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Komatsu HM400-2 Articulated Dump Truck Shop Manual PDF Download
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- KOMATSU HM400-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBERS:2001 and up
- PUBLICATION NUMBER:SEN00239-17
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Description
KOMATSU HM400-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
KOMATSU HM400-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU HM400-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
KOMATSU HM400-2 ARTICULATED DUMP TRUCK SERVICE REPAIR MANUAL
COVER ........................................................................................................................ 1 00 Index and foreword......................................................................................................... 0 Index..................................................................................................................... 3 Composition of shop manual............................................................................................ 4 Table of contents..................................................................................................... 6 Foreword and general information.......................................................................................... 17 Safety notice......................................................................................................... 18 How to read the shop manual........................................................................................... 23 Explanation of terms for maintenance standard......................................................................... 25 Handling of electric equipment and hydraulic component................................................................ 27 Handling of connectors newly used for engines......................................................................... 36 How to read electric wire code........................................................................................ 39 Precautions when carrying out operation............................................................................... 42 Method of disassembling and connecting push-pull type coupler......................................................... 45 Standard tightening torque table...................................................................................... 48 Conversion table...................................................................................................... 52 01 Specification.............................................................................................................. 0 Specification and technical data.......................................................................................... 59 Specification drawings................................................................................................ 60 Specifications........................................................................................................ 61 Weight table.......................................................................................................... 64 Fuel, coolant and lubricants.......................................................................................... 65 10 Structure, function and maintenance standard............................................................................... 0 Engine and cooling system................................................................................................. 69 Radiator, oil cooler, aftercooler..................................................................................... 70 Output shaft.......................................................................................................... 71 Power train, Part 1....................................................................................................... 75 Power train skeleton.................................................................................................. 76 Torque converter and transmission hydraulic piping.................................................................... 80 Brake cooling oil control valve (BCV)................................................................................. 82 Power train pump...................................................................................................... 83 Torque converter...................................................................................................... 86 Transmission.......................................................................................................... 92 Transmission control valve............................................................................................ 120 ECMV.................................................................................................................. 121 Main relief, torque converter relief valve............................................................................ 128 Power train, Part 2....................................................................................................... 131 Drive shaft........................................................................................................... 132 Axle.................................................................................................................. 140 Differential.......................................................................................................... 144 Limited slip differential............................................................................................. 156 Final drive........................................................................................................... 160 Steering system........................................................................................................... 165 Steering column....................................................................................................... 166 Brake system.............................................................................................................. 169 Brake piping.......................................................................................................... 170 Brake valve........................................................................................................... 172 Accumulator charge valve.............................................................................................. 175 Accumulator........................................................................................................... 179 Slack adjuster........................................................................................................ 180 Brake................................................................................................................. 182 Proportional reducing valve........................................................................................... 187 Brake system tank..................................................................................................... 188 Parking brake......................................................................................................... 190 Parking brake solenoid valve.......................................................................................... 194 Undercarriage and frame................................................................................................... 197 Suspension............................................................................................................ 198 Suspension cylinder................................................................................................... 203 Oscillation hitch..................................................................................................... 205 Hydraulic system.......................................................................................................... 209 Steering, hoist oil pressure piping diagram........................................................................... 210 Dump body control..................................................................................................... 211 Hydraulic tank and filter............................................................................................. 212 Flow amp valve........................................................................................................ 213 Steering valve........................................................................................................ 216 Steering cylinder..................................................................................................... 220 Hoist valve........................................................................................................... 222 Dump control valve (EPC valve)........................................................................................ 