................................................ 482 Retrieval of disabled machine that resulted from a trouble in electrical system .................................. 483 Retrieval of disabled machine due to traction control system (KTCS) failure ...................................... 487 Steering system ...................................................................................................... 489 Testing and adjusting steering circuit oil pressure .............................................................. 489 Brake system ......................................................................................................... 491 Testing and adjusting brake oil pressure ......................................................................... 491 Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas .................... 494 Testing braking performance ...................................................................................... 498 Bleeding air from brake circuit .................................................................................. 499 Testing wear of wheel brake disc ................................................................................. 500 Parking brake emergency releasing procedure ...................................................................... 501 Testing wear of parking brake pad and adjusting clearance ........................................................ 502 Hydraulic system ..................................................................................................... 504 Testing and adjusting suspension cylinder ........................................................................ 504 Testing and adjusting dump circuit oil pressure .................................................................. 510 Work equipment ....................................................................................................... 513 Adjusting dump body positioner sensor ............................................................................ 513 Testing and adjusting body mount ................................................................................. 514 Cab and its attachments .............................................................................................. 516 Cab tilt-up procedure ............................................................................................ 516 Electrical system .................................................................................................... 519 Setting and adjusting each equipment ............................................................................. 519 Special functions of machine monitor ............................................................................. 529 KOMTRAX terminal start-up procedure .............................................................................. 594 Handling voltage circuit of engine controller .................................................................... 598 Handling battery disconnect switch ............................................................................... 599 Pm clinic ............................................................................................................ 600 Pm Clinic service ................................................................................................ 600 40 Troubleshooting ....................................................................................................... 607 Table of contents .................................................................................................... 608 Related information on troubleshooting ............................................................................... 617 Troubleshooting points ........................................................................................... 617 Sequence of events in troubleshooting ............................................................................ 619 Check before troubleshooting ..................................................................................... 621 Inspection procedure before troubleshooting ...................................................................... 623 Preparation for troubleshooting of electrical system ............................................................. 641 Classification and procedures for troubleshooting ................................................................ 647 Symptom and troubleshooting numbers .............................................................................. 650 Information in troubleshooting table ............................................................................. 653 Connector list and layout ........................................................................................ 655 Connector contact identification ................................................................................. 671 T-branch box and T-branch adapter table .......................................................................... 709 Table of fuse locations .......................................................................................... 714 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .................................................... 718 Precautions on troubleshooting of machine monitor ................................................................ 721 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .......................... 723 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .................................. 728 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...................... 729 Failure codes table .............................................................................................. 730 Troubleshooting by failure code (Display of code) .................................................................... 745 Failure code [1500L0] Double Engagement of T/M Clutches .......................................................... 745 Failure code [15B0NX] Transmission Oil Filter Clogging ........................................................... 746 Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F ....................................................... 747 Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F ....................................................... 748 Failure code [15F7KM] Abuse of TM Forward Clutch Disk ............................................................ 749 Failure code [15G0MW] Failure of Clutch (Reverse) ................................................................ 750 Failure code [15G7KM] Abuse of TM Reverse Clutch Disk ............................................................ 753 Failure code [15H0MW] Failure of Clutch (High) ................................................................... 754 Failure code [15J0MW] Failure of Clutch (Low) .................................................................... 757 Failure code [15K0MW] Failure of Clutch (1st) .................................................................... 760 Failure code [15L0MW] Failure of Clutch (2nd) .................................................................... 763 Failure code [15M0MW] Failure of Clutch (3rd) .................................................................... 766 Failure code [15SBL1] Release Trouble of ECMV (Reverse) .......................................................... 769 Failure code [15SBMA] Malfunction of ECMV (Reverse) .............................................................. 772 Failure code [15SCL1] Release Trouble of ECMV (High) ............................................................. 773 Failure code [15SCMA] Malfunction of ECMV (High) ................................................................. 776 Failure code [15SDL1] Release Trouble of ECMV (Low) .............................................................. 777 Failure code [15SDMA] Malfunction of ECMV (Low) .................................................................. 780 Failure code [15SEL1] Release Trouble of ECMV (1st) .............................................................. 781 Failure code [15SEMA] Malfunction of ECMV (1st) .................................................................. 784 Failure code [15SFL1] Release Trouble of ECMV (2nd) .............................................................. 785 Failure code [15SFMA] Malfunction of ECMV (2nd) .................................................................. 788 Failure code [15SGL1] Release Trouble of ECMV (3rd) .............................................................. 789 Failure code [15SGMA] Malfunction of ECMV (3rd) .................................................................. 792 Failure code [15SJMA] Malfunction of ECMV (Lockup) ............................................................... 793 Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) ..................................................... 795 Failure code [2F00KM] Dragging of Parking Brake .................................................................. 797 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ....................................................... 799 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ........................................................ 800 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................. 801 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................. 802 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................. 803 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................. 804 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................ 805 Failure code [879CKB] Ventilating Sensor Short Circuit ........................................................... 806 Failure code [879EMC] Ventilation Damper Abnormality ............................................................. 807 Failure code [879FMC] Air Mix Damper Abnormality ................................................................. 