Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
$42.95
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
Language : English
Pages : 3642
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
Cover............................................................................................................................................................ 1 00 Index and Foreword....................................................................................................................................... 3 Index................................................................................................................................................... 4 Abbreviation List....................................................................................................................................... 25 Foreword, Safety, Basic Information..................................................................................................................... 31 How to Read the Shop Manual......................................................................................................................... 31 Safety Notice for Operation......................................................................................................................... 33 Precautions to Prevent Fire......................................................................................................................... 41 Procedures If Fire Occurs........................................................................................................................... 43 Precautions for Disposing of Waste Materials........................................................................................................ 44 Procedures for Exhaust Gas Regulations.............................................................................................................. 45 Precautions for DEF................................................................................................................................. 46 General Character and Precautions for Handling.................................................................................................. 46 Precautions for Adding.......................................................................................................................... 46 Precautions for Storage......................................................................................................................... 46 Precautions for Fire Hazard and Leakage......................................................................................................... 46 Other Precautions............................................................................................................................... 46 Store DEF........................................................................................................................................... 47 Precautions When You Handle Hydraulic Equipment..................................................................................................... 48 Precautions When You Disconnect and Connect Pipings................................................................................................. 51 Precautions When You Handle Electrical Equipment.................................................................................................... 58 Precautions When You Handle Fuel System Equipment................................................................................................... 60 Precautions When You Handle Intake System Equipment................................................................................................. 61 Practical Use of KOMTRAX............................................................................................................................ 62 Disconnect and Connect Push-Pull Type Coupler....................................................................................................... 63 How to Disconnect and Connect Type 1 Push-Pull Type Coupler..................................................................................... 63 How to Disconnect and Connect Type 2 Push-Pull Type Coupler..................................................................................... 64 How to Disconnect and Connect Type 3 Push-Pull Type Coupler..................................................................................... 65 Precautions for Disconnection and Connection of Connectors.......................................................................................... 67 How to Disconnect and Connect Deutsch Connector..................................................................................................... 71 How to Disconnect and Connect Slide Lock Type Connector............................................................................................. 72 How to Disconnect and Connect Connector with Lock to Pull........................................................................................... 74 How to Disconnect and Connect Connector with Lock to Push........................................................................................... 75 How to Disconnect and Connect Connector with Housing to Rotate...................................................................................... 77 How to Read the Codes for Electric Cable............................................................................................................ 78 Explanation of Terms for Maintenance Standard....................................................................................................... 82 Standard Tightening Torque Table.................................................................................................................... 85 Conversion Table.................................................................................................................................... 92 01 Specifications........................................................................................................................................... 97 Table of Contents....................................................................................................................................... 98 Abbreviation List....................................................................................................................................... 99 Specifications.......................................................................................................................................... 105 Specification Drawing............................................................................................................................... 105 Specification Drawing: HM400-5.................................................................................................................. 105 Specifications...................................................................................................................................... 107 Specifications: HM400-5......................................................................................................................... 107 Weight Table........................................................................................................................................ 113 Weight Table: HM400-5........................................................................................................................... 113 Table of Quantity of Oil and Coolant to be Added (North America Specification)...................................................................... 115 Table of Quantity of Fuel, Coolant and Lubricants (Australia Specification)......................................................................... 117 10 Structure and Function................................................................................................................................... 119 Table of Contents....................................................................................................................................... 120 Abbreviation List....................................................................................................................................... 124 Urea SCR System......................................................................................................................................... 130 Layout Drawing of Urea SCR System................................................................................................................... 130 Urea SCR System Diagram............................................................................................................................. 132 Function of Urea SCR System......................................................................................................................... 133 Function of DEF System.......................................................................................................................... 133 Inducement Strategy............................................................................................................................. 135 Component Parts of Urea SCR System.................................................................................................................. 149 DEF Mixing Tube................................................................................................................................. 149 SCR Assembly.................................................................................................................................... 149 DEF Tank........................................................................................................................................ 152 DEF Pump........................................................................................................................................ 154 DEF Injector.................................................................................................................................... 155 DEF Hose........................................................................................................................................ 156 DEF Tank Heating Valve.......................................................................................................................... 157 Boot-up System.......................................................................................................................................... 158 Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal).................................................................................... 158 Layout Drawing of Boot-up System (Machine with Gateway Function Controller)......................................................................... 160 System Operating Lamp System........................................................................................................................ 162 System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal).................................................................. 162 Function of System Operating Lamp System (Machine with KOMTRAX Terminal)........................................................................ 162 System Diagram of System Operating Lamp System (Machine with Gateway Function Controller)....................................................... 163 Function of System Operating Lamp System (Machine with Gateway Function Controller)............................................................. 163 Battery Disconnect Switch........................................................................................................................... 165 Layout Drawing of Battery Disconnect Switch..................................................................................................... 165 Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal)........................................................................... 165 Function of Battery Disconnect Switch (Machine with Gateway Function Controller)................................................................ 166 Engine System........................................................................................................................................... 167 Layout Drawing of Engine System..................................................................................................................... 167 Function of Engine System....................................................................................................................... 169 Automatic Idle Stop System.......................................................................................................................... 170 Function of Automatic Idle Stop System.......................................................................................................... 170 Component Parts of Engine System.................................................................................................................... 172 Damper.......................................................................................................................................... 172 VGT............................................................................................................................................. 173 EGR System...................................................................................................................................... 177 EGR Valve....................................................................................................................................... 180 EGR Cooler...................................................................................................................................... 182 KCCV System..................................................................................................................................... 183 KCCV Ventilator................................................................................................................................. 185 KDPF............................................................................................................................................ 187 Cooling System.......................................................................................................................................... 191 Layout Drawing of Cooling System.................................................................................................................... 191 Specifications of Cooling System................................................................................................................ 192 Radiator Fan Control System......................................................................................................................... 193 Radiator Fan Control System Diagram............................................................................................................. 193 Function of Radiator Fan Control System......................................................................................................... 193 Aftercooler Fan Control System...................................................................................................................... 195 Aftercooler Fan Control System Diagram.......................................................................................................... 195 Function of Aftercooler Fan Control System...................................................................................................... 195 Component Parts of Cooling System................................................................................................................... 197 Radiator Fan Pump............................................................................................................................... 197 Radiator Fan Motor.............................................................................................................................. 204 Aftercooler Fan Motor........................................................................................................................... 209 Center Brake Cooling Remote Motor............................................................................................................... 220 Center Brake Cooling Remote Pump................................................................................................................ 223 Hydraulic Oil Cooler Bypass Valve............................................................................................................... 224 Control System.......................................................................................................................................... 225 Layout Drawing of Control System (Machine with KOMTRAX Terminal).................................................................................... 225 Layout Drawing of Control System (Machine with Gateway Function Controller)......................................................................... 226 Retarder and Hoist Control System................................................................................................................... 227 System Diagram of Retarder and Hoist Control System (Machine with KOMTRAX Terminal)............................................................. 227 System Diagram of Retarder and Hoist Control System (Machine with Gateway Function Controller).................................................. 228 Machine Monitor System.............................................................................................................................. 229 System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal)........................................................................ 229 System Diagram of Machine Monitor System (Machine with Gateway Function Controller)............................................................. 230 Function of Machine Monitor System.............................................................................................................. 231 Rearview Monitor System............................................................................................................................. 232 System Diagram of Rearview Monitor System....................................................................................................... 232 Function of Rearview Monitor System............................................................................................................. 232 KOMTRAX System...................................................................................................................................... 233 KOMTRAX System Diagram (Machine with KOMTRAX Terminal).......................................................................................... 233 Function of KOMTRAX System (Machine with KOMTRAX Terminal)...................................................................................... 233 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)..................................................................... 234 Function of KOMTRAX System (Machine with Gateway Function Controller)........................................................................... 234 Payload Meter System................................................................................................................................ 235 Layout Drawing of Payload Meter System.......................................................................................................... 235 System Diagram of Payload Meter (Machine with KOMTRAX Terminal)................................................................................. 236 System Diagram of Payload Meter (Machine with Gateway Function Controller)...................................................................... 237 Function of Payload Meter System................................................................................................................ 237 Measurement Principle of Loading Mass........................................................................................................... 238 Component Parts of Control System................................................................................................................... 249 Machine Monitor................................................................................................................................. 249 Switch Panel.................................................................................................................................... 271 Rearview Monitor................................................................................................................................ 272 Rearview Camera................................................................................................................................. 274 KOMTRAX Terminal................................................................................................................................ 275 Gateway Function Controller..................................................................................................................... 277 Communication Terminal.......................................................................................................................... 280 Transmission Controller......................................................................................................................... 282 Retarder and Hoist Controller................................................................................................................... 289 Monitor Controller.............................................................................................................................. 294 Engine Controller............................................................................................................................... 299 Payload Meter Controller........................................................................................................................ 306 Accelerator Pedal............................................................................................................................... 315 Shift Lever..................................................................................................................................... 316 Retarder Control Lever.......................................................................................................................... 317 Fuel Feed Pump.................................................................................................................................. 318 Fuel Feed Pump Switch........................................................................................................................... 319 Hydraulic System........................................................................................................................................ 320 Layout Drawing of Hydraulic System.................................................................................................................. 320 Component Parts of Hydraulic System................................................................................................................. 321 Hydraulic Tank.................................................................................................................................. 321 Steering and Hoist Pump......................................................................................................................... 322 LS Valve........................................................................................................................................ 329 PC Valve........................................................................................................................................ 330 Power Train and Front Brake Cooling Duplex Pump, Aftercooler Fan Pump, and Center Brake Cooling Remote Motor Drive Pump......................... 334 Hoist Valve..................................................................................................................................... 336 Power Train System...................................................................................................................................... 341 Layout Drawing of Power Train System................................................................................................................ 341 Transmission Control System......................................................................................................................... 343 System Diagram of Transmission Control System (Machine with KOMTRAX Terminal)................................................................... 343 System Diagram of Transmission Control System (Machine with Gateway Function Controller)........................................................ 344 Shift Lever Positions and Automatic Gear Shift Range............................................................................................ 345 Gear Shift Control System........................................................................................................................... 349 Automatic Gear Shift Control of Gear Shift Control System....................................................................................... 349 Shift Hold System................................................................................................................................... 352 Function of Shift Hold System................................................................................................................... 352 Direction Control System............................................................................................................................ 353 Rim Pull Limit Function for Overload Prevention of Direction Control System..................................................................... 353 Function of Throttle Limit Function at F1 Start at D Position Setting of Direction Control System............................................... 353 Komatsu Traction Control System (KTCS).............................................................................................................. 354 Komatsu Traction Control System (KTCS) System Diagram........................................................................................... 354 Function of Komatsu Traction Control System (KTCS).............................................................................................. 354 Operation of Komatsu Traction Control System (KTCS) System Logic................................................................................ 355 Component Parts of Power Train System............................................................................................................... 357 Drive Shaft..................................................................................................................................... 357 Torque Converter and PTO........................................................................................................................ 359 Lockup Clutch ECMV.............................................................................................................................. 363 Transmission.................................................................................................................................... 366 Transmission Control Valve...................................................................................................................... 387 Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV...................................................................................... 389 Differential Lock Clutch ECMV................................................................................................................... 394 Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve.................................................................. 397 Axle............................................................................................................................................ 401 Differential.................................................................................................................................... 404 Final Drive..................................................................................................................................... 408 Work Equipment System................................................................................................................................... 412 Work Equipment Control.............................................................................................................................. 412 Layout Drawing of Work Equipment Control........................................................................................................ 412 Function of Work Equipment Control.............................................................................................................. 412 Hoist Control....................................................................................................................................... 