228 Pilot check valve..................................................................................................... 232 Hoist cylinder........................................................................................................ 233 Hydraulic pump........................................................................................................ 234 Cab and its attachments................................................................................................... 239 ROPS cab.............................................................................................................. 240 Cab tilt.............................................................................................................. 241 Air conditioner....................................................................................................... 244 Rear view monitor..................................................................................................... 252 Controller related.................................................................................................... 255 Electrical system, Part 1................................................................................................. 257 Machine monitor system................................................................................................ 258 Electrical system, Part 2................................................................................................. 279 Automatic shift control system........................................................................................ 280 Transmission controller............................................................................................... 283 Retarder control system............................................................................................... 312 Auto emergency steering system........................................................................................ 324 Battery disconnect switch............................................................................................. 326 Emergency engine stop switch.......................................................................................... 331 Dump control lever.................................................................................................... 333 Electrical system, Part 3................................................................................................. 339 Payload meter (Card type)............................................................................................. 340 Electrical system, Part 4................................................................................................. 373 Sensors, switches..................................................................................................... 374 KOMTRAX terminal system (if equipped)................................................................................. 383 20 Standard value table....................................................................................................... 0 Standard service value table.............................................................................................. 387 Standard value table for engine....................................................................................... 388 Standard value table for chassis...................................................................................... 389 30 Testing and adjusting...................................................................................................... 0 Testing and adjusting, Part 1............................................................................................. 395 Tools for testing, adjusting, and troubleshooting..................................................................... 396 Measuring engine speed................................................................................................ 401 Testing intake air pressure (boost pressure).......................................................................... 402 Testing exhaust temperature........................................................................................... 403 Testing exhaust gas color............................................................................................. 405 Adjusting valve clearance............................................................................................. 406 Testing compression pressure.......................................................................................... 407 Testing blow-by pressure.............................................................................................. 409 Testing engine oil pressure........................................................................................... 410 Testing EGR valve and bypass valve drive oil pressure................................................................. 411 Handling of fuel system devices....................................................................................... 412 Releasing residual pressure from fuel system.......................................................................... 412 Testing fuel pressure................................................................................................. 413 Testing fuel return and leakage amount................................................................................ 414 Bleeding air from fuel circuit........................................................................................ 417 Testing the fuel circuit for leakage.................................................................................. 419 Testing and adjusting fan belt tension................................................................................ 420 Testing and adjusting alternator belt tension......................................................................... 421 Testing and adjusting air conditioner compressor belt tension......................................................... 422 Adjusting the body mount.............................................................................................. 423 Testing and adjusting, Part 2............................................................................................. 425 Testing torque converter stall speed.................................................................................. 426 Testing power train oil pressure...................................................................................... 427 Testing and adjusting of differential lock oil pressure (differential lock spec.)..................................... 435 Adjusting transmission speed sensor................................................................................... 440 Testing and adjusting brake oil pressure.............................................................................. 442 Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas................. 446 Testing brake performance............................................................................................. 450 Bleeding air from brake circuit....................................................................................... 451 Testing wear of wheel brake disc...................................................................................... 452 Testing the parking brake pad wear.................................................................................... 453 Emergency release of the parking brake................................................................................ 455 Testing and adjusting steering circuit oil pressure................................................................... 456 Testing and adjusting suspension cylinder............................................................................. 458 Method of tilting cab up.............................................................................................. 462 Testing and adjusting dump circuit oil pressure....................................................................... 464 Adjusting body positioner sensor...................................................................................... 466 Adjusting length of spring in body heating spherical joint............................................................ 467 Handling of voltage circuit of engine controller...................................................................... 468 Adjusting transmission controller..................................................................................... 468 Method for emergency escape at electrical system failure.............................................................. 469 Testing and adjusting, Part 3............................................................................................. 