808 Failure code [879GKX] Refrigerant Abnormality .................................................................... 809 Failure code [989D00] Tilt Caution ............................................................................... 810 Failure code [989L00] Engine Controller Lock Caution1 ............................................................ 811 Failure code [989M00] Engine Controller Lock Caution2 ............................................................ 812 Failure code [989N00] Engine Controller Lock Caution3 ............................................................ 813 Failure code [A1U0N3] HC Desorb Request 1 ........................................................................ 814 Failure code [A1U0N4] HC Desorb Request 2 ........................................................................ 816 Failure code [AA10NX] Air Cleaner Clogging ....................................................................... 818 Failure code [AB00KE] Charge Voltage Low ......................................................................... 820 Failure code [AB00KY] Hot Short of Alternator R Terminal ......................................................... 821 Failure code [B@BAZG] Eng Oil Press Low .......................................................................... 822 Failure code [B@BAZK] Engine Oil Level Low ....................................................................... 823 Failure code [B@BCNS] Eng Water Overheat ......................................................................... 824 Failure code [B@BCZK] Eng Water Level Low ........................................................................ 825 Failure code [B@C6NS] Retarder Oil Overheat (Front) .............................................................. 827 Failure code [B@C8NS] Retarder Oil Overheat (Center) ............................................................. 828 Failure code [B@CENS] T/C Oil Temp. Overheat ..................................................................... 829 Failure code [B@JANS] Steering Oil Overheat ...................................................................... 830 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................ 831 Failure code [CA122] Chg Air Press Sensor High Error ............................................................. 832 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 834 Failure code [CA131] Throttle Sensor High Error .................................................................. 836 Failure code [CA132] Throttle Sensor Low Error ................................................................... 838 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................. 840 Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................. 842 Failure code [CA144] Coolant Temp Sens High Error ................................................................ 844 Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 846 Failure code [CA153] Chg Air Temp Sensor High Error .............................................................. 848 Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................... 850 Failure code [CA187] Sensor 2 Supply Volt Low Error .............................................................. 852 Failure code [CA221] Ambient Press Sensor High Error ............................................................. 854 Failure code [CA222] Ambient Press Sensor Low Error .............................................................. 856 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................. 858 Failure code [CA234] Eng Overspeed ............................................................................... 859 Failure code [CA238] Ne Speed Sensor Supply Volt Error ........................................................... 860 Failure code [CA239] Ne Speed Sens Supply Volt High Error ........................................................ 861 Failure code [CA271] IMV/PCV1 Short Error ........................................................................ 862 Failure code [CA272] IMV/PCV1 Open Error ......................................................................... 863 Failure code [CA273] PCV2 Short Error ............................................................................ 864 Failure code [CA274] PCV2 Open Error ............................................................................. 865 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 866 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................ 868 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................ 870 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................ 872 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................ 874 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................ 876 Failure code [CA343] ECM Critical Internal Failure ............................................................... 878 Failure code [CA351] Injectors Drive Circuit Error ............................................................... 879 Failure code [CA352] Sensor 1 Supply Volt Low Error .............................................................. 880 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................. 882 Failure code [CA357] Mass Air Flow Sensor Low Error .............................................................. 884 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................. 886 Failure code [CA431] Idle Validation Sw Error .................................................................... 887 Failure code [CA432] Idle Validation Process Error ............................................................... 890 Failure code [CA441] Battery Voltage Low Error ................................................................... 893 Failure code [CA442] Battery Voltage High Error .................................................................. 895 Failure code [CA449] Rail Press Very High Error .................................................................. 896 Failure code [CA451] Rail Press Sensor High Error ................................................................ 897 Failure code [CA452] Rail Press Sensor Low Error ................................................................. 899 Failure code [CA515] Rail Press Sens Sup Volt High Error ......................................................... 901 Failure code [CA516] Rail Press Sens Sup Volt Low Error .......................................................... 903 Failure code [CA553] Rail Press High Error ....................................................................... 905 Failure code [CA555] Crankcase Press High Error 1 ................................................................ 906 Failure code [CA556] Crankcase Press High Error 2 ................................................................ 907 Failure code [CA559] Rail Press Low Error ........................................................................ 908 Failure code [CA595] Turbo Speed High Error 2 .................................................................... 912 Failure code [CA687] Turbo Speed Low Error ....................................................................... 913 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................... 915 Failure code [CA691] Intake Air Temp Sens High Error ............................................................. 917 Failure code [CA692] Intake Air Temp Sens Low Error .............................................................. 919 Failure code [CA697] ECM Internal Temp Sensor High Error ......................................................... 921 Failure code [CA698] ECM Int Temp Sensor Low Error ............................................................... 922 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................. 923 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 924 Failure code [CA1117] Persistent Data Lost Error ................................................................. 926 Failure code [CA1664] KDOC Malfunction ........................................................................... 927 Failure code [CA1691] Regeneration Ineffective ................................................................... 930 Failure code [CA1695] Sensor 5 Supply Volt High Error ............................................................ 933 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................. 935 Failure code [CA1843] Crankcase Press Sens High Error ............................................................ 937 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................. 939 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................. 941 Failure code [CA1881] KDPF Delta P Sensor Low Error .............................................................. 943 Failure code [CA1883] KDPF Delta P Sens In Range Error ........................................................... 945 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................ 949 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................ 952 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................. 957 Failure code [CA1924] Dosing Fuel Valve 1 Low Error .............................................................. 959 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ......................................................... 961 Failure code [CA1927] Dosing Fuel Press Sens High Error .......................................................... 963 Failure code [CA1928] Dosing Fuel Press Sens Low Error ........................................................... 965 Failure code [CA1942] Crankcase Press Sens In Range Error ........................................................ 967 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ............................................................ 968 Failure code [CA1977] Fuel Doser Open/Short Error ................................................................ 