413 Hoist Control System Diagram.................................................................................................................... 413 Function of Hoist Control....................................................................................................................... 413 Component Parts of Work Equipment System............................................................................................................ 415 Dump Lever...................................................................................................................................... 415 Dump EPC Valve.................................................................................................................................. 420 Steering System......................................................................................................................................... 422 Layout Drawing of Steering System................................................................................................................... 422 Function of Steering System......................................................................................................................... 423 Steering Column..................................................................................................................................... 424 Structure of Steering Column.................................................................................................................... 424 Component Parts of Steering System.................................................................................................................. 425 Flow Amplifier Valve............................................................................................................................ 425 Steering Valve.................................................................................................................................. 429 Steering Pump Selector Solenoid Valve........................................................................................................... 434 Secondary Steering Pump......................................................................................................................... 435 Secondary Steering Motor........................................................................................................................ 436 Brake System............................................................................................................................................ 437 Layout Drawing of Brake System...................................................................................................................... 437 Retarder Control.................................................................................................................................... 439 Retarder Control System Diagram................................................................................................................. 439 Function of Retarder Control.................................................................................................................... 440 Parking Brake Interlock Function.................................................................................................................... 442 Function of Parking Brake Interlock Function.................................................................................................... 442 Operation of Parking Brake Interlock Function................................................................................................... 442 ARAC System......................................................................................................................................... 443 ARAC System Diagram............................................................................................................................. 443 Function of ARAC System......................................................................................................................... 443 Component Parts of Brake System..................................................................................................................... 444 Brake Charge Pump............................................................................................................................... 444 Parking Brake Solenoid Valve and Accumulator Charge Valve....................................................................................... 445 Parking Brake Solenoid Valve.................................................................................................................... 446 Accumulator Charge Valve........................................................................................................................ 446 Brake Circuit Accumulator....................................................................................................................... 451 Shut Off Solenoid Valve......................................................................................................................... 453 Brake Valve..................................................................................................................................... 454 Proportional Pressure Reducing Valve............................................................................................................ 457 Slack Adjuster.................................................................................................................................. 458 Brake........................................................................................................................................... 461 Front Brake Cooling Relief Valve................................................................................................................ 464 Center Brake Cooling Relief Valve............................................................................................................... 464 Brake System Tank............................................................................................................................... 465 Parking Brake................................................................................................................................... 466 Spring Cylinder................................................................................................................................. 467 Parking Brake Caliper........................................................................................................................... 469 Undercarriage and Frame................................................................................................................................. 471 Front Suspension.................................................................................................................................... 471 Structure of Front Suspension................................................................................................................... 471 Function of Front Suspension.................................................................................................................... 471 Center and Rear Suspensions......................................................................................................................... 473 Structure of Center and Rear Suspensions........................................................................................................ 473 Function of Center Suspension................................................................................................................... 473 Function of Rear Suspension..................................................................................................................... 474 Suspension Cylinder................................................................................................................................. 475 Structure of Suspension Cylinder................................................................................................................ 475 Function of Suspension Cylinder................................................................................................................. 476 Operation of Suspension Cylinder................................................................................................................ 477 Oscillation Hitch................................................................................................................................... 478 Structure of Oscillation Hitch.................................................................................................................. 478 Function of Oscillation Hitch................................................................................................................... 479 Work Equipment.......................................................................................................................................... 480 Structure of Work Equipment......................................................................................................................... 480 Function of Work Equipment.......................................................................................................................... 481 CAB Related Parts....................................................................................................................................... 482 ROPS CAB............................................................................................................................................ 482 Structure of ROPS CAB........................................................................................................................... 482 Function of ROPS CAB............................................................................................................................ 483 CAB Tilt............................................................................................................................................ 484 Structure of CAB Tilt........................................................................................................................... 484 20 Standard Value Table..................................................................................................................................... 485 Table of Contents....................................................................................................................................... 486 Abbreviation List....................................................................................................................................... 487 Standard Value Table for Engine......................................................................................................................... 493 Standard Value Table for Engine: HM400-5............................................................................................................ 493 Standard Value Table for Machine........................................................................................................................ 497 Standard Value Table for Machine: HM400-5........................................................................................................... 497 Machine Posture and Procedures to Measure Performance............................................................................................... 511 Standard Value Table for Electricity.................................................................................................................... 512 Standard Value Table for Electricity................................................................................................................ 512 30 Testing and Adjusting.................................................................................................................................... 529 Table of Contents....................................................................................................................................... 530 Abbreviation List....................................................................................................................................... 533 Related Information on Testing and Adjusting............................................................................................................ 539 Tools for Testing and Adjusting..................................................................................................................... 539 Sketch of Tools for Testing and Adjusting........................................................................................................... 547 Engine and Cooling System............................................................................................................................... 549 Examine Engine Speed................................................................................................................................ 549 How to Examine Engine Speed..................................................................................................................... 549 Examine Boost Pressure.............................................................................................................................. 552 How to Examine Boost Pressure................................................................................................................... 552 Examine Exhaust Gas Temperature..................................................................................................................... 554 How to Examine Exhaust Gas Temperature.......................................................................................................... 554 Examine Exhaust Gas Color........................................................................................................................... 557 How to Examine Exhaust Gas Color with the Handy Smoke Checker................................................................................... 557 How to Examine Exhaust Gas Color with Smoke Meter............................................................................................... 558 Examine Mass Air Flow and Temperature Sensor........................................................................................................ 560 How to Examine Mass Air Flow and Temperature Sensor............................................................................................. 560 Examine and Adjust Valve Clearance.................................................................................................................. 563 How to Examine Valve Clearance.................................................................................................................. 563 How to Adjust Valve Clearance................................................................................................................... 564 Examine Compression Pressure........................................................................................................................ 565 How to Examine Compression Pressure............................................................................................................. 565 Examine Blowby Pressure............................................................................................................................. 568 How to Examine Blowby Pressure.................................................................................................................. 568 Examine Engine Oil Pressure......................................................................................................................... 570 How to Examine Engine Oil Pressure on Machine Monitor........................................................................................... 570 How to Examine Engine Oil Pressure by Testing Tool.............................................................................................. 570 Examine EGR Valve and VGT Oil Pressure.............................................................................................................. 572 How to Examine EGR Valve and VGT Oil Pressure................................................................................................... 572 Examine Fuel Pressure............................................................................................................................... 574 How to Examine Fuel Pressure.................................................................................................................... 574 Examine Fuel Return Rate and Leakage................................................................................................................ 576 How to Examine Fuel Return Rate and Leakage..................................................................................................... 577 Bleed Air from Fuel System.......................................................................................................................... 582 How to Bleed Air from Fuel System............................................................................................................... 582 Examine Fuel Circuit for Leakage.................................................................................................................... 584 How to Examine Fuel System for Leakage.......................................................................................................... 584 Handle Cylinder Cut-out Mode Operation.............................................................................................................. 586 Handle No-Injection Cranking Operation.............................................................................................................. 587 Clean Fuel Doser.................................................................................................................................... 588 How to Clean Fuel Doser......................................................................................................................... 588 Write Injector Compensation Value to Engine Controller.............................................................................................. 591 How to Write Injector Compensation Value........................................................................................................ 591 Write Correction for Ash in Soot Accumulation to Engine Controller.................................................................................. 598 How to Write Correction for Ash in Soot Accumulation to Engine Controller....................................................................... 598 Examine SCR Related Functions....................................................................................................................... 599 Examine DEF Pump Raised Pressure................................................................................................................ 603 Examine Injection Volume from DEF Injector...................................................................................................... 606 Examine DEF Line Heater Relay 1................................................................................................................. 611 Examine DEF Line Heater Relay 2................................................................................................................. 615 Examine DEF Pump Heater Relay................................................................................................................... 619 Examine DEF Tank Heater Valve................................................................................................................... 623 Examine SCR Denitration Efficiency.............................................................................................................. 627 Clean DEF Tank...................................................................................................................................... 631 How to Clean DEF Tank........................................................................................................................... 631 Clean DEF Pump...................................................................................................................................... 636 How to Clean DEF Pump........................................................................................................................... 636 Examine Torque Converter Stall Speed................................................................................................................ 643 How to Examine Torque Converter Stall Speed..................................................................................................... 643 Examine Radiator Fan and Aftercooler Fan Speed...................................................................................................... 648 How to Examine Radiator Fan and Aftercooler Fan Speed........................................................................................... 648 Power Train............................................................................................................................................. 650 Examine Power Train Oil Pressure.................................................................................................................... 650 How to Examine Power Train Oil Pressure......................................................................................................... 653 Adjust Transmission Speed Sensor.................................................................................................................... 668 How to Adjust Transmission Speed Sensor......................................................................................................... 669 Adjust Transmission Controller...................................................................................................................... 671 How to Adjust Transmission Controller........................................................................................................... 671 Move Machine Which Has a Trouble in Electrical System............................................................................................... 672 How to Move Machine Which Has a Trouble in Engine Control System................................................................................ 672 How to Move Machine Which Has a Trouble in Transmission Control System.......................................................................... 672 Move Machine Which Has a Trouble in Traction Control System (KTCS).................................................................................. 679 How to Move Machine with Secondary KTCS Operation Connector..................................................................................... 681 Steering System......................................................................................................................................... 682 Examine and Adjust Steering Circuit Oil Pressure.................................................................................................... 682 How to Examine Steering Circuit Oil Pressure.................................................................................................... 682 How to Adjust Steering Circuit Oil Pressure..................................................................................................... 683 Bleed Air from Steering Cylinder Circuit............................................................................................................ 684 How to Bleed Air from Steering Cylinder Circuit................................................................................................. 684 Brake System............................................................................................................................................ 686 Examine and Adjust Brake Oil Pressure............................................................................................................... 686 How to Examine Brake Oil Pressure............................................................................................................... 686 How to Adjust Brake Oil Pressure................................................................................................................ 690 Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas................................................................................... 692 How to Examine Accumulator Nitrogen Gas Pressure................................................................................................ 692 How to Charge Accumulator Nitrogen Gas for Brake................................................................................................ 696 Release Remained Pressure in Brake Accumulator Circuit.............................................................................................. 701 How to Release Remained Pressure in Brake Accumulator Circuit................................................................................... 701 Bleed Air from Brake Circuit........................................................................................................................ 702 How to Bleed Air from Brake Circuit............................................................................................................. 702 Examine Brake Performance........................................................................................................................... 704 How to Examine Brake Performance................................................................................................................ 704 Examine Wear of Wheel Brake Disc.................................................................................................................... 708 How to Examine Wear of Wheel Brake Disc......................................................................................................... 708 Release Parking Brake Manually...................................................................................................................... 710 How to Release Parking Brake Manually........................................................................................................... 710 Examine and Adjust Wear of Parking Brake Pad........................................................................................................ 711 How to Examine Wear of Parking Brake Pad........................................................................................................ 711 How to Adjust Clearance of Parking Brake Pad.................................................................................................... 712 Hydraulic System........................................................................................................................................ 714 Examine and Adjust Suspension Cylinder.............................................................................................................. 714 How to Examine Suspension Cylinder.............................................................................................................. 715 How to Adjust Suspension Cylinder............................................................................................................... 715 Examine and Adjust Dump Circuit Oil Pressure........................................................................................................ 719 How to Examine Dump Circuit Oil Pressure........................................................................................................ 719 How to Adjust Dump Circuit Oil Pressure......................................................................................................... 720 Work Equipment.......................................................................................................................................... 722 Examine and Adjust Dump Body Positioner Sensor...................................................................................................... 722 How to Examine Dump Body Positioner Sensor...................................................................................................... 722 How to Adjust Dump Body Positioner Sensor....................................................................................................... 722 Examine and Adjust Dump Body Mount.................................................................................................................. 725 How to Examine Dump Body Mount.................................................................................................................. 725 How to Adjust Dump Body Mount................................................................................................................... 726 CAB Related Parts....................................................................................................................................... 