475 Setting and adjusting various equipments.............................................................................. 476 Special function of machine monitor................................................................................... 485 How to start operation of KOMTRAX terminal............................................................................ 530 Lamp display of KOMTRAX terminal...................................................................................... 535 Pm Clinic check sheet................................................................................................. 538 Initial setting of payload meter...................................................................................... 541 40 Troubleshooting............................................................................................................ 0 General information on troubleshooting.................................................................................... 543 Points to remember when troubleshooting............................................................................... 544 Sequence of events in troubleshooting................................................................................. 545 Check before troubleshooting.......................................................................................... 546 Classification and procedures for troubleshooting..................................................................... 547 Connection table for connector pin numbers............................................................................ 550 T-branch box and T-branch adapter table............................................................................... 586 Troubleshooting by failure code, General.................................................................................. 591 Troubleshooting by failure code, General.............................................................................. 592 Failure codes table............................................................................................... 592 Before troubleshooting by failure code............................................................................ 600 Information in troubleshooting table.............................................................................. 607 Troubleshooting by failure code, Part 1................................................................................... 610 Troubleshooting by failure code, Part 1............................................................................... 612 Failure code [1500L0] Double engagement........................................................................... 612 Failure code [15B0NX] Transmission oil filter: Clogged............................................................ 613 Failure code [15F0KM] R → F shifting abuse 1...................................................................... 615 Failure code [15F0MB] R → F shifting abuse 2...................................................................... 615 Failure code [15F7KM] Transmission forward clutch abuse........................................................... 616 Failure code [15G0MW] Trouble in reverse clutch system (Slip)..................................................... 617 Failure code [15G7KM] Transmission reverse clutch abuse........................................................... 619 Failure code [15H0MW] Trouble in Hi clutch system (Slip).......................................................... 620 Failure code [15J0MW] Trouble in Lo clutch system (Slip).......................................................... 622 Failure code [15K0MW] Trouble in 1st clutch system (Slip)......................................................... 624 Failure code [15L0MW] Trouble in 2nd clutch system (Slip)......................................................... 626 Failure code [15M0MW] Trouble in 3rd clutch system (Slip)......................................................... 628 Failure code [15SBL1] Trouble in reverse clutch pressure control valve I.......................................... 630 Failure code [15SBMA] Trouble in reverse clutch pressure control valve II......................................... 633 Failure code [15SCL1] Trouble in Hi clutch pressure control valve I............................................... 635 Failure code [15SCMA] Trouble in Hi clutch pressure control valve II.............................................. 638 Failure code [15SDL1] Trouble in Lo clutch pressure control valve I............................................... 640 Failure code [15SDMA] Trouble in Lo clutch pressure control valve II.............................................. 642 Troubleshooting by failure code, Part 2................................................................................... 646 Failure code [15SEL1] Trouble in 1st clutch pressure control valve I.................................................. 648 Failure code [15SEMA] Trouble in 1st clutch pressure control valve II................................................. 651 Failure code [15SFL1] Trouble in 2nd clutch pressure control valve I.................................................. 653 Failure code [15SFMA] Trouble in 2nd clutch pressure control valve II................................................. 657 Failure code [15SGL1] Trouble in 3rd clutch pressure control valve I.................................................. 659 Failure code [15SGMA] Trouble in 3rd clutch pressure control valve II................................................. 663 Failure code [15SJMA] Trouble in lockup clutch pressure control valve II.............................................. 665 Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve II......................... 667 Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2............................... 669 Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............................... 671 Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2................................ 673 Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1................................ 675 Failure code [2C4MNX] Clogging of retarder cooling oil filter......................................................... 677 Failure code [2F00KM] Dragging of parking brake....................................................................... 679 Failure code [2G42ZG] Lowering of accumulator oil pressure (front).................................................... 681 Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)..................................................... 681 Failure code [989A00] Operation of engine overrun prevention system................................................... 682 Failure code [989D00] Rear section tipping over alarm (Raising operation on slope).................................... 682 Failure code [A570NX] Clogging of engine oil filter................................................................... 683 Failure code [AA10NX] Clogging of air cleaner......................................................................... 685 Failure code [AB00MA] Trouble in battery charge circuit............................................................... 687 Failure code [B@BAZG] Lowering of engine oil pressure................................................................. 688 Failure code [B@BAZK] Lowering of engine oil level.................................................................... 689 Failure code [B@BCNS] Overheating of engine........................................................................... 690 Failure code [B@BCZK] Lowering of coolant level....................................................................... 691 Failure code [B@BFZK] Lowering of fuel level.......................................................................... 693 Failure code [B@C6NS] Overheating of brake cooling oil (front)........................................................ 694 Failure code [B@C7NS] Overheating of brake cooling oil (rear)......................................................... 694 Failure code [B@C8NS] Overheating of brake cooling oil (center)....................................................... 695 Failure code [B@CENS] Overheating of torque converter oil............................................................. 695 Failure code [B@JANS] Overheating of steering oil..................................................................... 696 Troubleshooting by failure code, Part 3................................................................................... 698 Failure code [CA111] Trouble in engine controller..................................................................... 701 Failure code [CA115] Trouble in engine Ne and Bkup speed sensors...................................................... 703 Failure code [CA122] Abnormally high charge pressure.................................................................. 