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kOMATSU HM400-3 ARTICULATED DUMP TRUCK(SEN05632-06) SHOP MANUAL- PDF Download
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- KOMATSU HM400-3 ARTICULATED DUMP TRUCK SHOP MANUAL
- Publication Number:SEN05632-06
- SERIAL NUMBERS 3001 and up
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Description
kOMATSU HM400-3 ARTICULATED DUMP TRUCK(SEN05632-06) SHOP MANUAL
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KOMATSU HM400-3 ARTICULATED DUMP TRUCK(SEN05632-06) SHOP MANUAL- PDF DOWNLOAD:
Description:
kOMATSU HM400-3 ARTICULATED DUMP TRUCK(SEN05632-06) SHOP MANUAL
• 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 isused 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 forthe 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 HM400-3 ARTICULATED DUMP TRUCK(SEN05632-06) SHOP MANUAL
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 ........................................................................................................ 100 EGR cooler ....................................................................................................... 102 KCCV layout drawing .............................................................................................. 104 KCCV ventilator .................................................................................................. 106 KDPF ............................................................................................................. 108 Cooling system ................................................................................................... 114 Radiator fan pump ................................................................................................ 116 Aftercooler fan motor ............................................................................................ 124 Radiator fan motor ............................................................................................... 135 Oil cooler bypass valve .......................................................................................... 144 Power train .......................................................................................................... 145 Power train system ............................................................................................... 145 Drive shaft ...................................................................................................... 147 Torque converter and transmission hydraulic piping ............................................................... 148 Torque converter ................................................................................................. 149 Transmission ..................................................................................................... 155 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 .............................................................................................. 259 Oscillation hitch ................................................................................................ 262 Hydraulic system ..................................................................................................... 263 Hydraulic component layout ....................................................................................... 263 Dump body control ................................................................................................ 265 Hydraulic tank ................................................................................................... 266 Steering and hoist pump .......................................................................................... 267 Hoist valve ...................................................................................................... 278 Steering pump selector solenoid valve ............................................................................ 284 Dump EPC valve ................................................................................................... 285 Center brake cooling remote motor ................................................................................ 287 Front brake cooling relief valve ................................................................................. 296 Center brake cooling relief valve ................................................................................ 297 Cab and its attachments .............................................................................................. 298 ROPS cab ......................................................................................................... 298 Cab tilt ......................................................................................................... 299 Electrical system .................................................................................................... 300 Electrical control system ........................................................................................ 300 Machine monitor system ........................................................................................... 329 Rear view monitor system ......................................................................................... 352 KOMTRAX system ................................................................................................... 356 System component parts ........................................................................................... 360 Sensor ........................................................................................................... 387 20 Standard value tables ................................................................................................. 435 Table of contents .................................................................................................... 436 Standard service value table ......................................................................................... 437 Standard value table for engine .................................................................................. 437 Standard value table for machine ................................................................................. 439 30 Testing and adjusting ................................................................................................. 447 Table of contents .................................................................................................... 448 Related information on testing and adjusting ......................................................................... 450 Tools for testing and adjusting .................................................................................. 450 Sketch of tools for testing and adjusting ........................................................................ 456 Engine and cooling system ............................................................................................ 459 Testing engine speed ............................................................................................. 459 Testing boost pressure ........................................................................................... 460 Testing exhaust gas temperature .................................................................................. 462 Testing exhaust gas color ........................................................................................ 464 Adjusting valve clearance ........................................................................................ 466 Testing compression pressure ..................................................................................... 468 Testing blowby pressure .......................................................................................... 470 Testing engine oil pressure ...................................................................................... 472 Testing EGR valve and KVGT driving oil pressure .................................................................. 474 Testing fuel pressure ............................................................................................ 475 Handling cylinder cutout mode operation .......................................................................... 476 Handling no‐injection cranking operation ......................................................................... 477 Testing fuel return rate and leakage ............................................................................. 478 Bleeding air from fuel circuit ................................................................................... 481 Testing fuel circuit for leakage ................................................................................. 482 Testing radiator fan and aftercooler fan speed ................................................................... 483 Replacing and adjusting belt for alternator and air conditioner compressor ....................................... 484 Procedures for cleaning fuel doser ............................................................................... 485 Writing compensation values at replacement of injector and engine controller ..................................... 488 Power train .......................................................................................................... 492 Testing torque converter stall speed ............................................................................. 492 Testing power train oil pressure ................................................................................. 494 Adjusting transmission speed sensor .............................................................................. 505 Adjusting transmission controller ................................................................................ 508 Retrieval of disabled machine that resulted from a trouble in electrical system .................................. 509 Retrieval of disabled machine due to traction control system (KTCS) failure ...................................... 513 Steering system ...................................................................................................... 515 Testing and adjusting steering circuit oil pressure .............................................................. 515 Brake system ......................................................................................................... 517 Testing and adjusting brake oil pressure ......................................................................... 517 Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas .................... 521 Testing braking performance ...................................................................................... 525 Bleeding air from brake circuit .................................................................................. 526 Testing wear of wheel brake disc ................................................................................. 527 Parking brake emergency releasing procedure ...................................................................... 528 Testing wear of parking brake pad and adjusting clearance ........................................................ 529 Hydraulic system ..................................................................................................... 531 Testing and adjusting suspension cylinder ........................................................................ 531 Testing and adjusting dump circuit oil pressure .................................................................. 