727 CAB Tilt Up......................................................................................................................................... 727 How to Tilt Up Cab.............................................................................................................................. 728 Adjust Tilt Lock Lever of Steering Wheel............................................................................................................ 734 How to Adjust Tilt Lock Lever of Steering Wheel................................................................................................. 734 Adjust Play of Operator Seat........................................................................................................................ 736 How to Adjust Play of Operator Seat............................................................................................................. 736 Electrical System....................................................................................................................................... 737 Set and Adjust Each Equipment....................................................................................................................... 737 Prepare for Transmission ECMV Current Adjustment................................................................................................ 739 How to Adjust Transmission ECMV Current......................................................................................................... 740 How to Set and Reset Transmission Initial Learning.............................................................................................. 743 How to Set Property Value of ARAC (Automatic Retarder Accelerator Control)...................................................................... 748 How to Do System Check of KTCS (Komatsu Traction Control System)................................................................................ 751 Set and Operate Machine Monitor..................................................................................................................... 753 Operator Mode................................................................................................................................... 757 Function to Show Technician Identification Status Screen........................................................................................ 757 Function to Show Operator Identification Input Screen........................................................................................... 757 Examine Function by LCD (Liquid Crystal Display)................................................................................................ 758 Examine Function of Service Meter and Odometer.................................................................................................. 759 How to Set Usage Limitation and Change Maintenance Password..................................................................................... 759 Service Mode.................................................................................................................................... 763 How to Operate Service Mode..................................................................................................................... 763 How to See Pre-defined Monitoring Information................................................................................................... 766 How to Examine Self-Define Monitor Information.................................................................................................. 774 Abnormality Record Menu......................................................................................................................... 791 How to See Maintenance Record................................................................................................................... 796 Maintenance Mode Setting........................................................................................................................ 798 How to Set Phone Number Entry................................................................................................................... 802 Default Menu.................................................................................................................................... 804 Diagnostic Tests Menu........................................................................................................................... 819 Adjustment Menu................................................................................................................................. 830 No-Injection Cranking Operation................................................................................................................. 836 Payload Meter Setting........................................................................................................................... 838 KOMTRAX Settings Menu........................................................................................................................... 861 How to Show Service Message..................................................................................................................... 865 How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal).................................................................................... 867 How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)................................................................................. 871 How to Start Up KOMTRAX System (Machine with Gateway Function Controller)........................................................................... 873 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)........................................................................ 878 Adjust Optical Axis of Head Lamp.................................................................................................................... 880 How to Adjust Optical Axis of Head Lamp......................................................................................................... 880 Set Region of Bluetooth(R) Compatible Radio......................................................................................................... 884 How to Set Region of Bluetooth(R) Compatible Radio.............................................................................................. 884 Handle Voltage Circuit of Engine Controller......................................................................................................... 886 Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal).................................................................................... 887 Handle Battery Disconnect Switch (Machine with Gateway Function Controller)......................................................................... 888 Examine Diodes...................................................................................................................................... 889 How to Examine Diodes by Digital Tester......................................................................................................... 889 How to Examine Diodes by Analog Tester.......................................................................................................... 889 Pm Clinic............................................................................................................................................... 890 Pm Clinic Service................................................................................................................................... 890 Pm Clinic Check Sheet........................................................................................................................... 893 40 Troubleshooting.......................................................................................................................................... 903 Table of Contents....................................................................................................................................... 904 Abbreviation List....................................................................................................................................... 917 Related Information to Troubleshooting.................................................................................................................. 923 General Troubleshooting Points...................................................................................................................... 923 Troubleshooting Points for Urea SCR System.......................................................................................................... 924 Sequence of Events in Troubleshooting............................................................................................................... 938 Checks Before Troubleshooting....................................................................................................................... 940 Inspection Procedure Before Troubleshooting......................................................................................................... 942 Walk-Around Check............................................................................................................................... 942 Test in Accordance with Testing Procedure........................................................................................................... 944 Examine Fuel Level and Type..................................................................................................................... 944 Examine for Impure Ingredient in Fuel........................................................................................................... 944 Examine DEF Level and Type...................................................................................................................... 945 Examine Fuel Prefilter.......................................................................................................................... 945 Examine Fuel Main Filter........................................................................................................................ 947 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type..................................................................................... 948 Examine Coolant Level (Reservoir Tank).......................................................................................................... 949 Examine Air Cleaner Clogging.................................................................................................................... 950 Clean Outer Element............................................................................................................................. 951 Replace Element................................................................................................................................. 953 Examine Hydraulic Oil Level..................................................................................................................... 955 Examine Hydraulic Oil Strainer.................................................................................................................. 955 Examine Hydraulic Oil Filter.................................................................................................................... 956 Examine Oil Level in Transmission Case.......................................................................................................... 957 Examine Oil Level in Differential Case.......................................................................................................... 957 Examine Oil Level in Final Drive Case........................................................................................................... 958 Bleed Air from Fuel System...................................................................................................................... 958 Bleed Air from Hydraulic System................................................................................................................. 958 How to Examine Electric Equipment............................................................................................................... 958 Preparation for Troubleshooting of Electrical System................................................................................................ 967 Procedure for Troubleshooting....................................................................................................................... 976 Symptom and Troubleshooting Numbers................................................................................................................. 978 Information Shown in Troubleshooting Table.......................................................................................................... 981 Connector List and Layout........................................................................................................................... 983 Connector Contact Connection Table..................................................................................................................1010 T-Branch Box and T-Branch Adapter Table.............................................................................................................1050 Fuse Location Table (Machine with KOMTRAX Terminal).................................................................................................1056 Fuse Location Table (Machine with Gateway Function Controller)......................................................................................1060 Precautions When You Clean and Replace KDPF (KCSF and KDOC).........................................................................................1064 Prepare Troubleshoot Machine Monitor................................................................................................................1068 Procedure to Make Harness Checker on Machine Monitor LCD Unit.......................................................................................1070 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])................................................................1076 Failure Code Table..................................................................................................................................1078 Troubleshooting by Failure Code (Display of Code).......................................................................................................1104 Failure Code [1500L0]...............................................................................................................................1104 Failure Code [15B0NX]...............................................................................................................................1105 Failure Code [15F0KM]...............................................................................................................................1107 Failure Code [15F0MB]...............................................................................................................................1108 Failure Code [15F7KM]...............................................................................................................................1109 Failure Code [15G0MW]...............................................................................................................................1110 Failure Code [15G7KM]...............................................................................................................................1113 Failure Code [15H0MW]...............................................................................................................................1114 Failure Code [15J0MW]...............................................................................................................................1117 Failure Code [15K0MW]...............................................................................................................................1120 Failure Code [15L0MW]...............................................................................................................................1123 Failure Code [15M0MW]...............................................................................................................................1126 Failure Code [15SBL1]...............................................................................................................................1129 Failure Code [15SBMA]...............................................................................................................................1132 Failure Code [15SCL1] (Applicable Machine: 10001 to 10171)..........................................................................................1133 Failure Code [15SCL1] (Applicable Machine: 10172 and Up)............................................................................................1136 Failure Code [15SCMA]...............................................................................................................................1139 Failure Code [15SDL1] (Applicable Machine: 10001 to 10171)..........................................................................................1140 Failure Code [15SDL1] (Applicable Machine: 10172 and Up)............................................................................................1143 Failure Code [15SDMA]...............................................................................................................................1146 Failure Code [15SEL1] (Applicable Machine: 10001 to 10171)..........................................................................................1147 Failure Code [15SEL1] (Applicable Machine: 10172 and Up)............................................................................................1150 Failure Code [15SEMA]...............................................................................................................................1153 Failure Code [15SFL1] (Applicable Machine: 10001 to 10171)..........................................................................................1154 Failure Code [15SFL1] (Applicable Machine: 10172 and Up)............................................................................................1157 Failure Code [15SFMA]...............................................................................................................................1160 Failure Code [15SGL1]...............................................................................................................................1161 Failure Code [15SGMA]...............................................................................................................................1164 Failure Code [15SJMA]...............................................................................................................................1165 Failure Code [15SKMA]...............................................................................................................................1167 Failure Code [2F00KM]...............................................................................................................................1169 Failure Code [2G42ZG]...............................................................................................................................1171 Failure Code [2G43ZG]...............................................................................................................................1172 Failure Code [879AKA]...............................................................................................................................1173 Failure Code [879AKB]...............................................................................................................................1174 Failure Code [879BKA]...............................................................................................................................1175 Failure Code [879BKB]...............................................................................................................................1177 Failure Code [879CKA]...............................................................................................................................1179 Failure Code [879CKB]...............................................................................................................................1180 Failure Code [879EMC]...............................................................................................................................1181 Failure Code [879FMC]...............................................................................................................................1182 Failure Code [879GKX]...............................................................................................................................1183 Failure Code [989D00]...............................................................................................................................1185 Failure Code [989L00]...............................................................................................................................1186 Failure Code [989M00]...............................................................................................................................1187 Failure Code [989N00]...............................................................................................................................1188 Failure Code [A1U0N3]...............................................................................................................................1189 Failure Code [A1U0N4]...............................................................................................................................1191 Failure Code [AA10NX]...............................................................................................................................1193 Failure Code [AB00KE]...............................................................................................................................1195 Failure Code [AB00KY]...............................................................................................................................1197 Failure Code [AQ10N3]...............................................................................................................................1199 Failure Code [AS00N3]...............................................................................................................................1201 Failure Code [AS00R2]...............................................................................................................................1203 Failure Code [AS00R3]...............................................................................................................................1204 Failure Code [AS00R4]...............................................................................................................................1205 Failure Code [AS00R5]...............................................................................................................................1206 Failure Code [AS00R6]...............................................................................................................................1207 Failure Code [AS00ZK]...............................................................................................................................1208 Failure Code [AS10KM]...............................................................................................................................1209 Failure Code [AS10NR]...............................................................................................................................1210 Failure Code [AS10NT]...............................................................................................................................1211 Failure Code [B@BAZG]...............................................................................................................................1212 Failure Code [B@BAZK]...............................................................................................................................1213 Failure Code [B@BCNS]...............................................................................................................................1214 Failure Code [B@BCQA]...............................................................................................................................1215 Failure Code [B@BCZK]...............................................................................................................................1217 Failure Code [B@C6NS]...............................................................................................................................1219 Failure Code [B@C8NS]...............................................................................................................................1220 Failure Code [B@CENS]...............................................................................................................................1221 Failure Code [B@JANS]...............................................................................................................................1222 Failure Code [CA115]................................................................................................................................1223 Failure Code [CA122]................................................................................................................................1224 Failure Code [CA123]................................................................................................................................1226 Failure Code [CA131]................................................................................................................................1228 Failure Code [CA132]................................................................................................................................1230 Failure Code [CA135]................................................................................................................................1233 Failure Code [CA141]................................................................................................................................1235 Failure Code [CA144]................................................................................................................................1237 Failure Code [CA145]................................................................................................................................1239 Failure Code [CA153]................................................................................................................................1241 Failure Code [CA154]................................................................................................................................1244 Failure Code [CA187]................................................................................................................................1247 Failure Code [CA221]................................................................................................................................1249 Failure Code [CA222]................................................................................................................................1251 Failure Code [CA227]................................................................................................................................1253 Failure Code [CA234]................................................................................................................................1254 Failure Code [CA238]................................................................................................................................1255 Failure Code [CA239]................................................................................................................................1257 Failure Code [CA249]................................................................................................................................1259 Failure Code [CA256]................................................................................................................................1261 Failure Code [CA271]................................................................................................................................1263 Failure Code [CA272]................................................................................................................................1265 Failure Code [CA273]................................................................................................................................1266 Failure Code [CA274]................................................................................................................................1268 Failure Code [CA322]................................................................................................................................1269 Failure Code [CA323]................................................................................................................................1271 Failure Code [CA324]................................................................................................................................1273 Failure Code [CA325]................................................................................................................................1275 Failure Code [CA331]................................................................................................................................1277 Failure Code [CA332]................................................................................................................................1279 Failure Code [CA343]................................................................................................................................1281 Failure Code [CA351]................................................................................................................................1282 Failure Code [CA352]................................................................................................................................1283 Failure Code [CA356]................................................................................................................................1286 Failure Code [CA357]................................................................................................................................1288 Failure Code [CA386]................................................................................................................................1290 Failure Code [CA431]................................................................................................................................1291 Failure Code [CA432]................................................................................................................................1294 Failure Code [CA441]................................................................................................................................1297 Failure Code [CA442]................................................................................................................................1300 Failure Code [CA449]................................................................................................................................1301 Failure Code [CA451]................................................................................................................................1302 Failure Code [CA452]................................................................................................................................1304 Failure Code [CA515]................................................................................................................................1306 Failure Code [CA516]................................................................................................................................1308 Failure Code [CA553]................................................................................................................................1310 Failure Code [CA555]................................................................................................................................1311 Failure Code [CA556]................................................................................................................................1312 Failure Code [CA559]................................................................................................................................1313 Failure Code [CA595]................................................................................................................................1318 Failure Code [CA687]................................................................................................................................1319 Failure Code [CA689]................................................................................................................................1321 Failure Code [CA691]................................................................................................................................1323 Failure Code [CA692]................................................................................................................................1325 Failure Code [CA697]................................................................................................................................1327 Failure Code [CA698]................................................................................................................................1328 Failure Code [CA731]................................................................................................................................1329 Failure Code [CA778]................................................................................................................................1330 Failure Code [CA1117]...............................................................................................................................1333 Failure Code [CA1664]...............................................................................................................................1334 Failure Code [CA1669]...............................................................................................................................1337 Failure Code [CA1673]...............................................................................................................................1338 Failure Code [CA1677]...............................................................................................................................1339 Failure Code [CA1678]...............................................................................................................................1340 Failure Code [CA1682]...............................................................................................................................1341 Failure Code [CA1683]...............................................................................................................................1345 Failure Code [CA1684]...............................................................................................................................1347 Failure Code [CA1686]...............................................................................................................................1349 Failure Code [CA1691]...............................................................................................................................1350 Failure Code [CA1694]...............................................................................................................................1353 Failure Code [CA1695]...............................................................................................................................1355 Failure Code [CA1696]...............................................................................................................................1356 Failure Code [CA1712]...............................................................................................................................1358 Failure Code [CA1713]...............................................................................................................................1361 Failure Code [CA1714]...............................................................................................................................1363 Failure Code [CA1715]...............................................................................................................................1364 Failure Code [CA1776]...............................................................................................................................1365 Failure Code [CA1777]...............................................................................................................................1368 Failure Code [CA1843]...............................................................................................................................1371 Failure Code [CA1844]...............................................................................................................................1373 Failure Code [CA1879]...............................................................................................................................1376 Failure Code [CA1881]...............................................................................................................................1379 Failure Code [CA1883]...............................................................................................................................1381 Failure Code [CA1885]...............................................................................................................................1385 Failure Code [CA1887]...............................................................................................................................1387 Failure Code [CA1921]...............................................................................................................................1389 Failure Code [CA1922]...............................................................................................................................1392 Failure Code [CA1923]...............................................................................................................................1397 Failure Code [CA1924]...............................................................................................................................1399 Failure Code [CA1925]...............................................................................................................................1401 Failure Code [CA1927]...............................................................................................................................1403 Failure Code [CA1928]...............................................................................................................................1405 Failure Code [CA1942]...............................................................................................................................1407 Failure Code [CA1963]...............................................................................................................................1408 Failure Code [CA1977]...............................................................................................................................1412 Failure Code [CA1993]...............................................................................................................................1415 Failure Code [CA2185]...............................................................................................................................1418 Failure Code [CA2186]...............................................................................................................................1420 Failure Code [CA2249]...............................................................................................................................1422 Failure Code [CA2265]...............................................................................................................................1423 Failure Code [CA2266]...............................................................................................................................1425 Failure Code [CA2271]...............................................................................................................................1428 Failure Code [CA2272]...............................................................................................................................1430 Failure Code [CA2349]...............................................................................................................................1433 Failure Code [CA2353]...............................................................................................................................1435 Failure Code [CA2357]...............................................................................................................................1437 Failure Code [CA2381]...............................................................................................................................1438 Failure Code [CA2382]...............................................................................................................................1440 Failure Code [CA2383]...............................................................................................................................1442 Failure Code [CA2386]...............................................................................................................................1444 Failure Code [CA2387]...............................................................................................................................1446 Troubleshooting Flowchart.......................................................................................................................1450 Failure Code [CA2555]...............................................................................................................................1451 Failure Code [CA2556]...............................................................................................................................1453 Failure Code [CA2637]...............................................................................................................................1455 Failure Code [CA2639]...............................................................................................................................1457 Failure Code [CA2732]...............................................................................................................................1460 Failure Code [CA2733]...............................................................................................................................1462 Failure Code [CA2741]...............................................................................................................................1464 Failure Code [CA2765]...............................................................................................................................1465 Failure Code [CA2771]...............................................................................................................................1466 Failure Code [CA2777]...............................................................................................................................1472 Failure Code [CA2878]...............................................................................................................................1475 Failure Code [CA2881]...............................................................................................................................1478 Failure Code [CA2976]...............................................................................................................................1481 Failure Code [CA3133]...............................................................................................................................1483 Failure Code [CA3134]...............................................................................................................................1485 Failure Code [CA3135]...............................................................................................................................1487 Failure Code [CA3142]...............................................................................................................................1491 Failure Code [CA3143]...............................................................................................................................1492 Failure Code [CA3144]...............................................................................................................................1493 Failure Code [CA3146]...............................................................................................................................1495 Failure Code [CA3147]...............................................................................................................................1496 Failure Code [CA3148]...............................................................................................................................1497 Failure Code [CA3151]...............................................................................................................................1499 Failure Code [CA3165]...............................................................................................................................1505 Failure Code [CA3167]...............................................................................................................................1507 Failure Code [CA3229]...............................................................................................................................1510 Failure Code [CA3231]...............................................................................................................................1512 Failure Code [CA3232]...............................................................................................................................1514 Failure Code [CA3235]...............................................................................................................................1518 Failure Code [CA3239]...............................................................................................................................1520 Failure Code [CA3241]...............................................................................................................................1523 Failure Code [CA3242]...............................................................................................................................1526 Failure Code [CA3251]...............................................................................................................................1529 Failure Code [CA3253]...............................................................................................................................1531 Failure Code [CA3254]...............................................................................................................................1535 Failure Code [CA3255]...............................................................................................................................1538 Failure Code [CA3256]...............................................................................................................................1542 Failure Code [CA3311]...............................................................................................................................1544 Failure Code [CA3312]...............................................................................................................................1546 Failure Code [CA3313]...............................................................................................................................1549 Failure Code [CA3314]...............................................................................................................................1550 Failure Code [CA3315]...............................................................................................................................1551 Failure Code [CA3316]...............................................................................................................................1554 Failure Code [CA3317]...............................................................................................................................1556 Failure Code [CA3318]...............................................................................................................................1557 Failure Code [CA3319]...............................................................................................................................1560 Failure Code [CA3321]...............................................................................................................................1561 Failure Code [CA3322]...............................................................................................................................1563 Failure Code [CA3419]...............................................................................................................................1566 Failure Code [CA3421]...............................................................................................................................1568 Failure Code [CA3497]...............................................................................................................................1570 Failure Code [CA3498]...............................................................................................................................1571 Failure Code [CA3543]...............................................................................................................................1572 Failure Code [CA3545]...............................................................................................................................1579 Failure Code [CA3547]...............................................................................................................................1581 Failure Code [CA3558]...............................................................................................................................1582 Failure Code [CA3559]...............................................................................................................................1584 Failure Code [CA3562]...............................................................................................................................1586 Failure Code [CA3563]...............................................................................................................................1588 Failure Code [CA3567]...............................................................................................................................1591 Failure Code [CA3568]...............................................................................................................................1594 Failure Code [CA3571]...............................................................................................................................1600 Failure Code [CA3572]...............................................................................................................................1602 Failure Code [CA3574]...............................................................................................................................1604 Failure Code [CA3575]...............................................................................................................................1607 Failure Code [CA3577]...............................................................................................................................1609 Failure Code [CA3578]...............................................................................................................................1611 Failure Code [CA3582]...............................................................................................................................1613 Failure Code [CA3583]...............................................................................................................................1620 Failure Code [CA3596]...............................................................................................................................1622 Failure Code [CA3649]...............................................................................................................................1627 Failure Code [CA3681]...............................................................................................................................1629 Failure Code [CA3682]...............................................................................................................................1634 Failure Code [CA3713]...............................................................................................................................1640 Failure Code [CA3717]...............................................................................................................................1643 Failure Code [CA3718]...............................................................................................................................1644 Failure Code [CA3725]...............................................................................................................................1645 Failure Code [CA3748]...............................................................................................................................1648 Failure Code [CA3751]...............................................................................................................................1651 Failure Code [CA3755]...............................................................................................................................1653 Failure Code [CA3866]...............................................................................................................................1655 Failure Code [CA3867]...............................................................................................................................1659 Failure Code [CA3868]...............................................................................................................................1662 Failure Code [CA3899]...............................................................................................................................1666 Failure Code [CA3911]...............................................................................................................................1668 Failure Code [CA3912]...............................................................................................................................1672 Failure Code [CA3932]...............................................................................................................................1674 Failure Code [CA3933]...............................................................................................................................1676 Failure Code [CA3934]...............................................................................................................................1678 Failure Code [CA3935]...............................................................................................................................1681 Failure Code [CA3936]...............................................................................................................................1683 Failure Code [CA4151]...............................................................................................................................1685 Failure Code [CA4152]...............................................................................................................................1689 Failure Code [CA4155]...............................................................................................................................1693 Failure Code [CA4156]...............................................................................................................................1696 Failure Code [CA4157]...............................................................................................................................1699 Failure Code [CA4158]...............................................................................................................................1701 Failure Code [CA4159]...............................................................................................................................1702 Failure Code [CA4161]...............................................................................................................................1703 Failure Code [CA4162]...............................................................................................................................1706 Failure Code [CA4163]...............................................................................................................................1709 Failure Code [CA4164]...............................................................................................................................1711 Failure Code [CA4165]...............................................................................................................................1713 Failure Code [CA4166]...............................................................................................................................1715 Failure Code [CA4168]...............................................................................................................................1717 Failure Code [CA4169]...............................................................................................................................1720 Failure Code [CA4171]...............................................................................................................................1724 Failure Code [CA4249]...............................................................................................................................1728 Failure Code [CA4251]...............................................................................................................................1732 Failure Code [CA4259]...............................................................................................................................1736 Failure Code [CA4261]...............................................................................................................................1739 Failure Code [CA4277]...............................................................................................................................1741 Failure Code [CA4281]...............................................................................................................................1745 Failure Code [CA4459]...............................................................................................................................1748 Failure Code [CA4461]...............................................................................................................................1751 Failure Code [CA4658]...............................................................................................................................1754 Failure Code [CA4731]...............................................................................................................................1758 Failure Code [CA4732]...............................................................................................................................1759 Failure Code [CA4739]...............................................................................................................................1760 Failure Code [CA4768]...............................................................................................................................1761 Failure Code [CA4769]...............................................................................................................................1763 Failure Code [CA4842]...............................................................................................................................1766 Failure Code [CA4952] (Machine with KOMTRAX Terminal)...............................................................................................1770 Failure Code [CA4952] (Machine with Gateway Function Controller)....................................................................................1772 Failure Code [CA5115]...............................................................................................................................1774 Failure Code [CA5179]...............................................................................................................................1777 Failure Code [CA5181]...............................................................................................................................1779 Failure Code [CA5383]...............................................................................................................................1781 Failure Code [D150KB]...............................................................................................................................1783 Failure Code [D150KZ]...............................................................................................................................1784 Failure Code [D151KB]...............................................................................................................................1785 Failure Code [D151KZ]...............................................................................................................................1786 Failure Code [D164KY]...............................................................................................................................1787 Failure Code [D19HKZ]...............................................................................................................................1789 Failure Code [D19JKZ]...............................................................................................................................1791 Failure Code [D1EHKA]...............................................................................................................................1793 Failure Code [D1EHKB]...............................................................................................................................1794 Failure Code [D1EHKY]...............................................................................................................................1795 Failure Code [D1EMKA]...............................................................................................................................1796 Failure Code [D1EMKB]...............................................................................................................................1797 Failure Code [D1EMKY]...............................................................................................................................1798 Failure Code [D1FBKB]...............................................................................................................................1799 Failure Code [D5ZHL6]...............................................................................................................................1801 Failure Code [D811MC] (Machine with KOMTRAX Terminal)...............................................................................................1803 Failure Code [D811MC] (Machine with Gateway Function Controller)....................................................................................1804 Failure Code [D862KA] (Machine with KOMTRAX Terminal)...............................................................................................1805 Failure Code [D862KA] (Machine with Gateway Function Controller)....................................................................................1806 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)...............................................................................................1807 Failure Code [D8ALKA] (Machine with Gateway Function Controller)....................................................................................1809 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)...............................................................................................1811 Failure Code [D8ALKB] (Machine with Gateway Function Controller)....................................................................................1813 Failure Code [D8AQK4] (Machine with KOMTRAX Terminal)...............................................................................................1815 Failure Code [D8AQK4] (Machine with Gateway Function Controller)....................................................................................1816 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)...............................................................................................1817 Failure Code [D8AQKR] (Machine with Gateway Function Controller)....................................................................................1819 Failure Code [D8G1KT]...............................................................................................................................1821 Failure Code [D8G6KT]...............................................................................................................................1822 Failure Code [DAF0KT]...............................................................................................................................1823 Failure Code [DAF0MB]...............................................................................................................................1824 Failure Code [DAF0MC]...............................................................................................................................1825 Failure Code [DAF3KK]...............................................................................................................................1826 Failure Code [DAF8KB]...............................................................................................................................1828 Failure Code [DAFDKB]...............................................................................................................................1830 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)...............................................................................................1832 Failure Code [DAFGMC] (Machine with Gateway Function Controller)....................................................................................1833 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)...............................................................................................1834 Failure Code [DAFLKA] (Machine with Gateway Function Controller)....................................................................................1836 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)...............................................................................................1838 Failure Code [DAFLKB] (Machine with Gateway Function Controller)....................................................................................1840 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)...............................................................................................1842 Failure Code [DAFQKR] (Machine with Gateway Function Controller)....................................................................................1843 Failure Code [DAQ0KK]...............................................................................................................................1844 Failure Code [DAQ0KT]...............................................................................................................................1846 Failure Code [DAQ0MC]...............................................................................................................................1847 Failure Code [DAQ1KA]...............................................................................................................................1848 Failure Code [DAQ2KK]...............................................................................................................................1851 Failure Code [DAQ9KQ]...............................................................................................................................1853 Failure Code [DAQLKA] (Machine with KOMTRAX Terminal)...............................................................................................1854 Failure Code [DAQLKA] (Machine with Gateway Function Controller)....................................................................................1856 Failure Code [DAQLKB] (Machine with KOMTRAX Terminal)...............................................................................................1858 Failure Code [DAQLKB] (Machine with Gateway Function Controller)....................................................................................1860 Failure Code [DAQQKR]...............................................................................................................................1862 Failure Code [DAQRKR]...............................................................................................................................1863 Failure Code [DAQRMA]...............................................................................................................................1864 Failure Code [DAQV00]...............................................................................................................................1865 Failure Code [DAQW00]...............................................................................................................................1866 Failure Code [DAZ9KQ]...............................................................................................................................1867 Failure Code [DAZQKR]...............................................................................................................................1868 Failure Code [DB10KT]...............................................................................................................................1869 Failure Code [DB10MC]...............................................................................................................................1870 Failure Code [DB11KA]...............................................................................................................................1871 Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch)...................................................................................1873 Failure Code [DB12KK]...............................................................................................................................1876 Failure Code [DB13KK]...............................................................................................................................1878 Failure Code [DB19KQ]...............................................................................................................................1880 Failure Code [DB1LKA] (Machine with KOMTRAX Terminal)...............................................................................................1881 Failure Code [DB1LKA] (Machine with Gateway Function Controller)....................................................................................1883 Failure Code [DB1LKB] (Machine with KOMTRAX Terminal)...............................................................................................1885 Failure Code [DB1LKB] (Machine with Gateway Function Controller)....................................................................................1887 Failure Code [DB1QKR]...............................................................................................................................1889 Failure Code [DB1QMA]...............................................................................................................................1890 Failure Code [DB1RKR]...............................................................................................................................1891 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)...............................................................................................1892 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720)................................................1898 Failure Code [DB2QKR] (Machine with Gateway Function Controller)....................................................................................1904 Failure Code [DB2QKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720).....................................1910 Failure Code [DB2RKR]...............................................................................................................................1916 Failure Code [DBS0KK]...............................................................................................................................1922 Failure Code [DBS0KK] (Machine with Payload Meter Controller: CR720)................................................................................1925 Failure Code [DBS6KP]...............................................................................................................................1928 Failure Code [DBS6KP] (Machine with Payload Meter Controller: CR720)................................................................................1931 Failure Code [DBSQKQ]...............................................................................................................................1934 Failure Code [DBSQKR] (Machine with KOMTRAX Terminal)...............................................................................................1935 Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720)................................................1940 Failure Code [DBSQKR] (Machine with Gateway Function Controller)....................................................................................1945 Failure Code [DBSQKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720).....................................1950 Failure Code [DD1ML4]...............................................................................................................................1955 Failure Code [DDAAL6]...............................................................................................................................1958 Failure Code [DDAAL6] (Machine with Emergency Engine Stop Switch)...................................................................................1960 Failure Code [DDTHKA] (Serial Number: 10001 - 10171)................................................................................................1963 Failure Code [DDTHKA] (Serial Number: 10172 and Up).................................................................................................1965 Failure Code [DDTJKA] (Serial Number: 10001 - 10171)................................................................................................1967 Failure Code [DDTJKA] (Serial Number: 10172 and Up).................................................................................................1969 Failure Code [DDTKKA] (Serial Number: 10001 - 10171)................................................................................................1971 Failure Code [DDTKKA] (Serial Number: 10172 and Up).................................................................................................1973 Failure Code [DDTLKA] (Serial Number: 10001 - 10171)................................................................................................1975 Failure Code [DDTLKA] (Serial Number: 10172 and Up).................................................................................................1977 Failure Code [DDTMKA]...............................................................................................................................1979 Failure Code [DDTNKA]...............................................................................................................................1981 Failure Code [DF10KA]...............................................................................................................................1983 Failure Code [DF10KB]...............................................................................................................................1987 Failure Code [DGF1KX]...............................................................................................................................1992 Failure Code [DGR3KB]...............................................................................................................................1994 Failure Code [DGR3L8]...............................................................................................................................1995 Failure Code [DGR4KB]...............................................................................................................................1997 Failure Code [DGR4L8]...............................................................................................................................1998 Failure Code [DGR6KB]...............................................................................................................................2000 Failure Code [DGR6L8]...............................................................................................................................2001 Failure Code [DGR7KX]...............................................................................................................................2003 Failure Code [DGT1KX]...............................................................................................................................2005 Failure Code [DHAAMA]...............................................................................................................................2007 Failure Code [DHACMA]...............................................................................................................................2009 Failure Code [DHP4KY]...............................................................................................................................2011 Failure Code [DHP4KY] (Machine with Payload Meter Controller: CR720)................................................................................2013 Failure Code [DHP4KZ]...............................................................................................................................2015 Failure Code [DHP4KZ] (Machine with Payload Meter Controller: CR720)................................................................................2017 Failure Code [DHP5KY]...............................................................................................................................2019 Failure Code [DHP5KY] (Machine with Payload Meter Controller: CR720)................................................................................2021 Failure Code [DHP5KZ]...............................................................................................................................2023 Failure Code [DHP5KZ] (Machine with Payload Meter Controller: CR720)................................................................................2025 Failure Code [DHP6KY]...............................................................................................................................2027 Failure Code [DHP6KY] (Machine with Payload Meter Controller: CR720)................................................................................2029 Failure Code [DHP6KZ]...............................................................................................................................2031 Failure Code [DHP6KZ] (Machine with Payload Meter Controller: CR720)................................................................................2033 Failure Code [DHP7KY]...............................................................................................................................2035 Failure Code [DHP7KY] (Machine with Payload Meter Controller: CR720)................................................................................2037 Failure Code [DHP7KZ]...............................................................................................................................2039 Failure Code [DHP7KZ] (Machine with Payload Meter Controller: CR720)................................................................................2041 Failure Code [DHQ2KX]...............................................................................................................................2043 Failure Code [DHT5KX]...............................................................................................................................2045 Failure Code [DHT5L6]...............................................................................................................................2047 Failure Code [DHT8KX]...............................................................................................................................2049 Failure Code [DHT8ZG]...............................................................................................................................2051 Failure Code [DHU2KX]...............................................................................................................................2053 Failure Code [DHU3KX]...............................................................................................................................2055 Failure Code [DHUAKX]...............................................................................................................................2057 Failure Code [DHUBKX]...............................................................................................................................2059 Failure Code [DHUCKX]...............................................................................................................................2061 Failure Code [DHUDKX]...............................................................................................................................2063 Failure Code [DHUEKX]...............................................................................................................................2065 Failure Code [DHUQKX]...............................................................................................................................2067 Failure Code [DHURKX]...............................................................................................................................2069 Failure Code [DJF1KA]...............................................................................................................................2071 Failure Code [DK30KX]...............................................................................................................................2073 Failure Code [DK51L5]...............................................................................................................................2075 Failure Code [DK52KX]...............................................................................................................................2078 Failure Code [DK53L8]...............................................................................................................................2080 Failure Code [DK54KX]...............................................................................................................................2082 Failure Code [DK60KX]...............................................................................................................................2084 Failure Code [DKH0KX]...............................................................................................................................2086 Failure Code [DKH1KX]...............................................................................................................................2088 Failure Code [DKH1KX] (Machine with Payload Meter Controller: CR720)................................................................................2090 Failure Code [DLF1KA]...............................................................................................................................2092 Failure Code [DLF1LC]...............................................................................................................................2094 Failure Code [DLF2KA]...............................................................................................................................2096 Failure Code [DLF2LC]...............................................................................................................................2098 Failure Code [DLF400]...............................................................................................................................2100 Failure Code [DLF4KA]...............................................................................................................................2101 Failure Code [DLF4LC]...............................................................................................................................2103 Failure Code [DLF6LC]...............................................................................................................................2105 Failure Code [DLF7LC]...............................................................................................................................2107 Failure Code [DLFDLC]...............................................................................................................................2109 Failure Code [DLFELC]...............................................................................................................................2111 Failure Code [DLFFLC]...............................................................................................................................2113 Failure Code [DLFGLC]...............................................................................................................................2114 Failure Code [DLM3KA]...............................................................................................................................2115 Failure Code [DLM3LC]...............................................................................................................................2117 Failure Code [DLM3MB]...............................................................................................................................2119 Failure Code [DLM4KA]...............................................................................................................................2120 Failure Code [DLM4LC]...............................................................................................................................2122 Failure Code [DLM4MB]...............................................................................................................................2124 Failure Code [DLT3KA]...............................................................................................................................2126 Failure Code [DLT3LC]...............................................................................................................................2128 Failure Code [DPQ1KR]...............................................................................................................................2130 Failure Code [DPQ2KR]...............................................................................................................................2133 Failure Code [DPQ3KR]...............................................................................................................................2136 Failure Code [DSJ0KR]...............................................................................................................................2140 Failure Code [DV00KB]...............................................................................................................................2141 Failure Code [DW2BKA]...............................................................................................................................2143 Failure Code [DW2BKB]...............................................................................................................................2144 Failure Code [DW2BKY]...............................................................................................................................2145 Failure Code [DW2BL1]...............................................................................................................................2146 Failure Code [DW2BLH]...............................................................................................................................2147 Failure Code [DW4BK4]...............................................................................................................................2148 Failure Code [DW4BMA]...............................................................................................................................2151 Failure Code [DW72KZ]...............................................................................................................................2154 Failure Code [DW73KA]...............................................................................................................................2156 Failure Code [DW73KB]...............................................................................................................................2158 Failure Code [DW73KY]...............................................................................................................................2160 Failure Code [DW7BKB]...............................................................................................................................2162 Failure Code [DW7BKY]...............................................................................................................................2164 Failure Code [DW7BKZ]...............................................................................................................................2165 Failure Code [DW7LKB]...............................................................................................................................2167 Failure Code [DW7LKY]...............................................................................................................................2168 Failure Code [DW7LKZ]...............................................................................................................................2169 Failure Code [DW7NKZ]...............................................................................................................................2170 Failure Code [DWNJKZ]...............................................................................................................................2172 Failure Code [DWNKKZ]...............................................................................................................................2174 Failure Code [DX13KA]...............................................................................................................................2176 Failure Code [DX13KB]...............................................................................................................................2178 Failure Code [DX13KY]...............................................................................................................................2180 Failure Code [DX16KA]...............................................................................................................................2181 Failure Code [DX16KB]...............................................................................................................................2182 Failure Code [DX16KY]...............................................................................................................................2184 Failure Code [DX29KA]...............................................................................................................................2185 Failure Code [DX29KB]...............................................................................................................................2187 Failure Code [DX29KY]...............................................................................................................................2189 Failure Code [DX30K4]...............................................................................................................................2190 Failure Code [DX30KA]...............................................................................................................................2192 Failure Code [DX30KB]...............................................................................................................................2194 Failure Code [DX30KY]...............................................................................................................................2196 Failure Code [DX30MA]...............................................................................................................................2198 Failure Code [DX31K4]...............................................................................................................................2200 Failure Code [DX31KA]...............................................................................................................................2202 Failure Code [DX31KB]...............................................................................................................................2204 Failure Code [DX31KY]...............................................................................................................................2206 Failure Code [DX31MA]...............................................................................................................................2208 Failure Code [DX32K4]...............................................................................................................................2210 Failure Code [DX32KA]...............................................................................................................................2212 Failure Code [DX32KB]...............................................................................................................................2214 Failure Code [DX32KY]...............................................................................................................................2216 Failure Code [DX32MA]...............................................................................................................................2218 Failure Code [DX33K4]...............................................................................................................................2220 Failure Code [DX33KA]...............................................................................................................................2222 Failure Code [DX33KB]...............................................................................................................................2224 Failure Code [DX33KY]...............................................................................................................................2226 Failure Code [DX33MA]...............................................................................................................................2228 Failure Code [DX34KA]...............................................................................................................................2230 Failure Code [DX34KB]...............................................................................................................................2231 Failure Code [DX34KY]...............................................................................................................................2233 Failure Code [DXH0KA]...............................................................................................................................2234 Failure Code [DXH0KB]...............................................................................................................................2236 Failure Code [DXH0KY]...............................................................................................................................2238 Failure Code [DXH1KA]...............................................................................................................................2240 Failure Code [DXH1KB]...............................................................................................................................2242 Failure Code [DXH1KY]...............................................................................................................................2244 Failure Code [DXH2KA]...............................................................................................................................2246 Failure Code [DXH2KB]...............................................................................................................................2249 Failure Code [DXH2KY]...............................................................................................................................2252 Failure Code [DXH3KA]...............................................................................................................................2255 Failure Code [DXH3KB]...............................................................................................................................2258 Failure Code [DXH3KY]...............................................................................................................................2261 Failure Code [DXH4KA]...............................................................................................................................2264 Failure Code [DXH4KB]...............................................................................................................................2266 Failure Code [DXH4KY]...............................................................................................................................2268 Failure Code [DXH5KA]...............................................................................................................................2271 Failure Code [DXH5KB]...............................................................................................................................2273 Failure Code [DXH5KY]...............................................................................................................................2275 Failure Code [DXH6KA]...............................................................................................................................2278 Failure Code [DXH6KB]...............................................................................................................................2280 Failure Code [DXH6KY]...............................................................................................................................2282 Failure Code [DXH7KA]...............................................................................................................................2285 Failure Code [DXH7KB]...............................................................................................................................2287 Failure Code [DXH7KY]...............................................................................................................................2289 Failure Code [DY30MA]...............................................................................................................................2292 Failure Code [DY30MC]...............................................................................................................................2295 Failure Code [DY30ME]...............................................................................................................................2298 Failure Code [DY32MC]...............................................................................................................................2300 Failure Code [F313KA]...............................................................................................................................2303 Failure Code [F313KB]...............................................................................................................................2305 Failure Code [F318KB]...............................................................................................................................2306 Failure Code [F318KY]...............................................................................................................................2308 Troubleshooting of Electrical System (E-Mode)...........................................................................................................2309 Engine Does Not Start (Engine Does Not Crank).......................................................................................................2309 Manual Preheating System Does Not Operate...........................................................................................................2315 Automatic Preheating System Does Not Operate........................................................................................................2318 While Preheating is in Operation, Preheating Monitor Does Not Come On...............................................................................2320 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing..........................................................................2322 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed).........2325 LCD Unit on Machine Monitor Shows Nothing...........................................................................................................2328 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)...............................................................2331 LCD Screen on Machine Monitor Does Not Show Correctly...............................................................................................2334 Meter Unit Display on Machine Monitor is Abnormal...................................................................................................2337 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal........................................................................................2340 LED Unit Lamp on Machine Monitor is Abnormal........................................................................................................2344 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly.................................................2346 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate..........................................................................2349 Switch Panel Buzzer of Machine Monitor is Abnormal..................................................................................................2352 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally....................................................................2355 DEF Level is Not Shown Correctly....................................................................................................................2356 Rearview Monitor Does Not Come On or Backlight Flickers.............................................................................................2359 Rearview Monitor Images are Not Shown Clearly.......................................................................................................2362 Rearview Monitor Brightness Cannot be Adjusted......................................................................................................2366 Night Mode Lamp of Rearview Monitor is Abnormal.....................................................................................................2369 Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled...........................................................2371 Guide Line on Rearview Monitor is Not Shown While Guide Line is Set.................................................................................2374 Fuel Gauge Does Not Show Normally...................................................................................................................2376 Seatbelt Caution Lamp Does Not Show Normally........................................................................................................2378 Machine Monitor Cannot be Operated When Starting Switch is in OFF Position..........................................................................2379 Alarm Buzzer Does Not Operate.......................................................................................................................2380 Alarm Buzzer Does Not Stop..........................................................................................................................2381 Engine Mode Selector Function Does Not Operate Correctly............................................................................................2383 AISS Function Does Not Operate Correctly............................................................................................................2385 Hoist Lever Does Not Operate Correctly..............................................................................................................2387 Fuel Feed Pump Does Not Operate or Stop Automatically...............................................................................................2389 Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly.............................................................................2392 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On..............................................................................................2396 Clearance Lamp Does Not Come On.....................................................................................................................2398 Tail Lamp Does Not Come On..........................................................................................................................2400 Headlamp (Low Beam) Does Not Come On................................................................................................................2402 Headlamp (High Beam) Does Not Come On...............................................................................................................2404 Head Lamps (Low Beam) and (High Beam) Do Not Come on................................................................................................2406 Passing Lamp Does Not Come On.......................................................................................................................2408 KOMTRAX System Does Not Operate Correctly (Machine with KOMTRAX Terminal)...........................................................................2410 KOMTRAX System Does Not Operate Correctly (Machine with Gateway Function Controller)................................................................2412 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)...........................................................................................2414 Information Shown in Troubleshooting Table (H-Mode).................................................................................................2414 System Chart of Hydraulic and Mechanical Systems....................................................................................................2415 Failure Mode and Cause Table........................................................................................................................2417 Machine Does Not Start..............................................................................................................................2427 Machine Does Not Travel Smoothly (Machine Hunts)....................................................................................................2430 Lockup is Not Released..............................................................................................................................2431 Strong Shock is Made When You Start Machine or Shift Gears..........................................................................................2432 Shiftup Does Not Operate............................................................................................................................2434 Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function............................................................2437 Travel Speed is Low or Power is Low During Travel with Torque Converter.............................................................................2439 Travel Speed is Low or Power is Low in Specified Gear Speed.........................................................................................2440 Time Lag is Large When You Start Machine or Shift Gears.............................................................................................2442 Torque Converter Oil Temperature is High............................................................................................................2445 Torque Converter Oil Pressure is Low................................................................................................................2447 Steering Wheel is Heavy to Operate..................................................................................................................2449 Steering Wheel is Disabled..........................................................................................................................2450 Steering Wheel Waggles..............................................................................................................................2451 Front Brake Does Not Operate Sufficiently...........................................................................................................2452 Center Brake Does Not Work Sufficiently.............................................................................................................2453 Speed is Low When Dump Body is Raised...............................................................................................................2454 Hydraulic Drift of Dump Body is Large...............................................................................................................2456 Dump Body is Disabled...............................................................................................................................2457 Radiator Fan Speed is Unusual (Too High or Low, or Fan Stops).......................................................................................2459 Aftercooler Fan Speed is Unusual (Too Much High or Low, or Fan Stops)...............................................................................2460 Unusual Noise is Heard from Around Radiator Fan.....................................................................................................2461 Unusual Noise is Heard from Around Aftercooler Fan..................................................................................................2462 Troubleshooting of Engine (S-Mode)......................................................................................................................2463 Information Shown in Troubleshooting Table (S-Mode).................................................................................................2463 Engine Does Not Crank When Starting Switch is Turned to Start Position..............................................................................2464 Engine Cranks but No Exhaust Smoke Comes Out........................................................................................................2465 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).............................................................2466 Engine Startability is Unsatisfactory...............................................................................................................2467 Engine Does Not Pick Up Smoothly....................................................................................................................2469 Engine Stops During Operation.......................................................................................................................2471 Engine Does Not Rotate Smoothly.....................................................................................................................2473 Engine Lacks Output (or Lacks Power)................................................................................................................2474 KDPF Becomes Clogged in a Short Time................................................................................................................2476 Engine Oil Consumption is Excessive.................................................................................................................2478 Engine Oil Becomes Dirty Quickly....................................................................................................................2479 Fuel Consumption is Excessive.......................................................................................................................2480 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...............................................................................2481 Engine Oil Pressure Drops...........................................................................................................................2482 Fuel Mixes Into Engine Oil..........................................................................................................................2484 Water Mixes Into Engine Oil (Milky).................................................................................................................2485 Coolant Temperature Increases Too High (Overheat)...................................................................................................2486 Unusual Noise is Heard..............................................................................................................................2487 Vibration is Excessive..............................................................................................................................2488 Air Cannot be Bled from Fuel Circuit................................................................................................................2489 Active Regeneration is Done Frequently..............................................................................................................2490 Active Regeneration Continues Long..................................................................................................................2492 White Smoke is Exhausted During Active Regeneration.................................................................................................2493 DEF Consumption is Excessive........................................................................................................................2494 There is an Unusual Smell (Irritating Odor).........................................................................................................2496 Foreign Materials Enter DEF (DEF Increases).........................................................................................................2497 50 Disassembly and Assembly.................................................................................................................................2499 Table of Contents.......................................................................................................................................2500 Abbreviation List.......................................................................................................................................2505 Related Information