Komatsu HM400-3M0 Articulated Dump Truck Shop Manual SEN06284-21 PDF

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Komatsu HM400-3M0 Articulated Dump Truck Shop Manual SEN06284-21 – PDF DOWNLOAD

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Komatsu HM400-3M0 Articulated Dump Truck Shop Manual SEN06284-21 – PDF DOWNLOAD

Language : English
Pages : 2294
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM400-3M0 Articulated Dump Truck Shop Manual SEN06284-21 – PDF DOWNLOAD

• SERIAL NUMBERS 5001 and up

SEN06284-21 1
00 Index and foreword . 3
Index . 4
Foreword, safety and general information 20
Important safety notice . 20
How to read the shop manual . 27
Explanation of terms for maintenance standard . 29
Handling equipment of fuel system devices . 31
Handling of intake system parts . 32
Handling of hydraulic equipment . 33
Method of disconnecting and connecting of push-pull type coupler 35
Handling of electrical equipment 38
How to read electric wire code 46
Precautions when performing operation . 49
Practical use of KOMTRAX 54
Standard tightening torque table 55
List of abbreviation 61
Conversion table 66
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 89
Turbocharger 90
EGR system layout drawing . 92
EGR system circuit diagram 93
EGR valve . 95
Bypass valve 97
Venturi system 99
EGR cooler 101
Muffler . 103
Cooling system 104
Radiator fan pump . 106
Aftercooler fan motor . 114
Radiator fan motor 125
Center brake cooling remote motor . 134
Center brake cooling remote pump 138
Oil cooler bypass valve . 139
Power train . 140
Power train system 140
Drive shaft . 142
Torque converter and transmission hydraulic piping 143
Torque converter 144
Transmission 150
Transmission control valve 175
Forward and reverse clutch ECMV and gear speed clutch ECMV 178
Lockup clutch ECMV 185
Differential lock clutch ECMV . 189
Main relief valve, torque converter relief valve, and main flow selector valve 193
Axle 199
Differential 202
Final drive . 206
Steering system . 209
Layout of steering devices 209
Steering column . 210
Flow amplifier valve 211
Steering valve 215
Emergency steering pump . 221
Emergency steering motor 222
Brake system 223
Layout of brake parts . 223
Parking brake solenoid and accumulator charge valve . 225
Accumulator . 231
Shut off solenoid valve . 232
Brake valve . 233
Proportional pressure reducing valve 238
Slack adjuster 240
Brake . 244
Brake system tank . 247
Parking brake . 248
Undercarriage and frame . 251
Suspension 251
Suspension cylinder . 255
Oscillation hitch . 258
Hydraulic system 259
Hydraulic component layout 259
Dump body control . 261
Hydraulic tank 262
Steering and hoist pump . 263
Hoist valve . 274
Steering pump selector solenoid valve . 280
Dump EPC valve 281
Center brake cooling remote motor . 283
Front brake cooling relief valve 292
Center brake cooling relief valve . 293
Cab and its attachments . 294
ROPS cab 294
Cab tilt 295
Electrical system . 296
Electrical control system . 296
Machine monitor system 327
Rear view monitor system 350
KOMTRAX system 354
System component parts 357
Sensor 391
20 Standard value tables 433
Table of contents . 434
Standard service value table 435
Standard value table for engine . 435
Standard value table for machine 437
30 Testing and adjusting 445
Table of contents . 446
Precautions before work 448
Related information on testing and adjusting 449
Tools for testing and adjusting . 449
Sketch of tools for testing and adjusting . 454
Engine and cooling system . 455
Testing engine speed 455
Testing boost pressure 456
Testing exhaust gas temperature . 458
Testing exhaust gas color . 460
Adjusting valve clearance . 462
Testing compression pressure 464
Testing blowby pressure . 466
Testing engine oil pressure . 467
Testing drive pressure of EGR valve and bypass valve 469
Testing fuel pressure . 470
Handling cylinder cutout mode operation . 471
Handling no‐injection cranking operation 472
Testing fuel return rate and leakage 473
Bleeding air from fuel system . 475
Testing fuel circuit for leakage 477
Testing radiator fan and aftercooler fan speed 478
Testing and adjusting alternator belt tension . 479
Testing and adjusting air conditioner compressor belt tension . 480
Power train 481
Testing torque converter stall speed . 481
Testing power train oil pressure . 483
Adjusting transmission speed sensor 494
Adjusting transmission controller 497
Retrieval of disabled machine that resulted from a trouble in electrical system 498
Retrieval of disabled machine due to traction control system (KTCS) failure 502
Steering system . 504
Testing and adjusting steering circuit oil pressure . 504
Bleed air from the steering cylinder circuit . 506
Testing and adjusting articulate angle sensor 508
Brake system . 510
Testing and adjusting brake oil pressure . 510
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas 514