536 Work equipment ....................................................................................................... 539 Adjusting dump body positioner sensor ............................................................................ 539 Testing and adjusting body mount ................................................................................. 540 Cab and its attachments .............................................................................................. 542 Cab tilt-up procedure ............................................................................................ 542 Electrical system .................................................................................................... 545 Setting and adjusting each equipment ............................................................................. 545 Special functions of machine monitor ............................................................................. 556 KOMTRAX terminal start-up procedure .............................................................................. 629 Handling voltage circuit of engine controller .................................................................... 633 Handling battery disconnect switch ............................................................................... 634 Pm clinic ............................................................................................................ 635 Pm Clinic service ................................................................................................ 635 40 Troubleshooting ....................................................................................................... 643 Table of contents .................................................................................................... 644 Related information on troubleshooting ............................................................................... 653 Troubleshooting points ........................................................................................... 653 Sequence of events in troubleshooting ............................................................................ 655 Check before troubleshooting ..................................................................................... 657 Inspection procedure before troubleshooting ...................................................................... 659 Classification and procedures for troubleshooting ................................................................ 678 Symptom and troubleshooting numbers .............................................................................. 681 Information in troubleshooting table ............................................................................. 684 Preparation for troubleshooting of electrical system ............................................................. 686 Connector list and layout ........................................................................................ 692 Connector contact identification ................................................................................. 708 T-branch box and T-branch adapter table .......................................................................... 746 Fuse location table .............................................................................................. 751 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .................................................... 755 Precautions on troubleshooting of machine monitor ................................................................ 758 Processing procedure of harness checker for troubleshooting of machine monitor LCD unit .......................... 760 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .................................. 765 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...................... 766 Failure codes table .............................................................................................. 767 Troubleshooting by failure code (Display of code) .................................................................... 788 Failure code [1500L0] Double Engagement of T/M Clutches .......................................................... 788 Failure code [15B0NX] Transmission Oil Filter Clogging ........................................................... 789 Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F ....................................................... 790 Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F ....................................................... 791 Failure code [15F7KM] Abuse of TM Forward Clutch Disk ............................................................ 792 Failure code [15G0MW] Failure of Clutch (Reverse) ................................................................ 793 Failure code [15G7KM] Abuse of TM Reverse Clutch Disk ............................................................ 796 Failure code [15H0MW] Failure of Clutch (High) ................................................................... 797 Failure code [15J0MW] Failure of Clutch (Low) .................................................................... 800 Failure code [15K0MW] Failure of Clutch (1st) .................................................................... 803 Failure code [15L0MW] Failure of Clutch (2nd) .................................................................... 806 Failure code [15M0MW] Failure of Clutch (3rd) .................................................................... 809 Failure code [15SBL1] Release Trouble of ECMV (Reverse) .......................................................... 812 Failure code [15SBMA] Malfunction of ECMV (Reverse) .............................................................. 815 Failure code [15SCL1] Release Trouble of ECMV (High) ............................................................. 816 Failure code [15SCMA] Malfunction of ECMV (High) ................................................................. 819 Failure code [15SDL1] Release Trouble of ECMV (Low) .............................................................. 820 Failure code [15SDMA] Malfunction of ECMV (Low) .................................................................. 823 Failure code [15SEL1] Release Trouble of ECMV (1st) .............................................................. 824 Failure code [15SEMA] Malfunction of ECMV (1st) .................................................................. 827 Failure code [15SFL1] Release Trouble of ECMV (2nd) .............................................................. 828 Failure code [15SFMA] Malfunction of ECMV (2nd) .................................................................. 831 Failure code [15SGL1] Release Trouble of ECMV (3rd) .............................................................. 832 Failure code [15SGMA] Malfunction of ECMV (3rd) .................................................................. 835 Failure code [15SJMA] Malfunction of ECMV (Lockup) ............................................................... 836 Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) ..................................................... 838 Failure code [2F00KM] Dragging of Parking Brake .................................................................. 840 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ....................................................... 842 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) ........................................................ 843 Failure code [879AKA] A/C Inner Sensor Open Circuit .............................................................. 844 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................. 845 Failure code [879BKA] A/C Outer Sensor Open Circuit .............................................................. 846 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................. 847 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................ 848 Failure code [879CKB] Ventilating Sensor Short Circuit ........................................................... 849 Failure code [879EMC] Ventilation Damper Abnormality ............................................................. 850 Failure code [879FMC] Air Mix Damper Abnormality ................................................................. 851 Failure code [879GKX] Refrigerant Abnormality .................................................................... 852 Failure code [989D00] Tilt Caution ............................................................................... 853 Failure code [989L00] Engine Controller Lock Caution1 ............................................................ 854 Failure code [989M00] Engine Controller Lock Caution2 ............................................................ 855 Failure code [989N00] Engine Controller Lock Caution3 ............................................................ 856 Failure code [A1U0N3] HC Desorb Request 1 ........................................................................ 857 Failure code [A1U0N4] HC Desorb Request 2 ........................................................................ 859 Failure code [AA10NX] Air Cleaner Clogging ....................................................................... 861 Failure code [AB00KE] Charge Voltage Low ......................................................................... 863 Failure code [AB00KY] Hot Short of Alternator R Terminal ......................................................... 865 Failure code [B@BAZG] Eng Oil Press Low .......................................................................... 867 Failure code [B@BAZK] Engine Oil Level Low ....................................................................... 868 Failure code [B@BCNS] Eng Water Overheat ......................................................................... 869 Failure code [B@BCZK] Eng Water Level Low ........................................................................ 870 Failure code [B@C6NS] Retarder Oil Overheat (Front) .............................................................. 872 Failure code [B@C8NS] Retarder Oil Overheat (Center) ............................................................. 873 Failure code [B@CENS] T/C Oil Temp. Overheat ..................................................................... 874 Failure code [B@JANS] Steering Oil Overheat ...................................................................... 875 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................ 876 Failure code [CA122] Chg Air Press Sensor High Error ............................................................. 877 Failure code [CA123] Chg Air Press Sensor Low Error .............................................................. 879 Failure code [CA131] Throttle Sensor High Error .................................................................. 881 Failure code [CA132] Throttle Sensor Low Error ................................................................... 883 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................. 886 Failure code [CA141] Eng Oil Press Sensor Low Error .............................................................. 888 Failure code [CA144] Coolant Temp Sens High Error ................................................................ 890 Failure code [CA145] Coolant Temp Sens Low Error ................................................................. 