on Disassembly and Assembly.........................................................................................................2511 How to Read This Manual.............................................................................................................................2511 Coating Materials List..............................................................................................................................2512 Special Tool List...................................................................................................................................2517 Sketches of Special Tools...........................................................................................................................2535 Engine and Cooling System...............................................................................................................................2554 Remove and Install Supply Pump Assembly.............................................................................................................2554 How to Remove Supply Pump Assembly..............................................................................................................2554 How to Install Supply Pump Assembly.............................................................................................................2555 Remove and Install Injector Assembly................................................................................................................2559 How to Remove Injector Assembly.................................................................................................................2559 How to Install Injector Assembly................................................................................................................2572 Remove and Install Fuel Doser Assembly..............................................................................................................2590 How to Remove Fuel Doser Assembly...............................................................................................................2590 How to Install Fuel Doser Assembly..............................................................................................................2591 Remove and Install Cylinder Head Assembly...........................................................................................................2594 How to Remove Cylinder Head Assembly............................................................................................................2595 How to Install Cylinder Head Assembly...........................................................................................................2609 Remove and Install EGR Valve Assembly...............................................................................................................2633 How to Remove EGR Valve Assembly................................................................................................................2633 How to Install EGR Valve Assembly...............................................................................................................2635 Remove and Install EGR Cooler Assembly..............................................................................................................2637 How to Remove EGR Cooler Assembly...............................................................................................................2637 How to Install EGR Cooler Assembly..............................................................................................................2641 Remove and Install Starter Assembly.................................................................................................................2645 How to Remove Starting Motor Assembly...........................................................................................................2645 How to Install Starting Motor Assembly..........................................................................................................2648 Remove and Install Alternator Belt..................................................................................................................2651 How to Remove Alternator Belt...................................................................................................................2651 How to Install Alternator Belt..................................................................................................................2652 Remove and Install Radiator Assembly................................................................................................................2654 How to Remove Radiator Assembly.................................................................................................................2654 How to Install Radiator Assembly................................................................................................................2659 Remove and Install Cooling Fan and Fan Motor Assembly...............................................................................................2666 How to Remove Cooling Fan and Fan Motor Assembly................................................................................................2666 How to Install Cooling Fan and Fan Motor Assembly...............................................................................................2672 Remove and Install Aftercooler Assembly.............................................................................................................2679 How to Remove Aftercooler Assembly..............................................................................................................2679 How to Install Aftercooler Assembly.............................................................................................................2681 Remove and Install Aftercooler Fan and Fan Motor Assembly...........................................................................................2685 How to Remove Aftercooler Fan and Fan Motor Assembly............................................................................................2685 How to Install Aftercooler Fan and Fan Motor Assembly...........................................................................................2686 Remove and Install Engine Assembly..................................................................................................................2689 How to Remove Engine Assembly...................................................................................................................2690 How to Install Engine Assembly..................................................................................................................2699 Remove and Install Engine Front Oil Seal............................................................................................................2710 How to Remove Engine Front Oil Seal.............................................................................................................2710 How to Install Engine Front Oil Seal............................................................................................................2711 Remove and Install Engine Rear Oil Seal.............................................................................................................2714 How to Remove Engine Rear Oil Seal..............................................................................................................2714 How to Install Engine Rear Oil Seal.............................................................................................................2715 Remove and Install Output Shaft.....................................................................................................................2722 How to Remove Output Shaft......................................................................................................................2723 How to Install Output Shaft.....................................................................................................................2726 Disassemble and Assemble Output Shaft...............................................................................................................2730 How to Disassemble Output Shaft.................................................................................................................2730 How to Assemble Output Shaft....................................................................................................................2731 Remove and Install DEF Tank Assembly................................................................................................................2733 How to Remove DEF Tank Assembly.................................................................................................................2733 How to Install DEF Tank Assembly................................................................................................................2738 Remove and Install DEF Tank Sensor Flange Assembly..................................................................................................2742 How to Remove DEF Tank Sensor Flange Assembly...................................................................................................2742 How to Install DEF Tank Sensor Flange Assembly..................................................................................................2747 Remove and Install DEF Tank Sensor..................................................................................................................2752 How to Remove DEF Tank Sensor...................................................................................................................2752 How to Install DEF Tank Sensor..................................................................................................................2753 Remove and Install DEF Tank Strainer................................................................................................................2755 How to Remove DEF Tank Strainer.................................................................................................................2755 How to Install DEF Tank Strainer................................................................................................................2755 Remove and Install KDPF Assembly....................................................................................................................2756 How to Remove KDPF Assembly.....................................................................................................................2757 How to Install KDPF Assembly....................................................................................................................2760 Disassemble and Assemble KDPF Assembly..............................................................................................................2764 How to Disassemble KDPF Assembly................................................................................................................2764 How to Assemble KDPF Assembly...................................................................................................................2768 Remove and Install SCR Assembly.....................................................................................................................2773 How to Remove SCR Assembly......................................................................................................................2773 How to Install SCR Assembly.....................................................................................................................2777 Remove and Install KCCV Assembly....................................................................................................................2782 How to Remove KCCV Assembly.....................................................................................................................2782 How to Install KCCV Assembly....................................................................................................................2784 Remove and Install DEF Mixing Tube..................................................................................................................2787 How to Remove DEF Mixing Tube...................................................................................................................2787 How to Install DEF Mixing Tube..................................................................................................................2794 Remove and Install DEF Injector.....................................................................................................................2802 How to Remove DEF Injector......................................................................................................................2802 How to Install DEF Injector.....................................................................................................................2805 Remove and Install DEF Pump.........................................................................................................................2808 How to Remove DEF Pump..........................................................................................................................2808 How to Install DEF Pump.........................................................................................................................2812 Remove and Install DEF Hose.........................................................................................................................2816 How to Remove DEF Hose..........................................................................................................................2816 How to Install DEF Hose.........................................................................................................................2820 Remove and Install Air Cleaner Assembly.............................................................................................................2825 How to Remove Air Cleaner Assembly..............................................................................................................2825 How to Install Air Cleaner Assembly.............................................................................................................2828 Remove and Install Air Conditioner Compressor Assembly..............................................................................................2831 How to Remove Air Conditioner Compressor Assembly...............................................................................................2832 How to Install Air Conditioner Compressor Assembly..............................................................................................2833 Power Train.............................................................................................................................................2836 Remove and Install Transmission and Front Differential Assembly.....................................................................................2836 How to Remove Transmission and Front Differential Assembly......................................................................................2836 How to Install Transmission and Front Differential Assembly.....................................................................................2850 Disconnect and Connect Transmission and Front Differential Assembly.................................................................................2865 How to Disconnect Transmission and Front Differential Assembly..................................................................................2865 How to Connect Transmission and Front Differential Assembly.....................................................................................2866 Disassemble and Assemble Front Differential Assembly................................................................................................2869 How to Disassemble Front Differential Assembly..................................................................................................2870 How to Assemble Front Differential Assembly.....................................................................................................2877 Disassemble and Assemble Torque Converter Assembly..................................................................................................2889 How to Disassemble Torque Converter Assembly....................................................................................................2890 How to Assemble Torque Converter Assembly.......................................................................................................2894 Disassemble and Assemble Transmission Assembly......................................................................................................2900 How to Disassemble Transmission Assembly........................................................................................................2901 How to Assemble Transmission Assembly...........................................................................................................2931 Remove and Install Center Differential Assembly.....................................................................................................2966 How to Remove Center Differential Assembly......................................................................................................2966 How to Install Center Differential Assembly.....................................................................................................2969 Disassemble and Assemble Center Differential Assembly...............................................................................................2973 How to Disassemble Center Differential Assembly.................................................................................................2974 How to Assemble Center Differential Assembly....................................................................................................2981 Remove and Install Rear Differential Assembly.......................................................................................................2994 How to Remove Rear Differential Assembly........................................................................................................2994 How to Install Rear Differential Assembly.......................................................................................................2996 Disassemble and Assemble Rear Differential Assembly.................................................................................................2998 How to Disassemble Rear Differential Assembly...................................................................................................2999 How to Assemble Rear Differential Assembly......................................................................................................3003 Remove and Install Front Final Drive and Brake Assembly.............................................................................................3012 How to Remove Front Final Drive and Brake Assembly..............................................................................................3012 How to Install Front Final Drive and Brake Assembly.............................................................................................3013 Disassemble and Assemble Front Final Drive and Brake Assembly.......................................................................................3015 How to Disassemble Front Final Drive and Brake Assembly.........................................................................................3016 How to Assemble Front Final Drive and Brake Assembly............................................................................................3024 Remove and Install Center Final Drive and Brake Assembly............................................................................................3035 How to Remove Center Final Drive and Brake Assembly.............................................................................................3035 How to Install Center Final Drive and Brake Assembly............................................................................................3037 Disassemble and Assemble Center Final Drive and Brake Assembly......................................................................................3039 How to Disassemble Center Final Drive and Brake Assembly........................................................................................3039 How to Assemble Center Final Drive and Brake Assembly...........................................................................................3046 Remove and Install Rear Final Drive Assembly........................................................................................................3055 How to Remove Rear Final Drive Assembly.........................................................................................................3055 How to Install Rear Final Drive Assembly........................................................................................................3056 Disassemble and Assemble Rear Final Drive Assembly..................................................................................................3058 How to Disassemble Rear Final Drive Assembly....................................................................................................3058 How to Assemble Rear Final Drive Assembly.......................................................................................................3061 Remove and Install Center Axle Assembly.............................................................................................................3066 How to Remove Center Axle Assembly..............................................................................................................3066 How to Install Center Axle Assembly.............................................................................................................3069 Remove and Install Rear Axle Assembly...............................................................................................................3073 How to Remove Rear Axle Assembly................................................................................................................3073 How to Install Rear Axle Assembly...............................................................................................................3076 Remove and Install Brake Accumulator................................................................................................................3079 How to Remove Brake Accumulator.................................................................................................................3079 How to Install Brake Accumulator................................................................................................................3091 Steering System.........................................................................................................................................3104 Disassemble and Assemble Steering Valve.............................................................................................................3104 How to Disassemble Steering Valve...............................................................................................................3104 How to Assemble Steering Valve..................................................................................................................3107 Disassemble and Assemble Steering Cylinder Assembly.................................................................................................3114 How to Disassemble Steering Cylinder Assembly...................................................................................................3114 How to Assemble Steering Cylinder Assembly......................................................................................................3118 Undercarriage and Frame.................................................................................................................................3123 Remove and Install Front Suspension Cylinder Assembly...............................................................................................3123 How to Remove Front Suspension Cylinder Assembly................................................................................................3123 How to Install Front Suspension Cylinder Assembly...............................................................................................3124 Remove and Install Rear Suspension Cylinder Assembly................................................................................................3126 How to Remove Rear Suspension Cylinder Assembly.................................................................................................3126 How to Install Rear Suspension Cylinder Assembly................................................................................................3127 Disassemble and Assemble Suspension Cylinder Assembly...............................................................................................3129 How to Disassemble Suspension Cylinder Assembly.................................................................................................3129 How to Assemble Suspension Cylinder Assembly....................................................................................................3130 Remove and Install Equalizer Bar Assembly...........................................................................................................3132 How to Remove Equalizer Bar Assembly............................................................................................................3132 How to Install Equalizer Bar Assembly...........................................................................................................3134 Remove and Install Front Wheel Assembly.............................................................................................................3137 How to Remove Front Wheel Assembly..............................................................................................................3138 How to Install Front Wheel Assembly.............................................................................................................3143 Remove and Install Rear (Front Side) Wheel Assembly.................................................................................................3148 How to Remove Rear (Front Side) Wheel Assembly..................................................................................................3148 How to Install Rear (Front Side) Wheel Assembly.................................................................................................3148 Remove and Install Rear (Back Side) Wheel Assembly..................................................................................................3149 How to Remove Rear (Back Side) Wheel Assembly...................................................................................................3149 How to Install Rear (Back Side) Wheel Assembly..................................................................................................3149 Remove and Install Hitch Frame Assembly.............................................................................................................3150 How to Remove Hitch Frame Assembly..............................................................................................................3151 How to Install Hitch Frame Assembly.............................................................................................................3159 Disassemble and Assemble Hitch Frame Assembly.......................................................................................................3168 How to Disassemble Hitch Frame Assembly.........................................................................................................3168 How to Assemble Hitch Frame Assembly............................................................................................................3170 Hydraulic System........................................................................................................................................3175 Remove and Install Hydraulic Tank Assembly..........................................................................................................3175 How to Remove Hydraulic Tank Assembly...........................................................................................................3175 How to Install Hydraulic Tank Assembly..........................................................................................................3180 Remove and Install Flow Amplifier Valve Assembly....................................................................................................3184 How to Remove Flow Amplifier Valve Assembly.....................................................................................................3184 How