Testing braking performance 522
Releasing remaining pressure in brake circuit 523
Bleeding air from brake circuit 525
Testing wear of wheel brake disc . 526
Parking brake emergency releasing procedure 527
Testing wear of parking brake pad and adjusting clearance 528
Hydraulic system 530
Testing and adjusting suspension cylinder . 530
Testing and adjusting dump circuit oil pressure . 535
Work equipment 538
Adjusting dump body positioner sensor . 538
Cab and its attachments . 540
Cab tilt up procedure . 540
Adjusting steering wheel tilt locklever 544
Electrical system . 546
Setting and adjusting each equipment 546
Special functions of machine monitor 557
KOMTRAX terminal start-up procedure . 628
Adjusting optical axis of headlamps 632
Handling voltage circuit of engine controller . 636
Handling battery disconnect switch 637
Pm clinic . 638
Pm Clinic service . 638
40 Troubleshooting 645
Table of contents . 646
Precautions before work 655
Related information on troubleshooting 656
Troubleshooting points 656
Sequence of events in troubleshooting . 658
Check before troubleshooting 660
Inspection procedure before troubleshooting . 662
Preparation for troubleshooting of electrical system 671
Classification and procedures for troubleshooting . 677
Symptom and troubleshooting numbers . 680
Information in troubleshooting table 682
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit . 684
Connector list and layout . 686
Connector contact identification 702
T-branch box and T-branch adapter table . 738
Fuse location table . 743
Precautions on troubleshooting of machine monitor . 747
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit . 749
Failure codes table . 754
Troubleshooting by failure code (Display of code) . 767
Failure code [1500L0] Double Engagement of T/M Clutches . 767
Failure code [15B0NX] Transmission Oil Filter Clogging 768
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F 769
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F 770
Failure code [15F7KM] Abuse of TM Forward Clutch Disk . 771
Failure code [15G0MW] Failure of Clutch (Reverse) . 772
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk . 775
Failure code [15H0MW] Failure of Clutch (High) 776
Failure code [15J0MW] Failure of Clutch (Low) . 779
Failure code [15K0MW] Failure of Clutch (1st) . 782
Failure code [15L0MW] Failure of Clutch (2nd) . 785
Failure code [15M0MW] Failure of Clutch (3rd) . 788
Failure code [15SBL1] Release Trouble of ECMV (Reverse) . 791
Failure code [15SBMA] Malfunction of ECMV (Reverse) . 794
Failure code [15SCL1] Release Trouble of ECMV (High) 795
Failure code [15SCMA] Malfunction of ECMV (High) 798
Failure code [15SDL1] Release Trouble of ECMV (Low) . 799
Failure code [15SDMA] Malfunction of ECMV (Low) . 802
Failure code [15SEL1] Release Trouble of ECMV (1st) . 803
Failure code [15SEMA] Malfunction of ECMV (1st) . 806
Failure code [15SFL1] Release Trouble of ECMV (2nd) . 807
Failure code [15SFMA] Malfunction of ECMV (2nd) . 810
Failure code [15SGL1] Release Trouble of ECMV (3rd) . 811
Failure code [15SGMA] Malfunction of ECMV (3rd) . 814
Failure code [15SJMA] Malfunction of ECMV (Lockup) 815
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.) 817
Failure code [2F00KM] Dragging of Parking Brake . 819
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 821
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) . 822
Failure code [879AKA] A/C Inner Sensor Open Circuit . 823
Failure code [879AKB] A/C Inner Sensor Short Circuit 824
Failure code [879BKA] A/C Outer Sensor Open Circuit . 825
Failure code [879BKB] A/C Outer Sensor Short Circuit 826
Failure code [879CKA] Ventilating Sensor Open Circuit . 827
Failure code [879CKB] Ventilating Sensor Short Circuit 828
Failure code [879EMC] Ventilation Damper Abnormality 829
Failure code [879FMC] Air Mix Damper Abnormality 830
Failure code [879GKX] Refrigerant Abnormality . 831
Failure code [989D00] Tilt Caution 832
Failure code [989L00] Engine Controller Lock Caution1 . 833
Failure code [989M00] Engine Controller Lock Caution2 . 834
Failure code [989N00] Engine Controller Lock Caution3 . 835
Failure code [AA10NX] Air Cleaner Clogging 836
Failure code [AB00KE] Charge Voltage Low 838
Failure code [AB00KY] Hot Short of Alternator R Terminal 839
Failure code [B@BAZG] Eng Oil Press Low . 840
Failure code [B@BAZK] Engine Oil Level Low 841
Failure code [B@BCNS] Eng Water Overheat 842
Failure code [B@BCZK] Eng Water Level Low . 843
Failure code [B@C6NS] Retarder Oil Overheat (Front) . 845
Failure code [B@C8NS] Retarder Oil Overheat (Center) 846
Failure code [B@CENS] T/C Oil Temp. Overheat 847
Failure code [B@JANS] Steering Oil Overheat . 848
Failure code [CA111] ECM Critical Internal Failure 849
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 850
Failure code [CA122] Chg Air Press Sensor High Error 851
Failure code [CA123] Chg Air Press Sensor Low Error . 853