705 Failure code [CA123] Abnormally low charge pressure................................................................... 707 Failure code [CA131] Abnormally high throttle sensor signal........................................................... 709 Failure code [CA132] Abnormally low throttle sensor signal............................................................ 711 Failure code [CA135] Abnormally high engine oil pressure.............................................................. 713 Failure code [CA141] Abnormally low engine oil pressure............................................................... 715 Failure code [CA144] Abnormally high coolant temperature.............................................................. 717 Failure code [CA145] Abnormally low coolant temperature............................................................... 719 Failure code [CA153] Abnormally high charge temperature............................................................... 721 Failure code [CA154] Abnormally low charge temperature................................................................ 723 Failure code [CA187] Abnormally low voltage in sensor power supply 2.................................................. 724 Failure code [CA221] Abnormally high ambient pressure................................................................. 725 Failure code [CA222] Abnormally low ambient pressure.................................................................. 727 Failure code [CA227] Abnormally high voltage in sensor power supply 2................................................. 729 Failure code [CA234] Engine overspeed................................................................................. 731 Failure code [CA238] Trouble in Ne speed sensor power supply.......................................................... 733 Failure code [CA263] Abnormally high fuel temperature................................................................. 735 Failure code [CA265] Abnormally low fuel temperature.................................................................. 737 Failure code [CA271] Short circuit in PCV1............................................................................ 738 Failure code [CA272] Disconnection in PCV1............................................................................ 739 Failure code [CA273] Short circuit in PCV2............................................................................ 740 Failure code [CA274] Disconnection in PCV2............................................................................ 741 Failure code [CA322] Disconnection or short circuit in injector #1 (L #1)............................................. 743 Failure code [CA323] Disconnection or short circuit in injector #5 (L #5)............................................. 745 Failure code [CA324] Disconnection or short circuit in injector #3 (L #3)............................................. 747 Failure code [CA325] Disconnection or short circuit in injector #6 (L #6)............................................. 749 Failure code [CA331] Disconnection or short circuit in injector #2 (L #2)............................................. 751 Failure code [CA332] Disconnection or short circuit in injector #4 (L #4)............................................. 753 Failure code [CA342] Matching error in engine controller data......................................................... 755 Failure code [CA351] Trouble in injector drive circuit................................................................ 757 Failure code [CA352] Abnormally low voltage in sensor power supply 1.................................................. 759 Failure code [CA386] Abnormally high voltage in sensor power supply 1................................................. 761 Troubleshooting by failure code, Part 4................................................................................... 764 Failure code [CA431] Trouble in idle validation switch................................................................ 767 Failure code [CA432] Trouble in idle validation process............................................................... 770 Failure code [CA441] Abnormally low voltage in power supply........................................................... 770 Failure code [CA442] Abnormally high voltage in power supply.......................................................... 771 Failure code [CA449] Abnormally high common rail pressure 2........................................................... 771 Failure code [CA451] Abnormally high common rail pressure............................................................. 773 Failure code [CA452] Abnormally low common rail pressure.............................................................. 775 Failure code [CA553] Abnormally high common rail pressure 1........................................................... 775 Failure code [CA554] In-range error in common rail pressure sensor.................................................... 776 Failure code [CA559] Supply pump low pressure 1....................................................................... 778 Failure code [CA689] Trouble in engine Ne speed sensor................................................................ 781 Failure code [CA731] Phase error in engine Bkup speed sensor.......................................................... 783 Failure code [CA757] Loss of all data in engine controller............................................................ 783 Failure code [CA778] Trouble in engine Bkup speed sensor.............................................................. 785 Failure code [CA1228] Trouble in EGR valve servo 1.................................................................... 787 Failure code [CA1625] Trouble in EGR valve servo 2.................................................................... 788 Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit............................................ 789 Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit............................................ 791 Failure code [CA1628] Trouble in bypass valve servo 1................................................................. 792 Failure code [CA1629] Trouble in bypass valve servo 2................................................................. 793 Failure code [CA1631] Abnormally high signal in bypass valve lift sensor.............................................. 795 Failure code [CA1632] Abnormally low signal in bypass valve lift sensor............................................... 797 Failure code [CA1633] Trouble in KOMNET............................................................................... 799 Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor.............................................. 801 Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor............................................. 803 Failure code [CA2185] Abnormally high voltage in throttle sensor power supply......................................... 805 Failure code [CA2186] Abnormally low voltage in throttle sensor power supply.......................................... 807 Failure code [CA2249] Low pressure in supply pump 2................................................................... 807 Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor......................................... 809 Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor.......................................... 811 Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit............................................... 813 Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit............................................... 815 Failure code [CA2555] Disconnection in intake air heater relay........................................................ 815 Failure code [CA2556] Short circuit in intake air heater relay........................................................ 817 Troubleshooting by failure code, Part 5................................................................................... 820 Failure code [DAF9KM] Wrong connection of connector................................................................... 822 Failure code [DAFRKR] Trouble in CAN communication (machine monitor).................................................. 823 Failure code [DAQ0KK] Lowering of source voltage...................................................................... 825 Failure code [DAQ0KT] Trouble in non-volatile memory.................................................................. 827 Failure code [DAQ2KK] Trouble in solenoid power supply system......................................................... 829 Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)....................................... 831 Failure code [DAQRKR] Trouble in CAN communication (Transmission controller).......................................... 