Komatsu HM400-3R Dump Truck Shop Manual SEN06205-1 PDF

Description

Komatsu HM400-3R Dump Truck Shop Manual SEN06205-10- PDF DOWNLOAD

FILE DETAILS:

Komatsu HM400-3R Dump Truck Shop Manual SEN06205-10- PDF DOWNLOAD 

Language : English
Pages : 1994
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HM400-3R Dump Truck Shop Manual SEN06205-10- PDF DOWNLOAD 

SERIAL NUMBERS 8001 and up

Composition of 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 is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu HM400-3R Dump Truck Shop Manual SEN06205-10- PDF DOWNLOAD

SERIAL NUMBERS 8001 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 18
Important safety notice 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 44
Precautions when performing operation 47
Practical use of KOMTRAX 52
Standard tightening torque table 53
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents 70
Specifications 71
Specification drawing 71
Specifications 73
Weight table 79
Table of fuel, coolant, and lubricants 80
10 Structure and function 83
Table of contents 84
Engine and cooling system 86
Engine related parts 86
Output shaft 87
Turbocharger 88
Muffler 90
Cooling system 91
Radiator fan pump 93
Aftercooler fan motor 101
Radiator fan motor 112
Center brake cooling remote motor 121
Center brake cooling remote pump 125
Oil cooler bypass valve 126
Power train 127
Power train system 127
Drive shaft 129
Torque converter and transmission hydraulic piping 130
Torque converter 131
Transmission 137
Transmission control valve 162
Forward and reverse clutch ECMV and gear speed clutch ECMV 165
Lockup clutch ECMV 172
Differential lock clutch ECMV 176
Main relief valve, torque converter relief valve, and main flow selector valve 180
Axle 186
Differential 189
Final drive 193
Steering system 197
Layout of steering devices 197
Steering column 198
Flow amplifier valve 199
Steering valve 203
Emergency steering pump 209
Emergency steering motor 210
Brake system 211
Layout of brake parts 211
Parking brake solenoid and accumulator charge valve 213
Accumulator 219
Shut off solenoid valve 220
Brake valve 221
Proportional pressure reducing valve 226
Slack adjuster 228
Brake 232
Brake system tank 235
Parking brake 236
Undercarriage and frame 239
Suspension 239
Suspension cylinder 243
Oscillation hitch 246
Hydraulic system 247
Hydraulic component layout 247
Dump body control 249
Hydraulic tank 250
Steering and hoist pump 251
Hoist valve 261
Steering pump selector solenoid valve 267
Dump EPC valve 268
Center brake cooling remote motor 270
Front brake cooling relief valve 279
Center brake cooling relief valve 280
Cab and its attachments 281
ROPS cab 281
Cab tilt 282
Electrical system 283
Electrical control system 283
Machine monitor system 312
KOMTRAX system 335
System component parts 339
Sensor 369
20 Standard value tables 411
Table of contents 412
Standard service value table 413
Standard value table for engine 413
Standard value table for machine 416
30 Testing and adjusting 423
Table of contents 424
Related information on testing and adjusting 427
Sketch of tools for testing and adjusting 432
Engine and cooling system 433
Testing engine speed 433
Testing boost pressure 434
Testing exhaust gas temperature 436
Testing exhaust gas color 438
Adjusting valve clearance 440
Testing compression pressure 442
Testing blowby pressure 444
Testing engine oil pressure 445
Testing fuel pressure 447
Handling cylinder cutout mode operation 448
Handling no‐injection cranking operation 449
Testing fuel return rate and leakage 450
Bleeding air from fuel system 452
Testing fuel circuit for leakage 454
Testing radiator fan and aftercooler fan speed 455
Testing and adjusting alternator belt tension 456
Testing and adjusting air conditioner compressor belt tension 457
Power train 458
Testing torque converter stall speed 458
Testing power train oil pressure 460
Adjusting transmission speed sensor 471
Adjusting transmission controller 474
Retrieval of disabled machine that resulted from a trouble in electrical system 475
Retrieval of disabled machine due to traction control system (KTCS) failure 479
Steering system 481
Testing and adjusting steering circuit oil pressure 481
Brake system 483
Testing and adjusting brake oil pressure 483
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas 487
Testing braking performance 495
Releasing remaining pressure in brake circuit 496
Bleeding air from brake circuit 498
Testing wear of wheel brake disc 499
Parking brake emergency releasing procedure 500
Testing wear of parking brake pad and adjusting clearance 501
Hydraulic system 503
Testing and adjusting suspension cylinder 503