Failure code [CA131] Throttle Sensor High Error . 855
Failure code [CA132] Throttle Sensor Low Error 857
Failure code [CA135] Eng Oil Press Sensor High Error 859
Failure code [CA141] Eng Oil Press Sensor Low Error . 861
Failure code [CA144] Coolant Temp Sens High Error . 863
Failure code [CA145] Coolant Temp Sens Low Error 865
Failure code [CA153] Chg Air Temp Sensor High Error . 867
Failure code [CA154] Chg Air Temp Sensor Low Error 869
Failure code [CA187] Sensor 2 Supply Volt Low Error . 871
Failure code [CA221] Ambient Press Sensor High Error 873
Failure code [CA222] Ambient Press Sens Low Error . 875
Failure code [CA227] Sensor 2 Supply Volt High Error 877
Failure code [CA234] Eng Overspeed 878
Failure code [CA238] Ne Speed Sensor Supply Volt Error 879
Failure code [CA263] Fuel Temp Sensor High Error 880
Failure code [CA265] Fuel Temp Sensor Low Error . 882
Failure code [CA271] IMV/PCV1 Short Error . 884
Failure code [CA272] IMV/PCV1 Open Error 885
Failure code [CA273] PCV2 Short Error . 886
Failure code [CA274] PCV2 Open Error 887
Failure code [CA322] Inj #1(L#1) Open/Short Error . 888
Failure code [CA323] Inj #5(L#5) Open/Short Error . 890
Failure code [CA324] Inj #3(L#3) Open/Short Error . 892
Failure code [CA325] Inj #6(L#6) Open/Short Error . 894
Failure code [CA331] Inj #2(L#2) Open/Short Error . 896
Failure code [CA332] Inj #4(L#4) Open/Short Error . 898
Failure code [CA342] Calibration Code Incompatibility . 900
Failure code [CA351] Injectors Drive Circuit Error 901
Failure code [CA352] Sensor 1 Supply Volt Low Error . 902
Failure code [CA386] Sensor 1 Supply Volt High Error 904
Failure code [CA431] Idle Validation Sw Error . 905
Failure code [CA432] Idle Validation Process Error 908
Failure code [CA441] Battery Voltage Low Error 911
Failure code [CA442] Battery Voltage High Error . 913
Failure code [CA449] Rail Press Very High Error . 914
Failure code [CA451] Rail Press Sensor High Error . 915
Failure code [CA452] Rail Press Sensor Low Error 917
Failure code [CA553] Rail Press High Error 919
Failure code [CA554] Rail Press Sensor In Range Error . 920
Failure code [CA559] Rail Press Low Error . 921
Failure code [CA689] Eng Ne Speed Sensor Error 925
Failure code [CA731] Eng Bkup Speed Sens Phase Error 927
Failure code [CA757] All Continuous Data Lost Error . 928
Failure code [CA778] Eng Bkup Speed Sensor Error 929
Failure code [CA1228] EGR valve servo error 1 . 931
Failure code [CA1625] EGR Valve Servo Error 2 . 932
Failure code [CA1626] Bypass Valve Solenoid Current High Error 933
Failure code [CA1627] Bypass Valve Solenoid Current Low Error . 935
Failure code [CA1628] Bypass Valve Servo Error 1 937
Failure code [CA1629] Bypass Valve Servo Error 2 938
Failure code [CA1631] BP valve Lift Position Sensor High Error 939
Failure code [CA1632] BP valve Lift Position Sensor Low Error . 941
Failure code [CA2185] Throt Sensor Sup Volt High Error 943
Failure code [CA2186] Throt Sensor Sup Volt Low Error . 945
Failure code [CA2249] Rail Press Very Low Error . 947
Failure code [CA2271] EGR Valve Pos Sens High Error . 948
Failure code [CA2272] EGR Valve Pos Sens Low Error 950
Failure code [CA2351] EGR Valve Solenoid Short Error 952
Failure code [CA2352] EGR Valve Solenoid Open Error . 954
Failure code [CA2555] Grid Htr Relay Volt Low Error . 956
Failure code [CA2556] Grid Htr Relay Volt High Error 958
Failure code [D150KB] Ground Fault of Emerg. Steering Relay . 960
Failure code [D150KZ] Failure of Emerg. Steering Relay 961
Failure code [D151KB] Ground Fault of Emerg. Steering Relay 2 . 962
Failure code [D151KZ] Failure of Emerg. Steering Relay 2 963
Failure code [D164KY] Hot Short of Head Light High Selector . 964
Failure code [D19HKZ] Failure of Stop Lamp (R&L) 965
Failure code [D19JKZ] Personal Code Relay Abnormality . 967
Failure code [D1EHKA] Disconnection of Engine Start Relay . 968
Failure code [D1EHKB] Ground Fault of Engine Start Relay 969
Failure code [D1EHKY] Hot Short of Engine Start Relay . 970
Failure code [D1EMKA] Disconnection of Parking Interlock Relay 971
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay . 972
Failure code [D1EMKY] Hot Short of Parking Interlock Relay 973
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay . 974
Failure code [D5ZHL6] Disconnection of Key SW C . 975
Failure code [D811MC] KOMTRAX Error . 977
Failure code [D862KA] GPS Antenna Open Circuit 978
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) . 979
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 981
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 . 983
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) . 984
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 985
Failure code [DAF0MB] Monitor ROM Abnormality . 986
Failure code [DAF0MC] Monitor Error . 987
Failure code [DAF3KK] Controller Power Source Low (MON) . 988