892 Failure code [CA153] Chg Air Temp Sensor High Error .............................................................. 894 Failure code [CA154] Chg Air Temp Sensor Low Error ............................................................... 896 Failure code [CA187] Sensor 2 Supply Volt Low Error .............................................................. 898 Failure code [CA221] Ambient Press Sens High Error ............................................................... 900 Failure code [CA222] Ambient Press Sens Low Error ................................................................ 902 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................. 904 Failure code [CA234] Eng Overspeed ............................................................................... 905 Failure code [CA238] Ne Speed Sensor Supply Volt Error ........................................................... 906 Failure code [CA239] Ne Speed Sens Supply Volt High Error ........................................................ 907 Failure code [CA271] IMV/PCV1 Short Error ........................................................................ 908 Failure code [CA272] IMV/PCV1 Open Error ......................................................................... 909 Failure code [CA273] PCV2 Short Error ............................................................................ 910 Failure code [CA274] PCV2 Open Error ............................................................................. 911 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................ 912 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................ 914 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................ 916 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................ 918 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................ 920 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................ 922 Failure code [CA343] ECM Critical Internal Failure ............................................................... 924 Failure code [CA351] Injectors Drive Circuit Error ............................................................... 925 Failure code [CA352] Sensor 1 Supply Volt Low Error .............................................................. 926 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................. 928 Failure code [CA357] Mass Air Flow Sensor Low Error .............................................................. 930 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................. 932 Failure code [CA431] Idle Validation Sw Error .................................................................... 933 Failure code [CA432] Idle Validation Process Error ............................................................... 936 Failure code [CA441] Battery Voltage Low Error ................................................................... 939 Failure code [CA442] Battery Voltage High Error .................................................................. 941 Failure code [CA449] Rail Press Very High Error .................................................................. 942 Failure code [CA451] Rail Press Sensor High Error ................................................................ 943 Failure code [CA452] Rail Press Sensor Low Error ................................................................. 945 Failure code [CA515] Rail Press Sens Sup Volt High Error ......................................................... 947 Failure code [CA516] Rail Press Sens Sup Volt Low Error .......................................................... 949 Failure code [CA553] Rail Press High Error ....................................................................... 951 Failure code [CA555] Crankcase Press High Error 1 ................................................................ 952 Failure code [CA556] Crankcase Press High Error 2 ................................................................ 953 Failure code [CA559] Rail Press Low Error ........................................................................ 954 Failure code [CA595] Turbo Speed High Error 2 .................................................................... 958 Failure code [CA687] Turbo Speed Low Error ....................................................................... 959 Failure code [CA689] Eng Ne Speed Sensor Error ................................................................... 961 Failure code [CA691] Intake Air Temp Sens High Error ............................................................. 963 Failure code [CA692] Intake Air Temp Sens Low Error .............................................................. 965 Failure code [CA697] ECM Internal Temp Sensor High Error ......................................................... 967 Failure code [CA698] ECM Int Temp Sensor Low Error ............................................................... 968 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................. 969 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 970 Failure code [CA1117] Persistent Data Lost Error ................................................................. 972 Failure code [CA1664] KDOC Malfunction ........................................................................... 973 Failure code [CA1691] Regeneration Ineffective ................................................................... 976 Failure code [CA1695] Sensor 5 Supply Volt High Error ............................................................ 979 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................. 981 Failure code [CA1843] Crankcase Press Sens High Error ............................................................ 983 Failure code [CA1844] Crankcase Press Sens Low Error ............................................................. 985 Failure code [CA1879] KDPF Delta P Sensor High Error ............................................................. 987 Failure code [CA1881] KDPF Delta P Sensor Low Error .............................................................. 989 Failure code [CA1883] KDPF Delta P Sens In Range Error ........................................................... 991 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................ 996 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................ 999 Failure code [CA1923] Dosing Fuel Valve 1 High Error .............................................................1004 Failure code [CA1924] Dosing Fuel Valve 1 Low Error ..............................................................1006 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error .........................................................1008 Failure code [CA1927] Dosing Fuel Press Sens High Error ..........................................................1010 Failure code [CA1928] Dosing Fuel Press Sens Low Error ...........................................................1012 Failure code [CA1942] Crankcase Press Sens In Range Error ........................................................1014 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ............................................................1015 Failure code [CA1977] Fuel Doser Open/Short Error ................................................................1017 Failure code [CA1993] KDPF Delta Pressure Low Error ..............................................................1019 Failure code [CA2185] Throt Sensor Sup Volt High Error ...........................................................1023 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................1025 Failure code [CA2249] Rail Press Very Low Error ..................................................................1027 Failure code [CA2265] Fuel Feed Pump Open Error ..................................................................1028 Failure code [CA2266] Fuel Feed Pump Short Error .................................................................1030 Failure code [CA2271] EGR Valve Pos Sens High Error ..............................................................1032 Failure code [CA2272] EGR Valve Pos Sens Low Error ...............................................................1034 Failure code [CA2349] EGR Valve Solenoid Open Error ..............................................................1036 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................1038 Failure code [CA2357] EGR Valve Servo Error ......................................................................1040 Failure code [CA2381] KVGT Pos Sens High Error ...................................................................1041 Failure code [CA2382] KVGT Pos Sens Low Error ....................................................................1043 Failure code [CA2383] KVGT Solenoid Open Error ...................................................................1045 Failure code [CA2386] KVGT Solenoid Short Error ..................................................................1047 Failure code [CA2387] KVGT Servo Error ...........................................................................1049 Failure code [CA2555] Grid Htr Relay Volt Low Error ..............................................................1050 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................1052 Failure code [CA2637] KDOC Face Plugging .........................................................................1054 Failure code [CA2639] Manual Stationary Regeneration Request .....................................................1056 Failure code [CA2732] Dosing Fuel Valve 2 High Error .............................................................1059 Failure code [CA2733] Dosing Fuel Valve 2 Low Error ..............................................................1061 Failure code [CA2741] Dosing Fuel Valve Swap Error ...............................................................1063 Failure code [CA2765] Inj Trim Data Error ........................................................................1065 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ............................................................1066 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 ...........................................................1069 Failure code [CA3133] KDPF Outlet Press Sens High Error ..........................................................1074 Failure code [CA3134] KDPF Outlet Press Sens Low Error ...........................................................1076 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ......................................................1078 Failure code [CA3167] Fuel Doser Degradation .....................................................................1082 Failure code [CA3251] KDOC Inlet Temp High Error .................................................................1085 Failure code [CA3253] KDOC Temp Error - Non Regeneration .........................................................1088 Failure code [CA3254] KDOC Outlet Temp High Error 1 ..............................................................1091 Failure code [CA3255] KDPF Temp Error - Non Regeneration .........................................................1094 Failure code [CA3256] KDPF Outlet Temp High Error 1 ..............................................................1098 Failure code [CA3311] KDOC Outlet Temp High Error 2 ..............................................................1101 Failure