Testing and adjusting dump circuit oil pressure 508
Work equipment 511
Adjusting dump body positioner sensor 511
Cab and its attachments 513
Cab tilt up procedure 513
Adjusting steering wheel tilt locklever 517
Electrical system 519
Setting and adjusting each equipment 519
Special functions of machine monitor 530
KOMTRAX terminal start-up procedure 594
Adjusting optical axis of headlamps 598
Handling voltage circuit of engine controller 602
Handling battery disconnect switch 603
Pm clinic 604
Pm Clinic service 604
40 Troubleshooting 611
Table of contents 612
Related information on troubleshooting 620
Troubleshooting points 620
Sequence of events in troubleshooting 622
Check before troubleshooting 624
Inspection procedure before troubleshooting 626
Preparation for troubleshooting of electrical system 635
Classification and procedures for troubleshooting 641
Symptom and troubleshooting numbers 644
Information in troubleshooting table 646
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 648
Connector list and layout 651
Connector contact identification 667
T-branch box and T-branch adapter table 703
Fuse location table 708
Precautions on troubleshooting of machine monitor 712
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 714
Failure codes table 719
Troubleshooting by failure code (Display of code) 731
Failure code [1500L0] Double Engagement of T/M Clutches 731
Failure code [15B0NX] Transmission Oil Filter Clogging 732
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F 733
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F 734
Failure code [15F7KM] Abuse of TM Forward Clutch Disk 735
Failure code [15G0MW] Failure of Clutch (Reverse) 736
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk 739
Failure code [15H0MW] Failure of Clutch (High) 740
Failure code [15J0MW] Failure of Clutch (Low) 743
Failure code [15K0MW] Failure of Clutch (1st) 746
Failure code [15L0MW] Failure of Clutch (2nd) 749
Failure code [15M0MW] Failure of Clutch (3rd) 752
Failure code [15SBL1] Release Trouble of ECMV (Reverse) 755
Failure code [15SBMA] Malfunction of ECMV (Reverse) 758
Failure code [15SCL1] Release Trouble of ECMV (High) 759
Failure code [15SCMA] Malfunction of ECMV (High) 762
Failure code [15SDL1] Release Trouble of ECMV (Low) 763
Failure code [15SDMA] Malfunction of ECMV (Low) 766
Failure code [15SEL1] Release Trouble of ECMV (1st) 767
Failure code [15SEMA] Malfunction of ECMV (1st) 770
Failure code [15SFL1] Release Trouble of ECMV (2nd) 771
Failure code [15SFMA] Malfunction of ECMV (2nd) 774
Failure code [15SGL1] Release Trouble of ECMV (3rd) 775
Failure code [15SGMA] Malfunction of ECMV (3rd) 778
Failure code [15SJMA] Malfunction of ECMV (Lockup) 779
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff ) 781
Failure code [2F00KM] Dragging of Parking Brake 783
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 785
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 786
Failure code [879AKA] A/C Inner Sensor Open Circuit 787
Failure code [879AKB] A/C Inner Sensor Short Circuit 788
Failure code [879BKA] A/C Outer Sensor Open Circuit 789
Failure code [879BKB] A/C Outer Sensor Short Circuit 790
Failure code [879CKA] Ventilating Sensor Open Circuit 791
Failure code [879CKB] Ventilating Sensor Short Circuit 792
Failure code [879EMC] Ventilation Damper Abnormality 793
Failure code [879FMC] Air Mix Damper Abnormality 794
Failure code [879GKX] Refrigerant Abnormality 795
Failure code [989D00] Tilt Caution 796
Failure code [989L00] Engine Controller Lock Caution1 797
Failure code [989M00] Engine Controller Lock Caution2 798
Failure code [989N00] Engine Controller Lock Caution3 799
Failure code [AA10NX] Air Cleaner Clogging 800
Failure code [AB00KE] Charge Voltage Low 802
Failure code [AB00KY] Hot Short of Alternator R Terminal 803
Failure code [B@BAZG] Eng Oil Press Low 804
Failure code [B@BAZK] Engine Oil Level Low 805
Failure code [B@BCNS] Eng Water Overheat 806
Failure code [B@BCZK] Eng Water Level Low 807
Failure code [B@C6NS] Retarder Oil Overheat (Front) 809
Failure code [B@C8NS] Retarder Oil Overheat (Center) 810
Failure code [B@CENS] T/C Oil Temp Overheat 811
Failure code [B@JANS] Steering Oil Overheat 812
Failure code [CA111] ECM Critical Internal Failure 813
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 814
Failure code [CA122] Chg Air Press Sensor High Error 815
Failure code [CA123] Chg Air Press Sensor Low Error 817
Failure code [CA131] Throttle Sensor High Error 819
Failure code [CA132] Throttle Sensor Low Error 821
Failure code [CA135] Eng Oil Press Sensor High Error 823
Failure code [CA141] Eng Oil Press Sensor Low Error 825