970 Failure code [CA1993] KDPF Delta Pressure Low Error .............................................................. 972 Failure code [CA2185] Throt Sensor Sup Volt High Error ........................................................... 976 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................ 978 Failure code [CA2249] Rail Press Very Low Error .................................................................. 980 Failure code [CA2265] Fuel Feed Pump Open Error .................................................................. 981 Failure code [CA2266] Fuel Feed Pump Short Error ................................................................. 983 Failure code [CA2271] EGR Valve Pos Sens High Error .............................................................. 986 Failure code [CA2272] EGR Valve Pos Sens Low Error ............................................................... 988 Failure code [CA2349] EGR Valve Solenoid Open Error .............................................................. 990 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................. 992 Failure code [CA2357] EGR Valve Servo Error ...................................................................... 994 Failure code [CA2381] KVGT Pos Sens High Error ................................................................... 995 Failure code [CA2382] KVGT Pos Sens Low Error .................................................................... 997 Failure code [CA2383] KVGT Solenoid Open Error ................................................................... 999 Failure code [CA2386] KVGT Solenoid Short Error ..................................................................1001 Failure code [CA2387] KVGT Servo Error ...........................................................................1003 Failure code [CA2555] Grid Htr Relay Volt Low Error ..............................................................1004 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................1006 Failure code [CA2637] KDOC Face Plugging .........................................................................1008 Failure code [CA2639] Manual Stationary Regeneration Request .....................................................1010 Failure code [CA2732] Dosing Fuel Valve 2 High Error .............................................................1013 Failure code [CA2733] Dosing Fuel Valve 2 Low Error ..............................................................1015 Failure code [CA2741] Dosing Fuel Valve Swap Error ...............................................................1017 Failure code [CA2765] Inj Trim Data Error ........................................................................1019 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ............................................................1020 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ...........................................................1023 Failure code [CA3133] KDPF Outlet Press Sens High Error ..........................................................1028 Failure code [CA3134] KDPF Outlet Press Sens Low Error ...........................................................1030 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ......................................................1032 Failure code [CA3167] Fuel Doser Degradation .....................................................................1036 Failure code [CA3251] KDOC Inlet Temp High Error .................................................................1039 Failure code [CA3253] KDOC Temp Error - Non Regeneration .........................................................1042 Failure code [CA3254] KDOC Outlet Temp High Error 1 ..............................................................1045 Failure code [CA3255] KDPF Temp Error - Non Regeneration .........................................................1048 Failure code [CA3256] KDPF Outlet Temp High Error 1 ..............................................................1051 Failure code [CA3311] KDOC Outlet Temp High Error 2 ..............................................................1054 Failure code [CA3312] KDPF Outlet Temp High Error 2 ..............................................................1057 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...........................................................1060 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................1063 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ........................................................1067 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................1071 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...........................................................1074 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................................1078 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...........................................................1083 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................1087 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error .......................................................1090 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...................................................1095 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....................................................1097 Failure code [D150KB] Ground Fault of Emerg. Steering Relay ......................................................1099 Failure code [D150KZ] Failure of Emerg. Steering Relay ...........................................................1100 Failure code [D164KY] Hot Short of Head Light High Selector ......................................................1101 Failure code [D19HKZ] Failure of Stop Lamp (R&L) .................................................................1102 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................1104 Failure code [D1EHKA] Disconnection of Engine Start Relay ........................................................1105 Failure code [D1EHKB] Ground Fault of Engine Start Relay .........................................................1106 Failure code [D1EHKY] Hot Short of Engine Start Relay ............................................................1107 Failure code [D1EMKA] Disconnection of Parking Interlock Relay ...................................................1108 Failure code [D1EMKB] Ground Fault of Parking Interlock Relay ....................................................1109 Failure code [D1EMKY] Hot Short of Parking Interlock Relay .......................................................1110 Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay ....................................................1111 Failure code [D5ZHL6] Disconnection of Key SW C ..................................................................1112 Failure code [D811MC] KOMTRAX Error ..............................................................................1114 Failure code [D862KA] GPS Antenna Open Circuit ...................................................................1115 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ......................................................1116 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .....................................................1118 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ....................................................................1120 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ......................................................................1121 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...................................................1122 Failure code [DAF0MB] Monitor ROM Abnormality ....................................................................1123 Failure code [DAF0MC] Monitor Error ..............................................................................1124 Failure code [DAF3KK] Controller Power Source Low (MON) ..........................................................1125 Failure code [DAF8KB] Camera Power Supply Short Circuit ..........................................................1127 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .....................................................1128 Failure code [DAFGMC] GPS Module Error ...........................................................................1130 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..........................................................1131 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .........................................................1133 Failure code [DAFQKR] CAN2 Discon (Monitor) ......................................................................1135 Failure code [DAQ0KK] Controller Power Source Low (T/M) ..........................................................1136 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ...................................................1138 Failure code [DAQ0MC] T/M Con Error ..............................................................................1139 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ..........................................................1140 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ............................................................1142 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .....................................................1144 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ..........................................................1145 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) .........................................................1147 Failure code [DAQQKR] CAN2 Discon (Transmission Con) .............................................................1149 Failure code [DAQRKR] CAN1 Discon (Transmission Con) .............................................................1150 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ....................................................1151 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................1152 