code [CA3312] KDPF Outlet Temp High Error 2 ..............................................................1104 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...........................................................1107 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................1110 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ........................................................1114 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................1119 Failure code [CA3317] KDOC Outlet Temp Sens High Error ...........................................................1122 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................................1126 Failure code [CA3319] KDPF Outlet Temp Sens High Error ...........................................................1131 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................1135 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error .......................................................1138 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...................................................1143 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....................................................1145 Failure code [D150KB] Ground Fault of Emerg. Steering Relay ......................................................1147 Failure code [D150KZ] Failure of Emerg. Steering Relay ...........................................................1148 Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2 ....................................................1149 Failure code [D151KZ] Failure of Emerg. Steering Relay 2 .........................................................1150 Failure code [D164KY] Hot Short of Head Light High Selector ......................................................1151 Failure code [D19HKZ] Failure of Stop Lamp (R&L) .................................................................1152 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................1154 Failure code [D1EHKA] Disconnection of Engine Start Relay ........................................................1155 Failure code [D1EHKB] Ground Fault of Engine Start Relay .........................................................1156 Failure code [D1EHKY] Hot Short of Engine Start Relay ............................................................1157 Failure code [D1EMKA] Disconnection of Parking Interlock Relay ...................................................1158 Failure code [D1EMKB] Ground Fault of Parking Interlock Relay ....................................................1159 Failure code [D1EMKY] Hot Short of Parking Interlock Relay .......................................................1160 Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay ....................................................1161 Failure code [D5ZHL6] Disconnection of Key SW C ..................................................................1162 Failure code [D811MC] KOMTRAX Error ..............................................................................1164 Failure code [D862KA] GPS Antenna Open Circuit ...................................................................1165 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ......................................................1166 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .....................................................1168 Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 ....................................................................1170 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ......................................................................1171 Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ...................................................1172 Failure code [DAF0MB] Monitor ROM Abnormality ....................................................................1173 Failure code [DAF0MC] Monitor Error ..............................................................................1174 Failure code [DAF3KK] Controller Power Source Low (MON) ..........................................................1175 Failure code [DAF8KB] Camera Power Supply Short Circuit ..........................................................1177 Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .....................................................1178 Failure code [DAFGMC] GPS Module Error ...........................................................................1180 Failure code [DAFLKA] Operating Lamp Open Circuit (MON) ..........................................................1181 Failure code [DAFLKB] Operating Lamp Short Circuit (MON) .........................................................1183 Failure code [DAFQKR] CAN2 Discon (Monitor) ......................................................................1185 Failure code [DAQ0KK] Controller Power Source Low (T/M) ..........................................................1186 Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ...................................................1188 Failure code [DAQ0MC] T/M Con Error ..............................................................................1189 Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) ..........................................................1190 Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ............................................................1192 Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .....................................................1194 Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ..........................................................1195 Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) .........................................................1197 Failure code [DAQQKR] CAN2 Discon (Transmission Con) .............................................................1199 Failure code [DAQRKR] CAN1 Discon (Transmission Con) .............................................................1200 Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ....................................................1201 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................1202 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...................................................................1203 Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) ...................................................1204 Failure code [DB10MC] RHC Error ..................................................................................1205 Failure code [DB11KA] Disconnection of Key SW ACC (RHC) ..........................................................1206 Failure code [DB12KK] Solenoid Power Source Low (RHC) ............................................................1208 Failure code [DB13KK] Controller Power Source Low (RHC) ..........................................................1210 Failure code [DB19KQ] Inconsistency of Model Selection (RHC) .....................................................1212 Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC) ....................................................1213 Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) ....................................................1215 Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) ...........................................................1217 Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ....................................................1218 Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) ...........................................................1219 Failure code [DB2QKR] CAN2 Discon (Engine Con) ...................................................................1220 Failure code [DB2RKR] CAN1 Discon (Engine Con) ...................................................................1225 Failure code [DBSQKR] CAN2 Discon (PLM) ..........................................................................1230 Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) .....................................................1235 Failure code [DD1ML4] Failure of ARAC SW .........................................................................1236 Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch .................................................1238 Failure code [DDTHKA] Disconnection of Fill Switch (High) ........................................................1240 Failure code [DDTJKA] Disconnection of Fill Switch (Low) .........................................................1242 Failure code [DDTKKA] Disconnection of Fill Switch (1st) .........................................................1244 Failure code [DDTLKA] Disconnection of Fill Switch (2nd) .........................................................1246 Failure code [DDTMKA] Disconnection of Fill Switch (3rd) .........................................................1248 Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) .....................................................1250 Failure code [DF10KA] Disconnection of Shift Lever Input .........................................................1252 Failure code [DF10KB] Ground Fault of Shift Lever Input ..........................................................1255 Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor .......................................................1259 Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C) ...................................................1261 Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) ...................................................1262 Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) ...................................................1263 Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F) ...................................................1264 Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S. ......................................................1266 Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor .......................................................1267 Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S. ...................................................1269 Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor .......................................................1271 Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) .....................................................1273 Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) .......................................................1275 Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) .....................................................1277 Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) .......................................................1279 Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) .....................................................1281 Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) .......................................................1283 Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) .....................................................1285 Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) .......................................................1287 Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. ....................................................1289 Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................................1291 Failure code [DHT5L6] Failure of T/C Oil Press Sensor ............................................................1293 Failure code [DHT8KX] Out of Range of Steering Oil Press. S. .....................................................1295 Failure code [DHT8ZG] Steering Oil Pressure Low ..................................................................1297 Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) .....................................................1298 Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R) .....................................................1300 Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) ....................................................1302 Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR) ....................................................1304 Failure code [DHUCKX] Out of Range of Parking Brake Press. S. ....................................................1306 Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 .................................................1308 Failure code [DHUEKX] Out of Range of Emerg. Steering Press. S.2 .................................................1310 Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) ....................................................1312 Failure code [DHURKX] Out of Range of Retarder Press. S. (CL) ....................................................1314 Failure code [DJF1KA] Disconnection of Fuel Level Sensor .........................................................1316 Failure code [DK30KX] Out of Range of Steering Angle Pot. ........................................................1318 Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS .....................................................1320 Failure code [DK52KX] Out of Range of Hoist Lever Potentio. ......................................................1323 Failure code [DK53L8] Failure of Hoist Lever Potentio. ...........................................................1325 Failure code [DK54KX] Out of Range of Body Potentio. .............................................................1326 Failure code [DK60KX] Out of Range of Acceleration Sensor ........................................................1328 Failure code [DKH0KX] Out of Range of Inclination Angle Sensor ...................................................1330 Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. .................................................1332 Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor ....................................................1334 Failure code [DLF1LC] Failure of T/M Input Speed Sensor ..........................................................1336 Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor ...................................................1338 Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor ...................................................1340 Failure code [DLF400] T/M Diff. Overrun Prevention Activated .....................................................1342 Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor ....................................................1343 Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor ..........................................................1345 Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) .........................................................1347 Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) .........................................................1349 Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) .........................................................1351 Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) .........................................................1353 Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) ......................................................1355 Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) .....................................................1356 Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor .................................................1357 Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor .......................................................1359 Failure code [DLM3MB] Radiator Fan Control Mismatch ..............................................................1361 Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor ......................................................1362 Failure code [DLM4LC] Failure of CAC Fan Speed Sensor ............................................................1364 Failure code [DLM4MB] CAC Fan Control Mismatch ...................................................................1366 Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) .................................................1367 Failure code [DLT3LC] Failure of Output Speed Sensor (Main) ......................................................1369 Failure code [DPQ1KR] LIN Discon (Switch Panel) ..................................................................1371 Failure code [DPQ2KR] LIN Discon (LED Unit) ......................................................................1374 Failure code [DPQ3KR] LIN Discon (Rear View Monitor) .............................................................1377 Failure code [DSJ0KR] CAN2 Discon (Meter Unit) ...................................................................1380 Failure code [DV00KB] Ground Fault of Buzzer Output ..............................................................1381 Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. ...................................................1383 Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. ....................................................1384 Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. .......................................................1385 Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve ....................................................1386 Failure code [DW2BLH] Malfunction of Main Flow Selector Valve ....................................................1387 Failure code [DW4BK4] Release Trouble of Parking Brake Valve .....................................................1388 Failure code [DW4BMA] Malfunction of Parking Brake Valve .........................................................1390 Failure code [DW72KZ] Failure of Kick out Solenoid ...............................................................1391 Failure code [DW73KA] Disconnection of Hoist Selector Sol. .......................................................1393 Failure code [DW73KB] Ground Fault of Hoist Selector Sol. ........................................................1395 Failure code [DW73KY] Hot Short of Hoist Selector Sol. ...........................................................1397 Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .....................................................1399 Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. ........................................................1401 Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol. ..........................................................1402 Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. ..........................................................1404 Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol. .............................................................1405 Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol. ...............................................................1406 Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. .....................................................1407 Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front) .......................................................1409 Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) ......................................................1411 Failure code [DX13KA] Disconnection of Hoist EPC Solenoid ........................................................1413 Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid .........................................................1415 Failure code [DX13KY] Hot Short of Hoist EPC Solenoid ............................................................1417 Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. ....................................................1419 Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. .....................................................1420 Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................................1422 Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol. .....................................................1423 Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. ......................................................1424 Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol. .........................................................1425 Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) ..................................................1426 Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) ....................................................1428 Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL) .....................................................1430 Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) ........................................................1432 Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) .....................................................1434 Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) ..................................................1436 Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) ....................................................1438 Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR) .....................................................1440 Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) ........................................................1442 Failure code [DX31MA] Malfunction of Retarder Valve (CR) .........................................................1444 Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) ..................................................1446 Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL) ....................................................1448 Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) .....................................................1450 Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL) ........................................................1452 Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) .....................................................1454 Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) .................................................1456 Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR) ....................................................1458 Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) .....................................................1460 Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) ........................................................1462 Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) .....................................................1464 Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol. ...................................................1466 Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol. ....................................................1467 Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol. .......................................................1469 Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) ...................................................1470 Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.) ....................................................1472 Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) .......................................................1474 Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ....................................................1476 Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) .....................................................1478 Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ........................................................1480 Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) ......................................................1482 Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) .......................................................1484 Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) ..........................................................1486 Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) .......................................................1487 Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) ........................................................1489 Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) ...........................................................1491 Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) .......................................................1494 Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ........................................................1496 Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) ...........................................................1498 Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) .......................................................1501 Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ........................................................1503 Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) ...........................................................1505 Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) .......................................................1508 Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ........................................................1510 Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) ...........................................................1512 Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) ...................................................1515 Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ....................................................1517 Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) .......................................................1519 Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor .....................................................1522 Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .....................................................1525 Failure code [DY30ME] Emerg. Steering Long-Time Activated ........................................................1528 Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2 ...................................................1530 Troubleshooting of electrical system (E-mode) ........................................................................1533 E-1 Engine does not start (Engine does not rotate) ...............................................................1533 E-2 Manual preheating system does not work .......................................................................1539 E-3 Automatic preheating system does not work ....................................................................1542 E-4 While preheating is working, preheating pilot lamp does not light up. ........................................1544 E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ..................................1546 E-6 LCD unit on machine monitor displays nothing .................................................................1549 E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ........................1551 E-8 LCD on machine monitor does not display properly .............................................................1553 E-9 Meter unit display on machine monitor is abnormal ............................................................1555 E-10 Night lighting lamp of meter unit on machine monitor is abnormal ............................................1558 E-11 LED unit lamp on machine monitor is abnormal ................................................................1561 E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly ....1563 E-13 2 switches operation of switch panel on machine monitor does not function ...................................1565 E-14 Switch panel buzzer of machine monitor is abnormal ..........................................................1567 E-15 Rear view monitor does not light up or backlight flickers ...................................................1569 E-16 Rear view monitor images are not displayed clearly ..........................................................1571 E-17 Rear view monitor brightness cannot be adjusted .............................................................1574 E-18 Night lighting lamp of rear view monitor is abnormal ........................................................1577 E-19 Rearview monitor does not display images while reverse linked display function is enabled ...................1579 E-20 Guide line on rear view monitor is not displayed while guide line is set ....................................1582 E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly ........................1584 E-22 Fuel level gauge does not indicate correct level ............................................................1585 E-23 Seat belt caution lamp indication is abnormal ...............................................................1587 E-24 Machine monitor cannot be operated when starting switch is in OFF position ..................................1588 E-25 Alarm buzzer does not sound .................................................................................1589 E-26 Alarm buzzer does not stop sounding .........................................................................1591 E-27 Engine mode selector function does not operate properly .....................................................1593 E-28 AISS function does not operate properly .....................................................................1594 E-29 Hoist lever does not operate properly .......................................................................1595 E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ......................................1597 E-31 None of headlamp, clearance lamp, and tail lamp lights ......................................................1601 E-32 Clearance lamp does not light up ............................................................................1603 E-33 Tail lamp does not light up .................................................................................1605 E-34 Low beam of headlamp does not light up ......................................................................1607 E-35 High beam of headlamp does not light up .....................................................................1609 E-36 Neither Low beam nor High beam of headlamp lights up ........................................................1611 E-37 High beams do not light up while passing switch is operated .................................................1613 E-38 KOMTRAX does not operate properly ...........................................................................1615 Troubleshooting of hydraulic and mechanical system (H-mode) ..........................................................1616 Information described in troubleshooting table (H-mode) ..........................................................1616 System chart of hydraulic and mechanical systems .................................................................1617 Failure mode and cause table .....................................................................................1619 H-1 Machine does not start .......................................................................................1623 H-2 Machine does not travel smoothly (engine hunts) ..............................................................1625 H-3 Lockup clutch is not disengaged ..............................................................................1626 H-4 Abnormally large shocks result from starting of machine and gear shifting ....................................1627 H-5 Machine does not upshift .....................................................................................1628 H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds ...............1630 H-7 Machine lacks travel speed or power during travel in torque converter drive mode .............................1631 H-8 Machine lacks travel speed or power during travel in specific gear speed .....................................1632 H-9 Machine starts or gear speed shifts with long time lag .......................................................1633 H-10 Torque converter oil temperature is high ....................................................................1635 H-11 Torque converter oil pressure is low ........................................................................1636 H-12 Front brake does not work sufficiently ......................................................................1637 H-13 Center brake does not work sufficiently .....................................................................1638 H-14 Steering wheel is heavy to turn .............................................................................1639 H-15 Steering wheel does not move ................................................................................1640 H-16 Steering wheel swings .......................................................................................1641 H-17 Dump body raise speed or power is slow ......................................................................1642 H-18 Dump body does not move .....................................................................................1644 H-19 Hydraulic drift of dump body is large .......................................................................1645 H-20 Radiator fan speed is abnormal (high, low, or stationary) ...................................................1646 H-21 Aftercooler fan speed is abnormal (high, low, or stationary) ................................................1647 H-22 Unusual noise is heard from around radiator fan .............................................................1648 H-23 Unusual noise is heard from around aftercooler fan ..........................................................1649 Troubleshooting of engine (S-mode) ...................................................................................1650 Information mentioned in troubleshooting table (S mode) ..........................................................1650 S-1 When starting switch is turned to START position, engine is not cranked ......................................1651 S-2 The engine cranks but exhaust smoke does not come out ........................................................1652 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) .......1653 S-4 Engine startability is poor ..................................................................................1654 S-5 Engine does not pick-up smoothly .............................................................................1656 S-6 Engine stops during operation ................................................................................1658 