Failure code [CA144] Coolant Temp Sens High Error 827
Failure code [CA145] Coolant Temp Sens Low Error 829
Failure code [CA153] Chg Air Temp Sensor High Error 831
Failure code [CA154] Chg Air Temp Sensor Low Error 833
Failure code [CA187] Sensor 2 Supply Volt Low Error 835
Failure code [CA221] Ambient Press Sensor High Error 837
Failure code [CA222] Ambient Press Sensor Low Error 839
Failure code [CA227] Sensor 2 Supply Volt High Error 841
Failure code [CA234] Eng Overspeed 842
Failure code [CA238] Ne Speed Sensor Supply Volt Error 843
Failure code [CA263] Fuel Temp Sensor High Error 844
Failure code [CA265] Fuel Temp Sensor Low Error 846
Failure code [CA271] IMV/PCV1 Short Error 848
Failure code [CA272] IMV/PCV1 Open Error 849
Failure code [CA273] PCV2 Short Error 850
Failure code [CA274] PCV2 Open Error 851
Failure code [CA322] Inj #1(L#1) Open/Short Error 852
Failure code [CA323] Inj #5(L#5) Open/Short Error 854
Failure code [CA324] Inj #3(L#3) Open/Short Error 856
Failure code [CA325] Inj #6(L#6) Open/Short Error 858
Failure code [CA331] Inj #2(L#2) Open/Short Error 860
Failure code [CA332] Inj #4(L#4) Open/Short Error 862
Failure code [CA342] Calibration Code Incompatibility 864
Failure code [CA351] Injectors Drive Circuit Error 865
Failure code [CA352] Sensor 1 Supply Volt Low Error 866
Failure code [CA386] Sensor 1 Supply Volt High Error 868
Failure code [CA431] Idle Validation Sw Error 869
Failure code [CA432] Idle Validation Process Error 872
Failure code [CA441] Battery Voltage Low Error 875
Failure code [CA442] Battery Voltage High Error 877
Failure code [CA449] Rail Press Very High Error 878
Failure code [CA451] Rail Press Sensor High Error 879
Failure code [CA452] Rail Press Sensor Low Error 881
Failure code [CA553] Rail Press High Error 883
Failure code [CA554] Rail Press Sensor In Range Error 884
Failure code [CA559] Rail Press Low Error 885
Failure code [CA689] Eng Ne Speed Sensor Error 889
Failure code [CA731] Eng Bkup Speed Sens Phase Error 891
Failure code [CA757] All Continuous Data Lost Error 892
Failure code [CA778] Eng Bkup Speed Sensor Error 893
Failure code [CA2185] Throt Sensor Sup Volt High Error 895
Failure code [CA2186] Throt Sensor Sup Volt Low Error 897
Failure code [CA2249] Rail Press Very Low Error 899
Failure code [CA2555] Grid Htr Relay Volt Low Error 900
Failure code [CA2556] Grid Htr Relay Volt High Error 902
Failure code [D150KB] Ground Fault of Emerg Steering Relay 904
Failure code [D150KZ] Failure of Emerg Steering Relay 905
Failure code [D151KB] Ground Fault of Emerg Steering Relay 2 906
Failure code [D151KZ] Failure of Emerg Steering Relay 2 907
Failure code [D164KY] Hot Short of Head Light High Selector 908
Failure code [D19HKZ] Failure of Stop Lamp (R&L) 909
Failure code [D19JKZ] Personal Code Relay Abnormality 911
Failure code [D1EHKA] Disconnection of Engine Start Relay 912
Failure code [D1EHKB] Ground Fault of Engine Start Relay 913
Failure code [D1EHKY] Hot Short of Engine Start Relay 914
Failure code [D1EMKA] Disconnection of Parking Interlock Relay 915
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay 916
Failure code [D1EMKY] Hot Short of Parking Interlock Relay 917
Failure code [D1FBKB] Ground Fault of Sol Self-Holding Relay 918
Failure code [D5ZHL6] Disconnection of Key SW C 919
Failure code [D811MC] KOMTRAX Error 921
Failure code [D862KA] GPS Antenna Open Circuit 922
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 923
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 925
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 927
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 928
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 929
Failure code [DAF0MB] Monitor ROM Abnormality 930
Failure code [DAF0MC] Monitor Error 931
Failure code [DAF3KK] Controller Power Source Low (MON) 932
Failure code [DAF8KB] Camera Power Supply Short Circuit 934
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 935
Failure code [DAFGMC] GPS Module Error 937
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 938
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 940
Failure code [DAFQKR] CAN2 Discon (Monitor) 942
Failure code [DAQ0KK] Controller Power Source Low (T/M) 943
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 945
Failure code [DAQ0MC] T/M Con Error 946
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) 947
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 949
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 951
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) 952
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 954
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 956