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...................................................................1153 Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) ...................................................1154 Failure code [DB10MC] RHC Error ..................................................................................1155 Failure code [DB11KA] Disconnection of Key SW ACC (RHC) ..........................................................1156 Failure code [DB12KK] Solenoid Power Source Low (RHC) ............................................................1158 Failure code [DB13KK] Controller Power Source Low (RHC) ..........................................................1160 Failure code [DB19KQ] Inconsistency of Model Selection (RHC) .....................................................1162 Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC) ....................................................1163 Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) ....................................................1165 Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) ...........................................................1167 Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ....................................................1168 Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) ...........................................................1169 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...................................................................1170 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...................................................................1175 Failure code [DBSQKR] CAN2 Discon (PLM) ..........................................................................1180 Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) .....................................................1185 Failure code [DD1ML4] Failure of ARAC SW .........................................................................1186 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .................................................1188 Failure code [DDTHKA] Disconnection of Fill Switch (High) ........................................................1190 Failure code [DDTJKA] Disconnection of Fill Switch (Low) .........................................................1192 Failure code [DDTKKA] Disconnection of Fill Switch (1st) .........................................................1194 Failure code [DDTLKA] Disconnection of Fill Switch (2nd) .........................................................1196 Failure code [DDTMKA] Disconnection of Fill Switch (3rd) .........................................................1198 Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) .....................................................1200 Failure code [DF10KA] Disconnection of Shift Lever Input .........................................................1202 Failure code [DF10KB] Ground Fault of Shift Lever Input ..........................................................1205 Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor .......................................................1209 Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C) ...................................................1211 Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) ...................................................1212 Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) ...................................................1213 Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F) ...................................................1214 Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S. ......................................................1216 Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor .......................................................1217 Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor .......................................................1219 Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) .....................................................1221 Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) .......................................................1223 Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) .....................................................1225 Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) .......................................................1227 Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) .....................................................1229 Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) .......................................................1231 Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) .....................................................1233 Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) .......................................................1235 Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ....................................................1237 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................................1239 Failure code [DHT5L6] Failure of T/C Oil Press Sensor ............................................................1241 Failure code [DHT8KX] Out of Range of Steering Oil Press. S. .....................................................1243 Failure code [DHT8ZG] Steering Oil Pressure Low ..................................................................1245 Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) .....................................................1246 Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R) .....................................................1248 Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) ....................................................1250 Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR) ....................................................1252 Failure code [DHUCKX] Out of Range of Parking Brake Press. S. ....................................................1254 Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 .................................................1256 Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) ....................................................1258 Failure code [DHURKX] Out of Range of Retarder Press. S. (CL) ....................................................1260 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .........................................................1262 Failure code [DK30KX] Out of Range of Steering Angle Pot. ........................................................1264 Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS .....................................................1266 Failure code [DK52KX] Out of Range of Hoist Lever Potentio. ......................................................1269 Failure code [DK53L8] Failure of Hoist Lever Potentio. ...........................................................1271 Failure code [DK54KX] Out of Range of Body Potentio. .............................................................1272 Failure code [DK60KX] Out of Range of Acceleration Sensor ........................................................1274 Failure code [DKH0KX] Out of Range of Inclination Angle Sensor ...................................................1276 Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. .................................................1278 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ....................................................1280 Failure code [DLF1LC] Failure of T/M Input Speed Sensor ..........................................................1282 Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor ...................................................1284 Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor ...................................................1286 Failure code [DLF400] T/M Diff. Overrun Prevention Activated .....................................................1288 Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor ....................................................1289 Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor ..........................................................1291 Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) .........................................................1293 Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) .........................................................1295 Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) .........................................................1297 Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) .........................................................1299 Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) ......................................................1301 Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) .....................................................1302 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .................................................1303 Failure code [DLM3MB] Radiator Fan Control Mismatch ..............................................................1305 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor .......................................................1306 Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor ......................................................1308 Failure code [DLM4MB] CAC Fan Control Mismatch ...................................................................1310 Failure code [DLM4LC] Failure of CAC Fan Speed Sensor ............................................................1311 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) .................................................1313 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ......................................................1315 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..................................................................1317 Failure code [DPQ2KR] LIN Discon (LED Unit) ......................................................................1320 