Failure code [DAF8KB] Camera Power Supply Short Circuit . 990
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 991
Failure code [DAFGMC] GPS Module Error 993
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) . 994
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 996
Failure code [DAFQKR] CAN2 Discon (Monitor) . 998
Failure code [DAQ0KK] Controller Power Source Low (T/M) . 999
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 1001
Failure code [DAQ0MC] T/M Con Error .1002
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .1003
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) .1005
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 1007
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) .1008
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 1010
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 1012
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 1013
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) .1017
Failure code [DAQV00] Neutral Coast Caution .1018
Failure code [DAQW00] Neutral Over Speed Caution 1019
Failure code [DAZ9KQ] A/C Model Selection Abnormality .1020
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1021
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) 1022
Failure code [DB10MC] RHC Error .1023
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) .1024
Failure code [DB12KK] Solenoid Power Source Low (RHC) .1026
Failure code [DB13KK] Controller Power Source Low (RHC) .1028
Failure code [DB19KQ] Inconsistency of Model Selection (RHC) 1030
Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC) .1031
Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC) .1033
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) 1035
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) .1036
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) 1037
Failure code [DB1Z00] Rollover Caution .1038
Failure code [DB1ZKM] Occurrence of Large Lateral Acceleration .1039
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1040
Failure code [DB2QKR] CAN2 Discon (Engine Con) (Machine with payload meter controller: CR720) 1045
Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) 1051
Failure code [DBSQKR] CAN2 Discon (PLM) 1052
Failure code [DBSQKR] CAN2 Discon (PLM) (Machine with payload meter controller: CR720) .1056
Failure code [DD1ML4] Failure of ARAC SW 1060
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1063
Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No.: 5001 to 5107 .1065
Failure code [DDTHKA] Disconnection of Fill Switch (High)Serial No.: 5108 and up .1067
Failure code [DDTJKA] Disconnection of Fill Switch (Low)Serial No.: 5001 to 5107 .1069
Failure code [DDTJKA] Disconnection of Fill Switch (Low)Serial No.: 5108 and up 1071
Failure code [DDTKKA] Disconnection of Fill Switch (1st)Serial No.: 5001 to 5107 .1073
Failure code [DDTKKA] Disconnection of Fill Switch (1st)Serial No.: 5108 and up 1075
Failure code [DDTLKA] Disconnection of Fill Switch (2nd)Serial No.: 5001 to 5107 .1077
Failure code [DDTLKA] Disconnection of Fill Switch (2nd)Serial No.: 5108 and up 1079
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)Serial No.: 5001 to 5107 .1081
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)Serial No.: 5108 and up 1083
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse)Serial No.: 5001 to 5107 .1085
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse)Serial No.: 5108 and up 1087
Failure code [DF10KA] Disconnection of Shift Lever Input 1089
Failure code [DF10KB] Ground Fault of Shift Lever Input .1092
Failure code [DGF1KX] Out of Range of T/M Oil Temp. Sensor 1096
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C) 1098
Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C) 1099
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F) 1100
Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F) 1101
Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S. .1103
Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor 1104
Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp. S. 1106
Failure code [DGR8KX] Out of Range of CAC Output Temp. S. .1108
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor 1110
Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) 1112
Failure code [DHP4KY] Hot Short of Suspension Press. S. (FR) (Machine with payload meter controller: CR720) 1114
Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) 1116
Failure code [DHP4KZ] Failure of Suspension Press. S. (FR) (Machine with payload meter controller: CR720) 1118
Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) 1120
Failure code [DHP5KY] Hot Short of Suspension Press. S. (FL) (Machine with payload meter controller: CR720) 1122
Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) 1124
Failure code [DHP5KZ] Failure of Suspension Press. S. (FL) (Machine with payload meter controller: CR720) 1126
Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) 1128
Failure code [DHP6KY] Hot Short of Suspension Press. S. (RR) (Machine with payload meter controller: CR720) 1130
Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) 1132
Failure code [DHP6KZ] Failure of Suspension Press. S. (RR) (Machine with payload meter controller: CR720) 1134
Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) 1136
Failure code [DHP7KY] Hot Short of Suspension Press. S. (RL) (Machine with payload meter controller: CR720) 1138
Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) 1140
Failure code [DHP7KZ] Failure of Suspension Press. S. (RL) (Machine with payload meter controller: CR720) 1142
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S. .1144
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor .1146
Failure code [DHT5L6] Failure of T/C Oil Press Sensor .1148
Failure code [DHT8KX] Out of Range of Steering Oil Press. S. 1150
Failure code [DHT8ZG] Steering Oil Pressure Low .1152
Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F) 1153
Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R) 1155
Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR) .1157
Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR) .1159
Failure code [DHUCKX] Out of Range of Parking Brake Press. S. .1161
Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1 1163
Failure code [DHUEKX] Out of Range of Emerg. Steering Press. S.2 1165
Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL) .1167
Failure code [DHURKX] Out of Range of Retarder Press. S. (CL) .1169
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1171
Failure code [DK30KX] Out of Range of Steering Angle Pot. .1173
Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS 1175
Failure code [DK52KX] Out of Range of Hoist Lever Potentio. .1178
Failure code [DK53L8] Failure of Hoist Lever Potentio. 1180
Failure code [DK54KX] Out of Range of Body Potentio. 1181
Failure code [DK60KX] Out of Range of Acceleration Sensor .1183
Failure code [DK80KT] IMU Internal Error .1185
Failure code [DK80KR] CAN J1939 Communication Error (IMU) 1186
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor 1189
Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. 1191
Failure code [DKH1KX] Out of Range of Long. Inclination Angle S. (Machine with payload meter controller: CR720) 1193
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor .1195
Failure code [DLF1LC] Failure of T/M Input Speed Sensor .1197
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor 1199
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 1201
Failure code [DLF400] T/M Diff. Overrun Prevention Activated 1203
Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor .1204
Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor .1206
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) 1208
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) 1210
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) 1212
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) 1214
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) .1216
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) 1217
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1218
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1220
Failure code [DLM3MB] Radiator Fan Control Mismatch .1222
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor .1223
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor .1225
Failure code [DLM4MB] CAC Fan Control Mismatch 1227
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main) 1228
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) .1230
Failure code [DPQ1KR] LIN Discon (Switch Panel) .1232
Failure code [DPQ2KR] LIN Discon (LED Unit) .1235
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1238
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1241
Failure code [DV00KB] Ground Fault of Buzzer Output .1242
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol. 1244
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol. .1245
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol. 1246
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve .1247
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve .1248
Failure code [DW4BK4] Release Trouble of Parking Brake Valve 1249
Failure code [DW4BMA] Malfunction of Parking Brake Valve 1251
Failure code [DW72KZ] Failure of Kick out Solenoid 1252
Failure code [DW73KA] Disconnection of Hoist Selector Sol. 1254
Failure code [DW73KB] Ground Fault of Hoist Selector Sol. .1256
Failure code [DW73KY] Hot Short of Hoist Selector Sol. 1258
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. 1260
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. .1262
Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol. .1263
Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol. .1265
Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol. 1266
Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol. 1267
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol. 1268
Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front) 1270
Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center) .1272
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid .1274
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid 1276
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid .1278
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. .1280
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. 1281
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. .1283
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol. 1284
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol. .1285
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol. 1286
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) .1287
Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL) .1289
Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL) 1291
Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL) .1293
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) 1295
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) .1297
Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR) .1299
Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR) 1301
Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR) .1303
Failure code [DX31MA] Malfunction of Retarder Valve (CR) 1305
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) .1307
Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL) .1309
Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL) 1311
Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL) .1313
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) 1315
Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) 1317
Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR) .1319
Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR) 1321
Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR) .1323
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) 1325
Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol. 1327
Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol. .1328
Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol. 1330
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.) 1331
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.) .1333
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.) 1335
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) .1337
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1339
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) .1341
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) .1343
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 1345
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) .1347
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 1348
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) .1350
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 1352
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1355
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) .1357
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1359
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1362
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) .1364
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1366
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1369
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) .1371
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1373
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1376
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) .1378
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1380
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor 1383
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor 1386
Failure code [DY30ME] Emerg. Steering Long-Time Activated .1389
Failure code [DY32MC] Malfunction 2 of Emerg. Steering Motor 2 1391
Troubleshooting of electrical system (E-mode) .1394
E-1 Engine does not start (Engine does not crank) .1394
E-2 Manual preheating system does not work 1399
E-3 Automatic preheating system does not work .1402
E-4 While preheating is working, preheating monitor does not light up .1404
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing .1406
E-6 LCD unit on machine monitor displays nothing 1409
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) .1411
E-8 LCD on machine monitor does not display properly 1413
E-9 Meter unit display on machine monitor is abnormal .1415
E-10 Night lighting lamp of meter unit on machine monitor is abnormal .1418
E-11 LED unit lamp on machine monitor is abnormal .1421
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly .1423
E-13 2 switches operation of switch panel on machine monitor does not function 1425
E-14 Switch panel buzzer of machine monitor is abnormal .1427
E-15 Rear view monitor does not light up or backlight flickers 1429