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 957
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 961
Failure code [DAQV00] Neutral Coast Caution 962
Failure code [DAQW00] Neutral Over Speed Caution 963
Failure code [DAZ9KQ] A/C Model Selection Abnormality 964
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 965
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) 966
Failure code [DB10MC] RHC Error 967
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) 968
Failure code [DB12KK] Solenoid Power Source Low (RHC) 970
Failure code [DB13KK] Controller Power Source Low (RHC) 972
Failure code [DB19KQ] Inconsistency of Model Selection (RHC) 974
Failure code [DB1LKA] Disconnection of System Ope Lamp (RHC) 975
Failure code [DB1LKB] Short Circuit of System Ope Lamp (RHC) 977
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) 979
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) 980
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) 981
Failure code [DB2QKR] CAN2 Discon (Engine Con) 982
Failure code [DBSQKR] CAN2 Discon (PLM) 987
Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) 991
Failure code [DD1ML4] Failure of ARAC SW 992
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 995
Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No : 8001 to 8203 997
Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No : 8204 and up 999
Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No : 8001 to 8203 1001
Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No : 8204 and up 1003
Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No : 8001 to 8203 1005
Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No : 8204 and up 1007
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No : 8001 to 8203 1009
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No : 8204 and up 1011
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No : 8001 to 8203 1013
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No : 8204 and up 1015
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No : 8001 to 8203 1017
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No : 8204 and up 1019
Failure code [DF10KA] Disconnection of Shift Lever Input 1021
Failure code [DF10KB] Ground Fault of Shift Lever Input 1024
Failure code [DGF1KX] Out of Range of T/M Oil Temp Sensor 1028
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp S (C) 1030
Failure code [DGR3L8] Failure of Retarder Oil Temp Sensor (C) 1031
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp S (F) 1032
Failure code [DGR4L8] Failure of Retarder Oil Temp Sensor (F) 1033
Failure code [DGR6KB] Ground Fault of Steering Oil Temp S 1035
Failure code [DGR6L8] Failure of Steering Oil Temp Sensor 1036
Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp S 1038
Failure code [DGR8KX] Out of Range of CAC Output Temp S 1040
Failure code [DGT1KX] Out of Range of T/C Oil Temp Sensor 1042
Failure code [DHP4KY] Hot Short of Suspension Press S (FR) 1044
Failure code [DHP4KZ] Failure of Suspension Press S (FR) 1046
Failure code [DHP5KY] Hot Short of Suspension Press S (FL) 1048
Failure code [DHP5KZ] Failure of Suspension Press S (FL) 1050
Failure code [DHP6KY] Hot Short of Suspension Press S (RR) 1052
Failure code [DHP6KZ] Failure of Suspension Press S (RR) 1054
Failure code [DHP7KY] Hot Short of Suspension Press S (RL) 1056
Failure code [DHP7KZ] Failure of Suspension Press S (RL) 1058
Failure code [DHQ2KX] Out of Range of Main Flow Sel Valve S 1060
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 1062
Failure code [DHT5L6] Failure of T/C Oil Press Sensor 1064
Failure code [DHT8KX] Out of Range of Steering Oil Press S 1066
Failure code [DHT8ZG] Steering Oil Pressure Low 1068
Failure code [DHU2KX] Out of Range of Acc Oil Press S (F) 1069
Failure code [DHU3KX] Out of Range of Acc Oil Press S (R) 1071
Failure code [DHUAKX] Out of Range of Retarder Press S (CR) 1073
Failure code [DHUBKX] Out of Range of Retarder Press S (FR) 1075
Failure code [DHUDKX] Out of Range of Emerg Steering Press S 1 1079
Failure code [DHUEKX] Out of Range of Emerg Steering Press S 2 1081
Failure code [DHUQKX] Out of Range of Retarder Press S (FL) 1083
Failure code [DHURKX] Out of Range of Retarder Press S (CL) 1085
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1087
Failure code [DK30KX] Out of Range of Steering Angle Pot 1089
Failure code [DK51L5] Failure of Retarder Lever Pot and RVS 1091
Failure code [DK52KX] Out of Range of Hoist Lever Potentio 1094
Failure code [DK53L8] Failure of Hoist Lever Potentio 1096
Failure code [DK54KX] Out of Range of Body Potentio 1097
Failure code [DK60KX] Out of Range of Acceleration Sensor 1099