833 Failure code [DAQRMA] Disagreement of option setting (Transmission controller)........................................ 835 Failure code [DB10KT] Trouble in non-volatile memory.................................................................. 835 Failure code [DB12KK] Trouble in solenoid power supply system......................................................... 837 Failure code [DB13KK] Lowering of battery direct voltage.............................................................. 839 Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 841 Failure code [DB1QMA] Disagreement of option setting (Retarder controller)............................................ 841 Failure code [DB1RKR] Trouble in CAN communication (Retarder controller).............................................. 843 Failure code [DB2RKR] Trouble in CAN communication (Engine controller)................................................ 845 Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal....................................... 847 Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve.......................................................... 849 Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve.......................................................... 850 Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve......................................................... 851 Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve......................................................... 852 Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve......................................................... 853 Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve..................................................... 854 Failure code [DF10KA] Input of no lever signals....................................................................... 855 Failure code [DF10KB] Input of multiple lever signals................................................................. 859 Failure code [DGF1KX] Transmission oil temperature out of range....................................................... 863 Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear)............................................. 865 Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear)............................................ 867 Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center)........................................... 869 Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 871 Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................ 873 Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................................... 875 Failure code [DGR6KX] Steering oil temperature out of range........................................................... 877 Troubleshooting by failure code, Part 6................................................................................... 880 Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system................................. 883 Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure sensor system.... 885 Failure code [DHT5L6] Trouble in torque converter oil pressure sensor................................................. 887 Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system....................................... 889 Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system........................................ 891 Failure code [DJF1KA] Disconnection in fuel level sensor system....................................................... 893 Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................ 895 Failure code [DK52KX] Trouble in dump lever potentiometer 1........................................................... 897 Failure code [DK53L8] Trouble in dump lever potentiometer 2........................................................... 899 Failure code [DK54KX] Trouble in dump positioner sensor............................................................... 901 Failure code [DKH0KX] Pitch angle sensor signal out of range.......................................................... 903 Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system................................... 905 Failure code [DLF1LC] Trouble in transmission input shaft speed sensor................................................ 906 Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system............................ 907 Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system............................ 908 Failure code [DLF4KA] Disconnection in transmission differential speed sensor system.................................. 909 Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system.................................. 910 Failure code [DV00KB] Short circuit in buzzer output circuit.......................................................... 911 Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system...................... 913 Failure code [DW73KZ] Trouble in dump selector valve output system.................................................... 915 Failure code [DW78KZ] Trouble in rear wheel BCV command output system................................................. 917 Failure code [DW79KZ] Trouble in front wheel BCV command output system................................................ 919 Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1........................... 921 Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure reducing valve..... 923 Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure reducing valve...... 925 Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure reducing valve......... 927 Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2........................... 929 Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1.......................... 931 Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure reducing valve.... 933 Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure reducing valve..... 935 Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure reducing valve........ 937 Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2.......................... 939 Troubleshooting by failure code, Part 7................................................................................... 942 Troubleshooting by failure code, Part 7............................................................................... 944 Failure code [DX13KA] Disconnection in output circuit of dump EPC valve........................................... 944 Failure code [DX13KB] Ground fault in output circuit of dump EPC valve............................................ 946 Failure code [DX13KY] Hot short in output circuit of dump EPC valve............................................... 948 Failure code [DX14KZ] Trouble in rear wheel differential lock command output system............................... 949 Failure code [DX15KZ] Trouble in front wheel differential lock command output system.............................. 951 Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid.............. 953 Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid............... 955 Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.................. 957 Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................................... 958 Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid.................................... 959 Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid....................................... 961 Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid....................................... 962 Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve............................. 964 Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve................................ 966 Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid....................................... 969 Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve............................. 971 Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve................................ 973 Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid...................................... 976 Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve............................ 978 Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve............................... 980 Troubleshooting by failure code, Part 8................................................................................... 984 Troubleshooting by failure code, Part 8............................................................................... 