E-16 Rear view monitor images are not displayed clearly .1431
E-17 Rear view monitor brightness cannot be adjusted 1434
E-18 Night lighting lamp of rear view monitor is abnormal .1437
E-19 Rearview monitor does not display images while reverse linked display function is enabled 1439
E-20 Guide line on rear view monitor is not displayed while guide line is set .1442
E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly .1444
E-22 Fuel level gauge does not indicate correct level .1445
E-23 Seat belt caution lamp indication is abnormal 1447
E-24 Machine monitor cannot be operated when starting switch is in OFF position .1448
E-25 Alarm buzzer does not sound 1449
E-26 Alarm buzzer does not stop sounding 1451
E-27 Engine mode selector function does not operate properly 1453
E-28 AISS function does not operate properly 1454
E-29 Hoist lever does not operate properly 1455
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly .1457
E-31 None of headlamp, clearance lamp, and tail lamp lights .1461
E-32 Clearance lamp does not light up .1463
E-33 Tail lamp does not light up 1465
E-34 Low beam of headlamp does not light up .1467
E-35 High beam of headlamp does not light up 1469
E-36 Neither Low beam nor High beam of headlamp lights up .1471
E-37 High beams do not light up while passing switch is operated 1473
E-38 KOMTRAX does not operate properly 1475
Troubleshooting of hydraulic and mechanical system (H-mode) .1476
Information described in troubleshooting table (H-mode) .1476
System chart of hydraulic and mechanical systems 1477
Failure mode and cause table 1479
H-1 Machine does not start 1483
H-2 Machine does not travel smoothly (engine hunts) .1485
H-3 Lockup clutch is not disengaged .1486
H-4 Abnormally large shocks result from starting of machine and gear shifting .1487
H-5 Machine does not upshift 1488
H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds 1490
H-7 Machine lacks travel speed or power during travel in torque converter drive mode 1491
H-8 Machine lacks travel speed or power during travel in specific gear speed 1492
H-9 Machine starts or gear speed shifts with long time lag 1493
H-10 Torque converter oil temperature is high .1495
H-11 Torque converter oil pressure is low .1496
H-12 Front brake does not work sufficiently .1497
H-13 Center brake does not work sufficiently 1498
H-14 Steering wheel is heavy to turn 1499
H-15 Steering wheel does not move .1500
H-16 Steering wheel swings 1501
H-17 Dump body raise speed or power is slow .1502
H-18 Dump body does not move 1504
H-19 Hydraulic drift of dump body is large 1505
H-20 Radiator fan speed is abnormal (high, low, or stationary) 1506
H-21 Aftercooler fan speed is abnormal (high, low, or stationary) .1507
H-22 Unusual noise is heard from around radiator fan 1508
H-23 Unusual noise is heard from around aftercooler fan .1509
Troubleshooting of engine (S-mode) 1510
Information mentioned in troubleshooting table (S mode) .1510
S-1 When starting switch is turned to START position, engine is not cranked .1511
S-2 The engine cranks but exhaust smoke does not come out .1512
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1513
S-4 Engine startability is poor .1514
S-5 Engine does not pick up smoothly 1516
S-6 Engine stops during operation .1518
S-7 Engine runs rough or is unstable 1520
S-8 Engine lacks power 1521
S-9 Exhaust smoke is black 1523
S-10 Engine oil consumption is excessive 1525
S-11 Oil becomes contaminated quickly .1526
S-12 Fuel consumption is excessive 1527
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1528
S-14 Oil pressure drops .1529
S-15 Fuel mixes into engine oil .1530
S-16 Water mixes into engine oil (milky) 1531
S-17 Coolant temperature rises too high (overheating) .1532
S-18 Unusual noise is heard .1533
S-19 Vibration is excessive .1534
S-20 Air cannot be bled from fuel circuit .1535
50 Disassembly and assembly .1537
Table of contents .1538
Precautions before work 1540
Related information on disassembly and assembly .1542
How to read this manual .1542
Coating materials list 1544
Special tools list 1550
Sketches of special tools .1573
Engine and cooling system .1597
Removal and installation of supply pump assembly 1597
Removal and installation of injector assembly .1601
Removal and installation of cylinder head assembly 1608
Removal and installation of radiator assembly .1620
Removal and installation of radiator core assembly 1625
Removal and installation of cooling fan and fan motor assembly for radiator .1627
Removal and installation of aftercooler assembly 1631
Removal and installation of cooling fan and fan motor assembly for aftercooler 1635
Removal and installation of engine assembly .1637
Removal and installation of engine front oil seal .1646
Removal and installation of engine rear oil seal 1650
Removal and installation of output shaft assembly .1660