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .............................................................1323 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...................................................................1326 Failure code [DV00KB] Ground Fault of Buzzer Output ..............................................................1327 Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ...................................................1329 Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ....................................................1330 Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. .......................................................1331 Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve ....................................................1332 Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ....................................................1333 Failure code [DW4BK4] Release Trouble of Parking Brake Valve .....................................................1334 Failure code [DW4BMA] Malfunction of Parking Brake Valve .........................................................1336 Failure code [DW72KZ] Failure of Kick out Solenoid ...............................................................1337 Failure code [DW73KA] Disconnection of Hoist Selector Sol. .......................................................1339 Failure code [DW73KB] Ground Fault of Hoist Selector Sol. ........................................................1341 Failure code [DW73KY] Hot Short of Hoist Selector Sol. ...........................................................1343 Failure code [DW78KZ] Failure of Brake Cooling Sol. (Rear) .......................................................1345 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .....................................................1347 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ........................................................1349 Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol. ..........................................................1350 Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. ..........................................................1352 Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol. .............................................................1353 Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol. ...............................................................1354 Failure code [DW7MKB] Ground Fault of Fan/Hoist Selector Sol. ....................................................1355 Failure code [DW7MKY] Hot Short of Fan/Hoist Selector Sol. .......................................................1357 Failure code [DW7MKZ] Failure of Fan/Hoist Selector Sol. .........................................................1358 Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. .....................................................1360 Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front) .......................................................1362 Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) ......................................................1364 Failure code [DX13KA] Disconnection of Hoist EPC Solenoid ........................................................1366 Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid .........................................................1368 Failure code [DX13KY] Hot Short of Hoist EPC Solenoid ............................................................1370 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ....................................................1372 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. .....................................................1373 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................................1375 Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol. .....................................................1376 Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. ......................................................1377 Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol. .........................................................1378 Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) ..................................................1379 Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) ....................................................1381 Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL) .....................................................1383 Failure code [DX30KY] Hot Short of Retarder EPC Valve Sol. (FL) ..................................................1385 Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) .....................................................1387 Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) ..................................................1389 Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) ....................................................1391 Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR) .....................................................1393 Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) ........................................................1395 Failure code [DX31MA] Malfunction of Retarder Valve (CR) .........................................................1397 Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) ..................................................1399 Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL) ....................................................1401 Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) .....................................................1403 Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL) ........................................................1405 Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) .....................................................1407 Failure code [DX33K4] Release Trouble of Retarder EPC Valve(FR) ..................................................1409 Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR) ....................................................1411 Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) .....................................................1413 Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) ........................................................1414 Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) .....................................................1416 Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) ...................................................1418 Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.) ....................................................1420 Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) .......................................................1422 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ....................................................1424 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) .....................................................1426 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ........................................................1428 Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ......................................................1430 Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) .......................................................1432 Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) ..........................................................1434 Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) .......................................................1435 Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) ........................................................1437 Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ...........................................................1439 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) .......................................................1442 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ........................................................1444 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ...........................................................1446 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) .......................................................1449 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ........................................................1451 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ...........................................................1453 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) .......................................................1456 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ........................................................1458 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ...........................................................1460 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ...................................................1463 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ....................................................1465 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) .......................................................1467 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor .....................................................1470 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .....................................................1472 Failure code [DY30ME] Emerg. Steering Long-Time Activated ........................................................1475 Troubleshooting of electrical system (E-mode) ........................................................................1477 E-1 Engine does not start (Engine does not rotate) ...............................................................1477 E-2 Manual preheating system does not work .......................................................................1483 E-3 Automatic preheating system does not work ....................................................................1486 E-4 While preheating is working, preheating monitor does not light