985 Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid...................................... 985 Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve............................ 987 Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve............................... 989 Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid...................................... 992 Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve............................ 994 Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve............................... 996 Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid.................................. 999 Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve........................1001 Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve...........................1003 Troubleshooting of electrical system (E-mode).............................................................................1007 Before troubleshooting for electrical system..........................................................................1008 Information in troubleshooting table..................................................................................1014 E-1 Engine does not start (Starting motor does not turn)..............................................................1015 E-2 Auto preheater does not operate...................................................................................1021 E-3 When starting switch is turned ON, machine monitor displays nothing...............................................1024 E-4 When starting switch is turned OFF, machine monitor cannot be operated............................................1028 E-5 Alarm buzzer does not stop sounding...............................................................................1032 E-6 Machine monitor does not normally display gauges, caution lamps, and character display section....................1033 E- 7 Display of character display section cannot be changed...........................................................1034 E- 8 Power mode selection function does not operate normally..........................................................1037 E- 9 AISS function does not operate normally..........................................................................1039 E-10 Right and left differential lock function does not operate normally (Differential lock-up specification) ........1041 E-11 Interaxle differential lock-up function does not operate normally................................................1045 E-12 Display of seat belt caution lamp is abnormal....................................................................1047 E-13 Turn signal lamps and pilot lamps do not operate normally........................................................1049 E-14 Night lighting is abnormal.......................................................................................1054 E-15 Backup lamp and backup buzzer operate abnormally.................................................................1061 E-16 Emergency steering system does not operate.......................................................................1066 E-17 Air conditioner does not operate normally........................................................................1070 Troubleshooting of hydraulic and mechanical system (H-mode)...............................................................1075 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................1077 Information in troubleshooting table..............................................................................1077 H-1 Machine does not start........................................................................................1078 H-2 Travel is not smooth (Machine hunts)..........................................................................1080 H-3 Lockup is not reset...........................................................................................1080 H-4 Start shock and gear shift shock are abnormally large.........................................................1081 H-5 Gear is not shifted up........................................................................................1082 H-6 Travel speed or power is low..................................................................................1084 H-7 Start and gearshift time lag is large.........................................................................1087 H-8 Torque converter oil temperature is high......................................................................1089 H-9 Torque converter oil temperature is low.......................................................................1090 H-10 Front brake does not work fully..............................................................................1091 H-11 Center brake does not work fully.............................................................................1092 H-12 Rear brake does not work fully...............................................................................1093 H-13 Steering wheel is heavy......................................................................................1094 H-14 Steering wheel does not move.................................................................................1095 H-15 Steering wheel waggle........................................................................................1096 H-16 Dump body raising speed is low...............................................................................1097 H-17 Dump body does not move......................................................................................1098 H-18 Hydraulic drift of dump body is large........................................................................1099 Troubleshooting of engine (S-mode)........................................................................................1101 Method of using troubleshooting chart.................................................................................1104 S-1 Starting performance of engine is poor...........................................................................1108 S-2 Engine does not start............................................................................................1110 S-3 Engine does not pick up smoothly.................................................................................1114 S-4 Engine stops during operation....................................................................................1115 S-5 Engine does not rotate smoothly..................................................................................1116 S-6 Engine lack output (or lacks power)..............................................................................1117 S-7 Exhaust gas is black (incomplete combustion).....................................................................1118 S-8 Oil consumption is excessive (or exhaust gas is blue)............................................................1120 S-9 Oil becomes dirty quickly........................................................................................1121 S-10 Fuel consumption is excessive...................................................................................1122 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...........................................1123 S-12 Oil pressure drops..............................................................................................1124 S-13 Oil level rises (Entry of coolant or fuel)......................................................................1126 S-14 Coolant temperature becomes too high (Overheating)..............................................................1128 S-15 Abnormal noise is made..........................................................................................1129 S-16 Vibration is excessive..........................................................................................1130 50 Disassembly and assembly................................................................................................... 0 General information on disassembly and assembly...........................................................................1133 How to read this manual...............................................................................................1134 Coating materials list................................................................................................1136 Special tool list.....................................................................................................1139 Sketches of special tools.............................................................................................1144 Engine and cooling system.................................................................................................1159 Removal and installation of fuel supply pump..........................................................................1160 Removal and installation of engine assembly...........................................................................1163 Removal and installation of cylinder head assembly....................................................................1171 Removal and installation of fuel injector assembly....................................................................1184 Removal and installation of radiator assembly.........................................................................1190 