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor 1101
Failure code [DKH1KX] Out of Range of Long Inclination Angle S 1103
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 1105
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 1107
Failure code [DLF2KA] Disconnection of T/M Inter Speed Sensor 1109
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 1111
Failure code [DLF400] T/M Diff Overrun Prevention Activated 1113
Failure code [DLF4KA] Disconnection of T/M Diff Speed Sensor 1114
Failure code [DLF4LC] Failure of T/M Diff Speed Sensor 1116
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) 1118
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) 1120
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) 1122
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) 1124
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) 1126
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) 1127
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1128
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1130
Failure code [DLM3MB] Radiator Fan Control Mismatch 1132
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor 1133
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor 1135
Failure code [DLM4MB] CAC Fan Control Mismatch 1137
Failure code [DLT3KA] Disconnection of Output Speed Sens (Main) 1138
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) 1140
Failure code [DPQ1KR] LIN Discon (Switch Panel) 1142
Failure code [DPQ2KR] LIN Discon (LED Unit) 1145
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1148
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1151
Failure code [DV00KB] Ground Fault of Buzzer Output 1152
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol 1154
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol 1155
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol 1156
Failure code [DW2BL1] Release Trouble of Main Flow Sel Valve 1157
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve 1158
Failure code [DW4BK4] Release Trouble of Parking Brake Valve 1159
Failure code [DW4BMA] Malfunction of Parking Brake Valve 1161
Failure code [DW72KZ] Failure of Kick out Solenoid 1162
Failure code [DW73KA] Disconnection of Hoist Selector Sol 1164
Failure code [DW73KB] Ground Fault of Hoist Selector Sol 1166
Failure code [DW73KY] Hot Short of Hoist Selector Sol 1168
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev Sol 1170
Failure code [DW7BKY] Hot Short of Radiator Fan Rev Sol 1172
Failure code [DW7BKZ] Failure of Radiator Fan Rev Sol 1173
Failure code [DW7LKB] Ground Fault of CAC Fan Rev Sol 1175
Failure code [DW7LKY] Hot Short of CAC Fan Rev Sol 1176
Failure code [DW7LKZ] Failure of CAC Fan Rev Sol 1177
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol 1178
Failure code [DWNJKZ] Failure of TCS Shut off Sol (Front) 1180
Failure code [DWNKKZ] Failure of TCS Shut off Sol (Center) 1182
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid 1184
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid 1186
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid 1188
Failure code [DX16KA] Disconnection of Rad Fan Pump EPC Sol 1190
Failure code [DX16KB] Ground Fault of Rad Fan Pump EPC Sol 1191
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol 1193
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol 1194
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol 1195
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol 1196
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) 1197
Failure code [DX30KA] Disconnection of Retarder EPC Sol (FL) 1199
Failure code [DX30KB] Ground Fault of Retarder EPC Sol (FL) 1201
Failure code [DX30KY] Hot Short of Retarder EPC Sol (FL) 1203
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) 1205
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) 1207
Failure code [DX31KA] Disconnection of Retarder EPC Sol (CR) 1209
Failure code [DX31KB] Ground Fault of Retarder EPC Sol (CR) 1211
Failure code [DX31KY] Hot Short of Retarder EPC Sol (CR) 1213
Failure code [DX31MA] Malfunction of Retarder Valve (CR) 1215
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) 1217
Failure code [DX32KA] Disconnection of Retarder EPC Sol (CL) 1219
Failure code [DX32KB] Ground Fault of Retarder EPC Sol (CL) 1221
Failure code [DX32KY] Hot Short of Retarder EPC Sol (CL) 1223
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) 1225
Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) 1227
Failure code [DX33KA] Disconnection of Retarder EPC Sol (FR) 1229
Failure code [DX33KB] Ground Fault of Retarder EPC Sol (FR) 1231
Failure code [DX33KY] Hot Short of Retarder EPC Sol (FR) 1233