up ............................................1488 E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ..................................1490 E-6 LCD unit on machine monitor displays nothing .................................................................1493 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ........................1495 E-8 LCD on machine monitor does not display properly .............................................................1497 E-9 Meter unit display on machine monitor is abnormal ............................................................1499 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ............................................1502 E-11 LED unit lamp on machine monitor is abnormal ................................................................1505 E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly ....1507 E-13 2 switches operation of switch panel on machine monitor does not function ...................................1509 E-14 Switch panel buzzer of machine monitor is abnormal ..........................................................1511 E-15 Rear view monitor does not light up or backlight flickers ...................................................1513 E-16 Rear view monitor images are not displayed clearly ..........................................................1515 E-17 Rear view monitor brightness cannot be adjusted .............................................................1518 E-18 Night lighting lamp of rear view monitor is abnormal ........................................................1521 E-19 Rearview monitor does not display images while reverse linked display function is enabled ...................1523 E-20 Guide line on rear view monitor is not displayed while guide line is set ....................................1526 E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly ........................1528 E-22 Fuel level gauge does not indicate correct level ............................................................1529 E-23 Seat belt caution lamp indication is abnormal ...............................................................1531 E-24 Machine monitor cannot be operated when starting switch is in OFF position ..................................1532 E-25 Alarm buzzer does not sound .................................................................................1533 E-26 Alarm buzzer does not stop sounding .........................................................................1535 E-27 Engine mode selector function does not operate properly .....................................................1537 E-28 AISS function does not operate properly .....................................................................1538 E-29 Hoist lever does not operate properly .......................................................................1539 E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ......................................1541 E-31 None of headlamp, clearance lamp, and tail lamp lights ......................................................1545 E-32 Clearance lamp does not light up ............................................................................1547 E-33 Tail lamp does not light up .................................................................................1549 E-34 Low beam of headlamp does not light up ......................................................................1551 E-35 High beam of headlamp does not light up .....................................................................1553 E-36 Neither Low beam nor High beam of headlamp lights up ........................................................1555 E-37 High beams do not light up while passing switch is operated .................................................1557 E-38 KOMTRAX does not operate properly ...........................................................................1559 Troubleshooting of hydraulic and mechanical system (H-mode) ..........................................................1560 Information described in troubleshooting table (H-mode) ..........................................................1560 System diagram of hydraulic and mechanical systems ...............................................................1561 Failure mode and cause table .....................................................................................1563 H-1 Machine does not start .......................................................................................1567 H-2 Machine does not travel smoothly (machine hunts) .............................................................1569 H-3 Lockup is not released .......................................................................................1570 H-4 Abnormally large shocks result from starting of machine and gear shifting ....................................1571 H-5 Gear is not shifted up .......................................................................................1572 H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds ...................1574 H-7 Machine lacks travel speed or power when traveling in torque converter drive mode ............................1575 H-8 Machine lacks travel speed or power when traveling at some gear speed ........................................1576 H-9 Large time lag is observed when machine starts and gear is shifted ...........................................1577 H-10 Oil temperature of torque converter is high .................................................................1579 H-11 Oil pressure of torque converter is low .....................................................................1580 H-12 Front brake does not work enough ............................................................................1581 H-13 Center brake does not work enough ...........................................................................1582 H-14 Steering wheel is heavy .....................................................................................1583 H-15 Steering wheel does not turn ................................................................................1584 H-16 Steering wheel waggles ......................................................................................1585 H-17 Dump body rising speed is low ...............................................................................1586 H-18 Dump body does not move .....................................................................................1587 H-19 Hydraulic drift of dump body is large .......................................................................1588 H-20 Radiator fan speed is unusual (excessively high or low, or fan stops) .......................................1589 H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) ....................................1590 H-22 Unusual noise is heard from around radiator fan .............................................................1591 H-23 Unusual noise is heard from around aftercooler fan ..........................................................1592 Troubleshooting of engine (S-mode) ...................................................................................1593 Information mentioned in troubleshooting table (S mode) ..........................................................1593 S-1 When starting switch is turned to START position, engine is not cranked ......................................1594 S-2 The engine cranks but exhaust smoke does not come out ........................................................1595 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) .......1596 S-4 Engine startability is poor ..................................................................................1597 S-5 Engine does not pick-up smoothly .............................................................................1599 S-6 Engine stops during operation ................................................................................1601 S-7 Engine runs rough or is unstable .............................................................................1603 S-8 Engine lacks power ...........................................................................................1604 S-9 KDPF gets clogged in a short time ............................................................................1606 S-10 Engine oil consumption is excessive .........................................................................1608 S-11 Engine oil becomes contaminated early .......................................................................1609 S-12 Fuel consumption is excessive ...............................................................................1610 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ............................................1611 S-14 Oil pressure drops ..........................................................................................1612 S-15 Fuel mixes into engine oil ..................................................................................1613 S-16 Water mixes into engine oil (milky) .........................................................................1614 S-17 Coolant temperature rises too high (overheating) ............................................................1615 S-18 Unusual noise is heard ......................................................................................1616 S-19 Vibration is excessive ......................................................................................1617 S-20 Air cannot be bled from fuel circuit ........................................................................1618 S-21 Active regeneration is executed frequently ..................................................................1619 S-22 Active regeneration takes a long time .......................................................................1620 S-23 White smoke is exhausted during active regeneration .........................................................1621 50 Disassembly and assembly ..............................................................................................1623 