Removal and installation of cooling assembly..........................................................................1194 Removal and installation of aftercooler...............................................................................1198 Removal and installation of engine front seal.........................................................................1201 Removal and installation of engine rear seal..........................................................................1203 Replacement procedure of exhaust pipe fire prevention cover...........................................................1207 Power train, Part 1.......................................................................................................1217 Removal and installation of output shaft assembly.....................................................................1218 Disassembly and assembly of output shaft assembly.....................................................................1222 Removal and installation of transmission and front differential assembly..............................................1225 Disconnection and coupling of front differential and transmission.....................................................1233 Disassembly and assembly of torque converter assembly.................................................................1234 Disassembly and assembly of transmission assembly.....................................................................1242 Power train, Part 2.......................................................................................................1285 Disassembly and assembly of front differential assembly...............................................................1286 Removal and installation of center differential assembly..............................................................1303 Disassembly and assembly of center differential assembly..............................................................1306 Removal and installation of rear differential assembly................................................................1321 Disassembly and assembly of rear differential assembly................................................................1323 Power train, Part 3.......................................................................................................1337 Removal and installation of front final drive and brake assembly......................................................1338 Disassembly and assembly of front final drive and brake assembly......................................................1340 Removal and installation of center final drive and brake assembly.....................................................1353 Disassembly and assembly of center final drive and plate assembly.....................................................1355 Removal and installation of rear final drive and brake assembly.......................................................1364 Disassembly and assembly of rear final drive and brake assembly.......................................................1366 Removal and installation of center axle assembly......................................................................1376 Removal and installation of rear axle assembly........................................................................1379 Undercarriage and frame...................................................................................................1383 Removal and installation of front suspension cylinder assembly........................................................1384 Removal and installation of rear suspension cylinder assembly.........................................................1386 Disassembly and assembly of front and rear suspension cylinder assembly...............................................1387 Removal and installation of equalizer bar assembly....................................................................1389 Removal and installation of front wheel assembly......................................................................1391 Removal and installation of rear front wheel assembly.................................................................1392 Removal and installation of rear rear wheel assembly..................................................................1392 Removal and installation of hitch frame assembly......................................................................1393 Disassembly and assembly of hitch frame...............................................................................1401 Removal and installation of body assembly.............................................................................1406 Hydraulic system..........................................................................................................1409 Disassembly and assembly of steering valve............................................................................1410 Removal and installation of flow amplifier valve assembly.............................................................1420 Removal and installation of hoist valve assembly......................................................................1422 Disassembly and assembly of hoist valve assembly......................................................................1424 Disassembly and assembly of steering cylinder assembly................................................................1426 Disassembly and assembly of hoist cylinder assembly...................................................................1432 Cab and its attachments...................................................................................................1441 Removal and installation of operator’s cab............................................................................1442 Removal and installation of operator’s cab glass (Stuck glass)........................................................1447 Disassembly and assembly of operator's seat assembly..................................................................1453 Removal and installation of air conditioner unit assembly.............................................................1463 Electrical system.........................................................................................................1469 Removal and installation of retarder controller assembly..............................................................1470 Removal and installation of transmission controller assembly..........................................................1472 Removal and installation of engine controller assembly................................................................1474 90 Diagrams and drawings...................................................................................................... 0 Hydraulic diagrams and drawings...........................................................................................1477 Power train hydraulic circuit diagram.................................................................................1479 Steering and hoist hydraulic circuit diagram..........................................................................1480 Brake hydraulic circuit diagram.......................................................................................1482 Brake cooling hydraulic circuit diagram...............................................................................1483 Differential lock hydraulic circuit diagram...........................................................................1484 Electrical diagrams and drawings..........................................................................................1486 Electrical circuit diagram for inside cab (1/4).......................................................................1488 Electrical circuit diagram for inside cab (2/4).......................................................................1489 Electrical circuit diagram for inside cab (3/4).......................................................................1490 Electrical circuit diagram for inside cab (4/4).......................................................................1491 Electrical circuit diagram for outside cab (1/4)......................................................................1492 Electrical circuit diagram for outside cab (2/4)......................................................................1493 Electrical circuit diagram for outside cab (3/4)......................................................................1494 Electrical circuit diagram for outside cab (4/4)......................................................................1495 Electrical circuit diagram for payload meter..........................................................................1496 Connectors table and arrangement drawing ............................................................................1497
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