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) 1235
Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol 1237
Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol 1238
Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol 1240
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff ) 1241
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff ) 1243
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff ) 1245
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 1247
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1249
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 1251
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) 1253
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 1255
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) 1257
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 1258
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) 1260
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 1262
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1265
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 1267
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1269
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1272
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 1274
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1276
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1279
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 1281
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1283
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1286
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 1288
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1290
Failure code [DY30MA] Malfunction 1 of Emerg Steering Motor 1293
Failure code [DY30MC] Malfunction 2 of Emerg Steering Motor 1296
Failure code [DY30ME] Emerg Steering Long-Time Activated 1299
Failure code [DY32MC] Malfunction 2 of Emerg Steering Motor 2 1301
Troubleshooting of electrical system (E-mode) 1304
E-1 Engine does not start (Engine does not crank) 1304
E-2 Manual preheating system does not work 1309
E-3 Automatic preheating system does not work 1312
E-4 While preheating is working, preheating monitor does not light up 1314
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing 1316
E-6 LCD unit on machine monitor displays nothing 1319
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 1321
E-8 LCD on machine monitor does not display properly 1323
E-9 Meter unit display on machine monitor is abnormal 1325
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 1328
E-11 LED unit lamp on machine monitor is abnormal 1331
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly 1333
E-13 2 switches operation of switch panel on machine monitor does not function 1335
E-14 Switch panel buzzer of machine monitor is abnormal 1337
E-15 Some items of gauges and caution lamps on machine monitor are not displayed properly 1339
E-16 Fuel level gauge does not indicate correct level 1340
E-17 Seat belt caution lamp indication is abnormal 1342
E-18 Machine monitor cannot be operated when starting switch is in OFF position 1343
E-19 Alarm buzzer does not sound 1344
E-20 Alarm buzzer does not stop sounding 1346
E-21 Engine mode selector function does not operate properly 1348
E-22 AISS function does not operate properly 1349
E-23 Hoist lever does not operate properly 1350
E-24 Turn signal lamp and winker lamp (hazard lamp) do not operate properly 1352
E-25 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up 1356
E-26 Small lamp (clearance lamp) does not light up 1358
E-27 Tail lamp does not light up 1360
E-28 Low beam head lamp does not light up 1362
E-29 High beam head lamp does not light up 1364
E-30 Neither Low beam nor High beam head lamps lights up 1366
E-31 High beams do not light up while passing switch is operated 1368
E-32 KOMTRAX does not operate properly 1370
Troubleshooting of hydraulic and mechanical system (H-mode) 1371
Information described in troubleshooting table (H-mode) 1371
System chart of hydraulic and mechanical systems 1372
Failure mode and cause table 1374
H-1 Machine does not start 1378
H-2 Machine does not travel smoothly (engine hunts) 1380
H-3 Lockup clutch is not disengaged 1381
H-4 Abnormally large shocks result from starting of machine and gear shifting 1382
H-5 Machine does not upshift 1383
H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds 1385
H-7 Machine lacks travel speed or power during travel in torque converter drive mode 1386
H-8 Machine lacks travel speed or power during travel in specific gear speed 1387
H-9 Machine starts or gear speed shifts with long time lag 1388
H-10 Torque converter oil temperature is high 1390