Table of contents ....................................................................................................1624 Related information on disassembly and assembly ......................................................................1626 How to read this manual ..........................................................................................1626 Coating materials list ...........................................................................................1628 Special tools list ...............................................................................................1632 Sketches of special tools ........................................................................................1637 Engine and cooling system ............................................................................................1655 Removal and installation of supply pump assembly .................................................................1655 Removal and installation of injector assembly ....................................................................1662 Removal and installation of cylinder head assembly ...............................................................1674 Removal and installation of radiator assembly ....................................................................1686 Removal and installation of radiator fan and fan motor ...........................................................1689 Removal and installation of aftercooler assembly .................................................................1692 Removal and installation of aftercooler fan and fan motor assembly ...............................................1696 Removal and installation of engine assembly ......................................................................1699 Removal and installation of engine front oil seal ................................................................1706 Removal and installation of engine rear oil seal .................................................................1711 Removal and installation of output shaft assembly ................................................................1717 Disassembly and assembly of output shaft assembly ................................................................1721 Removal and installation of KDPF assembly ........................................................................1724 Disassembly and assembly of KDPF assembly ........................................................................1728 Removal and installation of KCCV assembly ........................................................................1737 Removal and installation of air cleaner assembly .................................................................1738 Power train ..........................................................................................................1740 Removal and installation of transmission and front differential assembly .........................................1740 Disconnection and connection of front differential assembly and transmission assembly ............................1752 Disassembly and assembly of front differential assembly ..........................................................1753 Disassembly and assembly of torque converter assembly ............................................................1764 Disassembly and assembly of transmission assembly ................................................................1771 Removal and installation of center differential assembly .........................................................1807 Disassembly and assembly of center differential assembly .........................................................1811 Removal and installation of rear differential assembly ...........................................................1823 Disassembly and assembly of rear differential assembly ...........................................................1825 Removal and installation of front final drive and brake assembly .................................................1835 Disassembly and assembly of front final drive and brake assembly .................................................1841 Removal and installation of center final drive and brake assembly ................................................1851 Disassembly and assembly of center final drive and brake assembly ................................................1853 Disassembly and assembly of rear final drive assembly ............................................................1860 Removal and installation of center axle assembly .................................................................1866 Removal and installation of rear axle assembly ...................................................................1869 Steering system ......................................................................................................1871 Disassembly and assembly of steering cylinder assembly ...........................................................1871 Undercarriage and frame ..............................................................................................1877 Removal and installation of front suspension cylinder assembly ...................................................1877 Removal and installation of rear suspension assembly .............................................................1883 Disassembly and assembly of suspension cylinder assembly .........................................................1885 Removal and installation of equalizer bar assembly ...............................................................1887 Removal and installation of hitch frame assembly .................................................................1890 Disassembly and assembly of hitch frame assembly .................................................................1899 Hydraulic system .....................................................................................................1904 Removal and installation of flow amplifier valve assembly ........................................................1904 Removal and installation of hoist valve assembly .................................................................1907 Disassembly and assembly of hoist cylinder assembly ..............................................................1910 Body .................................................................................................................1916 Removal and installation of dump body assembly ...................................................................1916 Cab and its attachments ..............................................................................................1918 Removal and installation of operator's cab assembly ..............................................................1918 Removal and installation of operator's cab glass (adhered glass) .................................................1922 Removal and installation of operator's seat assembly .............................................................1928 Electrical system ....................................................................................................1930 Removal and installation of machine monitor assembly .............................................................1930 Removal and installation of engine controller assembly ...........................................................1932 Removal and installation of retarder and hoist controller assembly ...............................................1934 Removal and installation of transmission controller assembly .....................................................1935 Removal and installation of mass air flow and temperature sensor .................................................1936 Removal and installation of KOMTRAX terminal assembly ............................................................1937 Air conditioner unit .................................................................................................1938 Removal and installation of air conditioner unit assembly ........................................................1938 Removal and installation of air conditioner compressor assembly ..................................................1943 60 Maintenance standard ..................................................................................................1945 Table of contents ....................................................................................................1946 Engine and cooling system ............................................................................................1947 Engine mount .....................................................................................................1947 Output shaft .....................................................................................................1948 Radiator fan pump ................................................................................................1949 Radiator fan motor ...............................................................................................1951 Aftercooler fan motor ............................................................................................1953 Power train ..........................................................................................................1955 Drive shaft ......................................................................................................1955 Torque converter and transmission mount ..........................................................................1956 Torque converter .................................................................................................1957 Transmission .....................................................................................................1960 Transmission control valve .......................................................................................1969 Forward and reverse clutch ECMV and gear speed clutch ECMV .......................................................1970 