S-7 Engine runs rough or is unstable .............................................................................1660 S-8 Engine lacks power ...........................................................................................1661 S-9 KDPF gets clogged in a short time ............................................................................1663 S-10 Engine oil consumption is excessive .........................................................................1665 S-11 Engine oil becomes contaminated early .......................................................................1666 S-12 Fuel consumption is excessive ...............................................................................1667 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ............................................1668 S-14 Oil pressure drops ..........................................................................................1669 S-15 Fuel mixes into engine oil ..................................................................................1670 S-16 Water mixes into engine oil (milky) .........................................................................1671 S-17 Coolant temperature rises too high (overheating) ............................................................1672 S-18 Unusual noise is heard ......................................................................................1673 S-19 Vibration is excessive ......................................................................................1674 S-20 Air cannot be bled from fuel circuit ........................................................................1675 S-21 Active regeneration is executed frequently ..................................................................1676 S-22 Active regeneration takes a long time .......................................................................1677 50 Disassembly and assembly ..............................................................................................1679 Table of contents ....................................................................................................1680 Related information on disassembly and assembly ......................................................................1682 How to read this manual ..........................................................................................1682 Coating materials list ...........................................................................................1684 Special tools list ...............................................................................................1688 Sketches of special tools ........................................................................................1696 Engine and cooling system ............................................................................................1717 Removal and installation of supply pump assembly .................................................................1717 Removal and installation of injector assembly ....................................................................1720 Removal and installation of cylinder head assembly ...............................................................1735 Removal and installation of radiator assembly ....................................................................1754 Removal and installation of cooling fan and fan motor assembly for radiator ......................................1759 Removal and installation of aftercooler assembly .................................................................1764 Removal and installation of cooling fan and fan motor assembly for aftercooler ...................................1767 Removal and installation of engine assembly ......................................................................1769 Removal and installation of engine front oil seal ................................................................1777 Removal and installation of engine rear oil seal .................................................................1779 Removal and installation of output shaft assembly ................................................................1785 Disassembly and assembly of output shaft assembly ................................................................1789 Removal and installation of KDPF assembly ........................................................................1792 Disassembly and assembly of KDPF assembly ........................................................................1795 Removal and installation of KCCV assembly ........................................................................1804 Removal and installation of air cleaner assembly .................................................................1806 Power train ..........................................................................................................1808 Removal and installation of transmission and front differential assembly .........................................1808 Disconnection and connection of front differential assembly and transmission assembly ............................1820 Disassembly and assembly of front differential assembly ..........................................................1822 Disassembly and assembly of torque converter assembly ............................................................1837 Disassembly and assembly of transmission assembly ................................................................1844 Removal and installation of center differential assembly .........................................................1884 Disassembly and assembly of center differential assembly .........................................................1888 Removal and installation of rear differential assembly ...........................................................1902 Disassembly and assembly of rear differential assembly ...........................................................1904 Removal and installation of front final drive and brake assembly .................................................1914 Disassembly and assembly of front final drive and brake assembly .................................................1916 Removal and installation of center final drive and brake assembly ................................................1928 Disassembly and assembly of center final drive and brake assembly ................................................1930 Removal and installation of rear final drive assembly ............................................................1940 Disassembly and assembly of rear final drive assembly ............................................................1941 Removal and installation of center axle assembly .................................................................1946 Removal and installation of rear axle assembly ...................................................................1949 Steering system ......................................................................................................1952 Disassembly and assembly of steering cylinder assembly ...........................................................1952 Disassembly and assembly of steering valve .......................................................................1958 Undercarriage and frame ..............................................................................................1968 Removal and installation of front suspension cylinder assembly ...................................................1968 Removal and installation of rear suspension cylinder assembly ....................................................1969 Disassembly and assembly of suspension cylinder assembly .........................................................1970 Removal and installation of equalizer bar assembly ...............................................................1972 Removal and installation of front wheel assembly .................................................................1974 Removal and installation of rear (front side) wheel assembly .....................................................1980 Removal and installation of rear (back side) wheel assembly ......................................................1981 Removal and installation of hitch frame assembly .................................................................1982 Disassembly and assembly of hitch frame assembly .................................................................1989 Hydraulic system .....................................................................................................1994 Removal and installation of flow amplifier valve assembly ........................................................1994 Removal and installation of hoist valve assembly .................................................................1997 Disassembly and assembly of hoist valve assembly .................................................................2001 Disassembly and assembly of hoist cylinder assembly ..............................................................2005 Body .................................................................................................................2011 Removal and installation of dump body assembly ...................................................................2011 Cab and its attachments ..............................................................................................2014 Removal and installation of operator's cab assembly ..............................................................2014 Removal and installation of operator's cab glass (adhered glass) .................................................2018 .1 Removal:HM300-K183-520 K 00 A .............................................................................2019 Removal and installation of operator's seat assembly .............................................................2024 Removal and installation of seat belt ............................................................................2026 Electrical system ....................................................................................................2027 Removal and installation of machine monitor assembly .............................................................2027 Removal and installation of engine controller assembly ...........................................................2029 Removal and installation of retarder and hoist controller assembly ...............................................2030 Removal and installation of transmission controller assembly .....................................................2031 Removal and installation of mass air flow and temperature sensor .................................................2032 Removal and installation of KOMTRAX terminal assembly ............................................................2033 Air conditioner unit .............................................................................................2034 60 Maintenance standard ..................................................................................................2041 Table of contents ....................................................................................................2042 Engine and cooling system ............................................................................................2043 Engine mount .....................................................................................................2043 Output shaft .....................................................................................................2044 Radiator fan pump ................................................................................................2045 Radiator fan motor ...............................................................................................2047 Aftercooler fan motor ............................................................................................2048 Power train ..........................................................................................................2050 Drive shaft ......................................................................................................2050 Torque converter and transmission mount ..........................................................................2052 Torque converter .................................................................................................2053 Transmission .....................................................................................................2056 Transmission control valve .......................................................................................2064 Forward and reverse clutch ECMV and gear speed clutch ECMV .......................................................2065 Lockup clutch ECMV ...............................................................................................2066 Differential lock clutch ECMV ....................................................................................2067 Main relief valve, torque converter relief valve, and main flow selector valve ...................................2068 Differential .....................................................................................................2070 Axle .............................................................................................................2073 Final drive ......................................................................................................2075 Steering system ......................................................................................................2080 Steering column ..................................................................................................2080 Steering cylinder ................................................................................................2081 Emergency steering pump ..........................................................................................2082 Brake system .........................................................................................................2083 Slack adjuster ...................................................................................................2083 Brake ............................................................................................................2085 Parking brake ....................................................................................................2088 Undercarriage and frame ..............................................................................................2090 Suspension .......................................................................................................2090 Suspension cylinder ..............................................................................................2094 Oscillation hitch ................................................................................................2096 Hydraulic system .....................................................................................................2098 Steering and hoist pump ..........................................................................................2098 Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors ................2101 Center brake cooling pump ........................................................................................2103 Brake charge pump ................................................................................................2104 Center brake cooling remote pump .................................................................................2105 Center brake cooling remote motor ................................................................................2106 Hoist valve ......................................................................................................2108 Hoist cylinder ...................................................................................................2110 80 Appendix ..............................................................................................................2111 Table of contents ....................................................................................................2112 Air conditioner components ...........................................................................................2113 Precautions for refrigerant ......................................................................................2113 Air conditioner component ........................................................................................2114 Configuration and function of refrigeration cycle ................................................................2117 Outline of refrigeration cycle ...................................................................................2118 Air conditioner unit .............................................................................................2120 Dual pressure switch .............................................................................................2125 Air conditioner controller .......................................................................................2126 Compressor .......................................................................................................2127 Condenser ........................................................................................................2128 Receiver drier ...................................................................................................2129 Outer temperature sensor (outside air temperature sensor) ........................................................2130 Procedure for testing and troubleshooting ........................................................................2131 Circuit diagram and arrangement of connector pins ................................................................2133 System diagram ...................................................................................................2135 Input and output signals of the air conditioner controller .......................................................2136 Parts and connectors layout ......................................................................................2138 Testing air leakage (duct) .......................................................................................2143 Testing with self-diagnosis function .............................................................................2146 How to open the electrical system abnormality record screen in service mode of the machine monitor ...............2147 Testing vent (mode) changeover ...................................................................................2149 Testing FRESH/RECIRC air changeover ..............................................................................2150 Testing (dual) pressure switch for refrigerant ...................................................................2151 Testing relays ...................................................................................................2153 Troubleshooting chart 1 ..........................................................................................2155 Troubleshooting chart 2 ..........................................................................................2156 Information in troubleshooting table .............................................................................2159 Failure code list related to air conditioner .....................................................................2160 Failure code [879AKA] A/C Inner sensor Open Circuit ..............................................................2161 Failure code [879AKB] A/C Inner sensor Short Circuit .............................................................2162 Failure code [879BKA] A/C Outer sensor Open Circuit ..............................................................2163 Failure code [879BKB] A/C Outer sensor Short Circuit .............................................................2165 Failure code [879CKA] Ventilating sensor Open Circuit ............................................................2167 Failure code [879CKB] Ventilating sensor Short Circuit ...........................................................2168 Failure code [879EMC] Ventilating Damper Abnormality .............................................................2169 Failure code [879FMC] Air Mix Damper Abnormality .................................................................2170 Failure code [879GKX] Refrigerant Abnormality ....................................................................2171 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ...................................2173 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....................................2175 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...........................2178 A-4 Troubleshooting for FRESH/RECIRC air changeover ..............................................................2180 Troubleshooting with gauge pressure ..............................................................................2182 Connection of service tool .......................................................................................2185 Precautions for disconnecting and connecting air conditioner piping ..............................................2187 Handling of compressor oil .......................................................................................2189 90 Diagrams and drawings .................................................................................................2191 Table of contents ....................................................................................................2192 Hydraulic circuit diagram ............................................................................................2193 Symbols in hydraulic circuit diagram .............................................................................2193 Power train hydraulic circuit diagram.............................................................................2197 Hydraulic circuit diagram.........................................................................................2198 Electric circuit diagram .............................................................................................2214 Symbols in electric circuit diagram ..............................................................................2214 Inside cab electric circuit diagram...............................................................................2199 Outside cab electrical circuit diagram............................................................................2206 Circuit diagram related to payload meter..........................................................................2213 INDEX.....................................................................................................................2218
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