H-11 Torque converter oil pressure is low 1391
H-12 Front brake does not work sufficiently 1392
H-13 Center brake does not work sufficiently 1393
H-14 Steering wheel is heavy to turn 1394
H-15 Steering wheel does not move 1395
H-16 Steering wheel swings 1396
H-17 Dump body raise speed or power is slow 1397
H-18 Dump body does not move 1399
H-19 Hydraulic drift of dump body is large 1400
H-20 Radiator fan speed is abnormal (high, low, or stationary) 1401
H-21 Aftercooler fan speed is abnormal (high, low, or stationary) 1402
H-22 Unusual noise is heard from around radiator fan 1403
H-23 Unusual noise is heard from around aftercooler fan 1404
Troubleshooting of engine (S-mode) 1405
Information mentioned in troubleshooting table (S mode) 1405
S-1 Engine does not crank when starting switch is turned to START position 1406
S-2 The engine cranks but exhaust smoke does not come out 1407
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1408
S-4 Engine startability is poor 1409
S-5 Engine does not pick up smoothly 1411
S-6 Engine stops during operation 1413
S-7 Engine runs rough or is unstable 1415
S-8 Engine lacks power 1416
S-9 Exhaust smoke is black 1418
S-10 Engine oil consumption is excessive 1420
S-11 Oil becomes contaminated quickly 1421
S-12 Fuel consumption is excessive 1422
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1423
S-14 Oil pressure drops 1424
S-15 Fuel mixes into engine oil 1425
S-16 Water mixes into engine oil (milky) 1426
S-17 Coolant temperature rises too high (overheating) 1427
S-18 Unusual noise is heard 1428
S-19 Vibration is excessive 1429
S-20 Air cannot be bled from fuel circuit 1430
50 Disassembly and assembly 1431
Table of contents 1432
Related information on disassembly and assembly 1434
How to read this manual 1434
Coating materials list 1436
Special tools list 1440
Sketches of special tools 1451
Engine and cooling system 1469
Removal and installation of supply pump assembly 1469
Removal and installation of injector assembly 1473
Removal and installation of cylinder head assembly 1480
Removal and installation of radiator assembly 1492
Removal and installation of radiator core assembly 1497
Removal and installation of cooling fan and fan motor assembly for radiator 1499
Removal and installation of aftercooler assembly 1501
Removal and installation of cooling fan and fan motor assembly for aftercooler 1505
Removal and installation of engine assembly 1507
Removal and installation of engine front oil seal 1516
Removal and installation of engine rear oil seal 1520
Removal and installation of output shaft assembly 1526
Disassembly and assembly of output shaft assembly 1531
Removal and installation of air cleaner assembly 1534
Removal and installation of fire prevention cover on exhaust pipe 1536
Power train 1540
Removal and installation of transmission and front differential assembly 1540
Disconnection and connection of front differential assembly and transmission assembly 1552
Disassembly and assembly of front differential assembly 1554
Disassembly and assembly of torque converter assembly 1569
Disassembly and assembly of transmission assembly 1577
Removal and installation of center differential assembly 1617
Disassembly and assembly of center differential assembly 1621
Removal and installation of rear differential assembly 1635
Disassembly and assembly of rear differential assembly 1637
Removal and installation of front final drive and brake assembly 1647
Disassembly and assembly of front final drive and brake assembly 1649
Removal and installation of center final drive and brake assembly 1661
Disassembly and assembly of center final drive and brake assembly 1663
Removal and installation of rear final drive assembly 1673
Disassembly and assembly of rear final drive assembly 1674
Removal and installation of center axle assembly 1679
Removal and installation of rear axle assembly 1683
Steering system 1686
Disassembly and assembly of steering cylinder assembly 1686
Undercarriage and frame 1692
Removal and installation of front suspension cylinder assembly 1692
Removal and installation of rear suspension cylinder assembly 1694
Disassembly and assembly of suspension cylinder assembly 1696
Removal and installation of equalizer bar assembly 1698
Removal and installation of front wheel assembly 1700
Removal and installation of rear (front side) wheel assembly 1704
Removal and installation of rear (back side) wheel assembly 1705
Removal and installation of hitch frame assembly 1706
Disassembly and assembly of hitch frame assembly 1713
Hydraulic system 1718
Removal and installation of flow amplifier valve assembly 1718