Lockup clutch ECMV ...............................................................................................1971 Differential lock clutch ECMV ....................................................................................1972 Main relief valve, torque converter relief valve, and main flow selector valve ...................................1973 Axle .............................................................................................................1975 Differential .....................................................................................................1978 Final drive ......................................................................................................1981 Steering system ......................................................................................................1985 Steering column ..................................................................................................1985 Steering cylinder ................................................................................................1986 Brake system .........................................................................................................1987 Slack adjuster ...................................................................................................1987 Brake ............................................................................................................1989 Parking brake ....................................................................................................1991 Undercarriage and frame ..............................................................................................1993 Suspension .......................................................................................................1993 Suspension cylinder ..............................................................................................1997 Oscillation hitch ................................................................................................1998 Hydraulic system .....................................................................................................2000 Steering and hoist control pump ..................................................................................2000 Front brake cooling duplex pump and aftercooler fan pump .........................................................2003 Center brake cooling pump ........................................................................................2004 Brake charge pump ................................................................................................2005 Hoist valve ......................................................................................................2006 Hoist cylinder ...................................................................................................2008 80 Appendix ..............................................................................................................2009 Table of contents ....................................................................................................2010 Air conditioner components ...........................................................................................2011 Precautions for refrigerant ......................................................................................2011 Air conditioner component ........................................................................................2012 Configuration and function of refrigeration cycle ................................................................2015 Outline of refrigeration cycle ...................................................................................2016 Air conditioner unit .............................................................................................2018 Dual pressure switch .............................................................................................2023 Air conditioner controller .......................................................................................2024 Compressor .......................................................................................................2025 Condenser ........................................................................................................2026 Receiver drier ...................................................................................................2027 Outer temperature sensor (outside air temperature sensor) ........................................................2028 Procedure for testing and troubleshooting ........................................................................2029 Circuit diagram and arrangement of connector pins ................................................................2031 System diagram ...................................................................................................2033 Input and output signals of the air conditioner controller .......................................................2034 Parts and connectors layout ......................................................................................2036 Details ..........................................................................................................2037 Testing air leakage (duct) .......................................................................................2041 Testing with self-diagnosis function .............................................................................2044 How to open the electrical system abnormality record screen in service mode of the machine monitor ...............2045 Testing vent (mode) changeover ...................................................................................2047 Testing FRESH/RECIRC air changeover ..............................................................................2048 Testing (dual) pressure switch for refrigerant ...................................................................2049 Testing relays ...................................................................................................2051 Troubleshooting chart 1 ..........................................................................................2053 Troubleshooting chart 2 ..........................................................................................2054 Information in troubleshooting table .............................................................................2057 Failure code list related to air conditioner .....................................................................2058 Failure code [879AKA] A/C Inner Sensor Open Circuit ..............................................................2059 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................2060 Failure code [879BKA] A/C Outer sensor Open Circuit ..............................................................2061 Failure code [879BKB] A/C Outer sensor Short Circuit .............................................................2063 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................2065 Failure code [879CKB] Ventilating Sensor Short Circuit ...........................................................2066 Failure code [879EMC] Ventilation Damper Abnormality .............................................................2067 Failure code [879FMC] Air Mix Damper Abnormality .................................................................2068 Failure code [879GKX] Refrigerant Abnormality ....................................................................2069 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ...................................2071 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....................................2073 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...........................2076 A-4 Troubleshooting for FRESH/RECIRC air changeover ..............................................................2078 Troubleshooting with gauge pressure ..............................................................................2080 Connection of service tool .......................................................................................2083 Precautions for disconnecting and connecting air conditioner piping ..............................................2085 Handling of compressor oil .......................................................................................2087 90 Diagrams and drawings .................................................................................................2089 Table of contents ....................................................................................................2090 Hydraulic circuit diagram ............................................................................................2091 Symbols in hydraulic circuit diagram .............................................................................2091 Power train hydraulic circuit diagram.............................................................................2095 Steering and hoist hydraulic circuit diagram .....................................................................2096 Brake hydraulic circuit diagram ..................................................................................2097 Brake cooling system hydraulic circuit diagram ...................................................................2098 Electric circuit diagram .............................................................................................2100 Symbols in electric circuit diagram ..............................................................................2100 Inside cab electric circuit diagram...............................................................................2104 Outside cab electrical circuit diagram............................................................................2111 INDEX.....................................................................................................................2118
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