Disassembly and assembly of output shaft assembly .1669
Removal and installation of air cleaner assembly 1672
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1674
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .1676
Removal and installation of fire prevention cover on exhaust pipe .1679
Power train .1683
Removal and installation of transmission and front differential assembly 1683
Disconnection and connection of front differential assembly and transmission assembly .1705
Disassembly and assembly of front differential assembly .1707
Disassembly and assembly of torque converter assembly .1742
Disassembly and assembly of transmission assembly .1750
Removal and installation of center differential assembly 1790
Disassembly and assembly of center differential assembly 1796
Removal and installation of rear differential assembly 1830
Disassembly and assembly of rear differential assembly 1834
Removal and installation of front final drive and brake assembly 1854
Disassembly and assembly of front final drive and brake assembly 1858
Removal and installation of center final drive and brake assembly .1892
Disassembly and assembly of center final drive and brake assembly .1898
Removal and installation of rear final drive assembly .1928
Disassembly and assembly of rear final drive assembly .1933
Removal and installation of center axle assembly 1942
Removal and installation of rear axle assembly 1948
Steering system .1951
Disassembly and assembly of steering cylinder assembly 1951
Undercarriage and frame .1957
Removal and installation of front suspension cylinder assembly 1957
Removal and installation of rear suspension cylinder assembly .1959
Disassembly and assembly of suspension cylinder assembly 1961
Removal and installation of equalizer bar assembly 1963
Removal and installation of front wheel assembly 1965
Removal and installation of rear (front side) wheel assembly 1969
Removal and installation of rear (back side) wheel assembly .1970
Removal and installation of hitch frame assembly 1971
Disassembly and assembly of hitch frame assembly 1978
Hydraulic system 1983
Removal and installation of flow amplifier valve assembly .1983
Removal and installation of hoist valve assembly 1986
Disassembly and assembly of hoist valve assembly 1990
Disassembly and assembly of hoist cylinder assembly .1994
Body 2006
Removal and installation of dump body assembly 2006
Removal and installation of operator’s cab assembly 2009
Removal and installation of operator’s cab glass (adhered glass) 2014
Removal and installation of operator’s seat assembly 2020
Removal and installation of seat belt .2022
Electrical system .2023
Removal and installation of machine monitor assembly 2023
Removal and installation of engine controller assembly 2025
Removal and installation of retarder and hoist controller assembly 2027
Removal and installation of transmission controller assembly 2028
Removal and installation of KOMTRAX terminal assembly .2029
Air conditioner unit 2030
Removal and installation of air conditioner unit assembly .2030
Removal and installation of air conditioner compressor assembly .2035
Removal and installation of air conditioner condenser .2037
60 Maintenance standard .2039
Table of contents .2040
Engine and cooling system .2041
Engine mount 2041
Output shaft 2042
Radiator fan pump .2043
Radiator fan motor 2045
Aftercooler fan motor .2046
Power train .2048
Drive shaft .2048
Torque converter and transmission mount .2050
Torque converter 2051
Transmission 2054
Transmission control valve 2062
Forward and reverse clutch ECMV and gear speed clutch ECMV 2063
Lockup clutch ECMV 2064
Differential lock clutch ECMV .2065
Main relief valve, torque converter relief valve, and main flow selector valve 2066
Differential 2068
Axle 2071
Final drive .2073
Steering system .2078
Steering column .2078
Steering cylinder .2079
Emergency steering pump .2080
Brake system 2081
Slack adjuster 2081
Brake .2083
Parking brake .2086
Undercarriage and frame .2088
Suspension 2088
Suspension cylinder .2092
Oscillation hitch .2094
Hydraulic system 2096
Steering and hoist pump .2096
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors .2099
Center brake cooling pump .2101
Brake charge pump .2102
Center brake cooling remote pump 2103
Center brake cooling remote motor .2104
Hoist valve .2106
Hoist cylinder 2108
80 Appendix .2109
Table of contents .2110
Precautions before work 2111
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 .2199
Electric circuit diagram 2203
Symbols in electric circuit diagram .2203
Inside cab electrical circuit diagram (Serial No.: 5001 to 5107) .2207
Inside cab electrical circuit diagram (Serial No.: 5108 and up) 2223
Inside cab electrical circuit diagram (Machine with payload meter controller: CR720) .2239
Outside cab electrical circuit diagram 2255
Electrical circuit diagram of engine 2281
INDEX 2283

DESCRIPTION:

G.B 27/12/24