Removal and installation of hoist valve assembly 1721
Disassembly and assembly of hoist valve assembly 1725
Disassembly and assembly of hoist cylinder assembly 1728
Body 1740
Removal and installation of dump body assembly 1740
Cabanditsattachments 1743
Removalandinstallationofoperator’scabassembly 1743
Removal and installation of operator’s cab glass (adhered glass) 1748
Removal and installation of operator’s seat assembly 1754
Removal and installation of seat belt 1756
Electrical system 1757
Removal and installation of machine monitor assembly 1757
Removal and installation of engine controller assembly 1759
Removal and installation of retarder and hoist controller assembly 1761
Removal and installation of transmission controller assembly 1762
Removal and installation of KOMTRAX terminal assembly 1763
Air conditioner unit 1764
Removal and installation of air conditioner unit assembly 1764
Removal and installation of air conditioner compressor assembly 1769
Removal and installation of air conditioner condenser 1771
60 Maintenance standard 1773
Table of contents 1774
Engine and cooling system 1775
Engine mount 1775
Output shaft 1776
Radiator fan pump 1777
Aftercooler fan motor 1779
Radiator fan motor 1781
Power train 1782
Drive shaft 1782
Torque converter and transmission mount 1784
Torque converter 1785
Transmission 1788
Transmission control valve 1796
Forward and reverse clutch ECMV and gear speed clutch ECMV 1797
Lockup clutch ECMV 1798
Differential lock clutch ECMV 1799
Main relief valve, torque converter relief valve, and main flow selector valve 1800
Differential 1802
Axle 1805
Final drive 1807
Steering system 1812
Steering column 1812
Steering cylinder 1813
Emergency steering pump 1814
Brake system 1815
Slack adjuster 1815
Brake 1817
Parking brake 1820
Undercarriage and frame 1822
Suspension 1822
Suspension cylinder 1826
Oscillation hitch 1828
Hydraulic system 1830
Steering and hoist pump 1830
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors 1833
Center brake cooling pump 1835
Brake charge pump 1836
Center brake cooling remote pump 1837
Center brake cooling remote motor 1838
Hoist valve 1840
Hoist cylinder 1842
80 Appendix 1843
Table of contents 1844
Air conditioner components 1845
Precautions for refrigerant 1845
Air conditioner component 1846
Configuration and function of refrigeration cycle 1849
Outline of refrigeration cycle 1850
Air conditioner unit 1852
Dual pressure switch 1857
Air conditioner controller 1858
Compressor 1859
Condenser 1860
Receiver drier 1861
Outer temperature sensor (outside air temperature sensor) 1862
Procedure for testing and troubleshooting 1863
Circuit diagram and arrangement of connector pins 1865
System diagram 1867
Input and output signals of the air conditioner controller 1868
Parts and connectors layout 1870
Testing air leakage (duct) 1875
Testing with self-diagnosis function 1878
How to open the electrical system abnormality record screen in service mode of the machine monitor 1879
Testing vent (mode) changeover 1881
Testing FRESH/RECIRC air changeover 1882
Testing (dual) pressure switch for refrigerant 1883
Testing relays 1885
Troubleshooting chart 1 1887
Troubleshooting chart 2 1888
Information in troubleshooting table 1891
Failure code list related to air conditioner 1892
Failure code [879AKA] A/C Inner sensor Open Circuit 1893
Failure code [879AKB] A/C Inner sensor Short Circuit 1894
Failure code [879BKA] A/C Outer sensor Open Circuit 1895
Failure code [879BKB] A/C Outer sensor Short Circuit 1897
Failure code [879CKA] Ventilating sensor Open Circuit 1899
Failure code [879CKB] Ventilating sensor Short Circuit 1900
Failure code [879EMC] Ventilating Damper Abnormality 1901
Failure code [879FMC] Air Mix Damper Abnormality 1902
Failure code [879GKX] Refrigerant Abnormality 1903
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1905
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1907
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1910
A-4 Troubleshooting for FRESH/RECIRC air changeover 1912
Troubleshooting with gauge pressure 1914
Connection of service tool 1917
Precautions for disconnecting and connecting air conditioner piping 1919
Handling of compressor oil 1921
90 Diagrams and drawings 1923
Table of contents 1924
Hydraulic circuit diagram 1925
Symbols in hydraulic circuit diagram 1925
Power train hydraulic circuit diagram 1929
Hydraulic circuit diagram 1931
Electric circuit diagram 1933
Symbols in electric circuit diagram 1933
Inside cab electrical circuit diagram 1937
Outside cab electrical circuit diagram 1969
Electrical circuit diagram of engine 1981
INDEX 1983

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S.V 27/12/24