to Install Flow Amplifier Valve Assembly....................................................................................................3187 Remove and Install Hoist Valve Assembly.............................................................................................................3190 How to Remove Hoist Valve Assembly..............................................................................................................3190 How to Install Hoist Valve Assembly.............................................................................................................3195 Disassemble and Assemble Hoist Valve Assembly.......................................................................................................3199 How to Disassemble Hoist Valve Assembly.........................................................................................................3199 How to Assemble Hoist Valve Assembly............................................................................................................3200 Disassemble and Assemble Hoist Cylinder Assembly....................................................................................................3203 How to Disassemble Hoist Cylinder Assembly......................................................................................................3203 How to Assemble Hoist Cylinder Assembly.........................................................................................................3206 Work Equipment..........................................................................................................................................3212 Remove and Install Dump Body Assembly...............................................................................................................3212 How to Remove Body Assembly.....................................................................................................................3212 How to Install Body Assembly....................................................................................................................3214 CAB Related Parts.......................................................................................................................................3217 Remove and Install Operator Cab Assembly............................................................................................................3217 How to Remove Operator Cab Assembly.............................................................................................................3218 How to Install Operator Cab Assembly............................................................................................................3221 Remove and Install Operator Cab Glass (Adhered Glass)...............................................................................................3225 How to Remove Operator Cab Glass (Adhered Glass)................................................................................................3226 How to Install Operator Cab Glass (Adhered Glass)...............................................................................................3226 Remove and Install Air Conditioner Unit Assembly....................................................................................................3231 How to Remove Air Conditioner Unit Assembly.....................................................................................................3232 How to Install Air Conditioner Unit Assembly....................................................................................................3238 Remove and Install Operator Seat Assembly (Made by GRAMMER).........................................................................................3244 How to Remove Operator Seat Assembly............................................................................................................3244 How to Install Operator Seat Assembly...........................................................................................................3245 Remove and Install Operator Seat Assembly (Made by SEARS)...........................................................................................3247 How to Remove Operator Seat Assembly............................................................................................................3247 How to Install Operator Seat Assembly...........................................................................................................3249 How to Remove and Install Seat Belt.................................................................................................................3252 How to Remove Seat Belt.........................................................................................................................3252 How to Install Seatbelt.........................................................................................................................3253 Electrical System.......................................................................................................................................3254 Remove and Install Engine Controller Assembly.......................................................................................................3254 How to Remove Engine Controller Assembly........................................................................................................3254 How to Install Engine Controller Assembly.......................................................................................................3257 Remove and Install Retarder and Hoist Controller Assembly...........................................................................................3260 How to Remove Retarder and Hoist Controller Assembly............................................................................................3260 How to Install Retarder and Hoist Controller Assembly...........................................................................................3261 Remove and Install Transmission Controller Assembly.................................................................................................3262 How to Remove Transmission Controller Assembly..................................................................................................3262 How to Install Transmission Controller Assembly.................................................................................................3263 Remove and Install Machine Monitor Assembly.........................................................................................................3264 How to Remove Machine Monitor Assembly..........................................................................................................3264 How to Install Machine Monitor Assembly.........................................................................................................3266 Remove and Install Mass Air Flow and Temperature Sensor.............................................................................................3269 How to Remove Mass Air Flow and Temperature Sensor..............................................................................................3269 How to Install Mass Air Flow and Temperature Sensor.............................................................................................3271 Remove and Install SCR Temperature Sensor...........................................................................................................3273 How to Remove SCR Temperature Sensor............................................................................................................3273 How to Install SCR Temperature Sensor...........................................................................................................3275 Remove and Install KOMTRAX Terminal Assembly........................................................................................................3277 How to Remove KOMTRAX Terminal Assembly.........................................................................................................3277 How to Install KOMTRAX Terminal Assembly........................................................................................................3278 Remove and Install Gateway Function Controller Assembly.............................................................................................3279 How to Remove Gateway Function Controller Assembly..............................................................................................3279 How to Install Gateway Function Controller Assembly.............................................................................................3281 Remove and Install Communication Terminal Wiring Harness............................................................................................3285 How to Remove Communication Terminal Wiring Harness.............................................................................................3285 How to Install Communication Terminal Wiring Harness............................................................................................3292 Remove and Install Communication Terminal...........................................................................................................3298 How to Remove Communication Terminal............................................................................................................3298 How to Install Communication Terminal...........................................................................................................3304 60 Maintenance Standard.....................................................................................................................................3311 Table of Contents.......................................................................................................................................3312 Abbreviation List.......................................................................................................................................3314 Engine and Cooling System...............................................................................................................................3320 Maintenance Standard for Engine Mount...............................................................................................................3320 Maintenance Standard for Damper.....................................................................................................................3321 Maintenance Standard for Radiator Fan Pump..........................................................................................................3322 Maintenance Standard for Servo Valve of Radiator Fan Pump.......................................................................................3323 Maintenance Standard for Radiator Fan Motor.........................................................................................................3324 Maintenance Standard for Aftercooler Fan Motor......................................................................................................3325 Power Train.............................................................................................................................................3328 Maintenance Standard for Drive Shaft................................................................................................................3328 Maintenance Standard for Torque Converter and Transmission Mount....................................................................................3330 Maintenance Standard for Torque Converter and PTO...................................................................................................3331 Maintenance Standard for Lockup Clutch ECMV.........................................................................................................3334 Maintenance Standard for Transmission...............................................................................................................3335 Maintenance Standard for FL, R Clutch...........................................................................................................3340 Maintenance Standard for FH, 1st Clutch.........................................................................................................3341 Maintenance Standard for 2nd, 3rd Clutch........................................................................................................3342 Maintenance Standard for Differential Lock Clutch...............................................................................................3343 Maintenance Standard for Transmission Control Valve.................................................................................................3345 Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV.................................................................3346 Maintenance Standard for Differential Lock Clutch ECMV..............................................................................................3347 Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve.............................................3348 Maintenance Standard for Front Axle.................................................................................................................3350 Maintenance Standard for Center Axle................................................................................................................3351 Maintenance Standard for Rear Axle..................................................................................................................3352 Maintenance Standard for Front Differential.........................................................................................................3353 Maintenance Standard for Center Differential........................................................................................................3354 Maintenance Standard for Rear Differential..........................................................................................................3355 Maintenance Standard for Front Final Drive..........................................................................................................3356 Maintenance Standard for Center Final Drive.........................................................................................................3358 Maintenance Standard for Rear Final Drive...........................................................................................................3359 Steering System.........................................................................................................................................3361 Maintenance Standard for Steering Column............................................................................................................3361 Maintenance Standard for Steering Cylinder..........................................................................................................3362 Brake System............................................................................................................................................3363 Maintenance Standard for Front Slack Adjuster.......................................................................................................3363 Maintenance Standard for Center Slack Adjuster......................................................................................................3364 Maintenance Standard for Front Brake................................................................................................................3365 Maintenance Standard for Center Brake...............................................................................................................3367 Maintenance Standard for Parking Brake..............................................................................................................3368 Undercarriage and Frame.................................................................................................................................3370 Maintenance Standard for Front Suspension...........................................................................................................3370 Maintenance Standard for Center and Rear Suspensions................................................................................................3372 Maintenance Standard for Front Suspension Cylinder..................................................................................................3375 Maintenance Standard for Rear Suspension Cylinder...................................................................................................3376 Maintenance Standard for Oscillation Hitch..........................................................................................................3377 Hydraulic System........................................................................................................................................3379 Maintenance Standard for Steering and Hoist Pump....................................................................................................3379 Maintenance Standard for Servo Valve for Steering and Hoist Pump................................................................................3380 Maintenance Standard for Power Train and Front Brake Cooling Duplex Pump, Aftercooler Fan Pump, and Center Brake Cooling Remote Motor Drive Pump....3382 Maintenance Standard for Center Brake Cooling Pump..................................................................................................3384 Maintenance Standard for Center Brake Cooling Remote Pump...........................................................................................3385 Maintenance Standard for Center Brake Cooling Remote Motor..........................................................................................3386 Maintenance Standard for Brake Charge Pump..........................................................................................................3389 Maintenance Standard for Hoist Valve................................................................................................................3390 Work Equipment..........................................................................................................................................3392 Maintenance Standard for Hoist Cylinder.............................................................................................................3392 80 Appendix.................................................................................................................................................3395 Table of Contents.......................................................................................................................................3396 Abbreviation List.......................................................................................................................................3398 Air Conditioner System..................................................................................................................................3404 Precautions for Refrigerant.........................................................................................................................3404 Air Conditioner Component...........................................................................................................................3405 Specifications of Air Conditioner...................................................................................................................3407 Structure and Function of Refrigeration Cycle.......................................................................................................3408 Outline of Refrigeration Cycle......................................................................................................................3409 Component Parts of Air Conditioner System...............................................................................................................3411 Air Conditioner Unit................................................................................................................................3411 Configuration Diagram of Air Conditioner Unit...................................................................................................3411 Function of Air Conditioner Unit................................................................................................................3413 Component Parts of Air Conditioner Unit.............................................................................................................3415 Function of Evaporator as Air Conditioner Unit Component........................................................................................3416 Function of Heater Core as Air Conditioner Unit Component.......................................................................................3416 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.....................................................................3416 Function of Servo Motor as Air Conditioner Unit Component.......................................................................................3416 Structure of Expansion Valve as Air Conditioner Unit Component..................................................................................3417 Function of Expansion Valve as Air Conditioner Unit Component...................................................................................3417 Operate Expansion Valve as Air Conditioner Unit Component.......................................................................................3417 Function of Dual Pressure Switch................................................................................................................3418 Air Conditioner Controller..........................................................................................................................3419 Structure of Air Conditioner Controller.........................................................................................................3419 Compressor..........................................................................................................................................3420 Structure of Compressor.........................................................................................................................3420 Specifications of Compressor....................................................................................................................3420 Function of Compressor..........................................................................................................................3420 Condenser...........................................................................................................................................3421 Structure of Condenser..........................................................................................................................3421 Specifications of Condenser.....................................................................................................................3421 Function of Condenser...........................................................................................................................3421 Receiver Drier......................................................................................................................................3422 Structure of Receiver Dryer.....................................................................................................................3422 Specifications of Receiver Dryer................................................................................................................3422 Function of Receiver Dryer......................................................................................................................3422 Air Conditioner Related Sensors.....................................................................................................................3423 Structure of Outside Temperature Sensor.........................................................................................................3423 Function of Outside Air Temperature Sensor......................................................................................................3423 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.............................................................................3424 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..................................................................................3426 System Diagram of Air Conditioner.......................................................................................................................3428 Input and Output Signals of Air Conditioner Controller..............................................................................................3429 Function of Air Conditioner Controller..........................................................................................................3430 Locations of Air Conditioner Parts and Layout of Connectors.............................................................................................3431 Examine Air Leakage (Duct)..............................................................................................................................3434 How to Examine Air Leakage (Duct)...................................................................................................................3434 Examine Air Conditioner with Self-Diagnosis Function....................................................................................................3438 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.................................................................3439 Examine Vent (Mode) Changeover..........................................................................................................................3441 How to Examine Vent (Mode) Changeover...............................................................................................................3441 Examine Fresh/Recirc Air Changeover.....................................................................................................................3442 How to Examine Fresh/Recirc Air Changeover..........................................................................................................3442 Examine Refrigerant (Dual) Pressure Switch..............................................................................................................3443 How to Examine Refrigerant (Dual) Pressure Switch...................................................................................................3443 Examine Relay...........................................................................................................................................3444 How to Examine Relay................................................................................................................................3444 Air Conditioner Troubleshooting Chart 1.................................................................................................................3446 Air Conditioner Troubleshooting Chart 2.................................................................................................................3447 Information Shown in Troubleshooting Table..............................................................................................................3450 Failure Code [879AKA]...................................................................................................................................3451 Failure Code [879AKB]...................................................................................................................................3452 Failure Code [879BKA]...................................................................................................................................3453 Failure Code [879BKB]...................................................................................................................................3455 Failure Code [879CKA]...................................................................................................................................3457 Failure Code [879CKB]...................................................................................................................................3458 Failure Code [879EMC]...................................................................................................................................3459 Failure Code [879FMC]...................................................................................................................................3460 Failure Code [879GKX]...................................................................................................................................3461 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)..........................................................................3463 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)...........................................................................3465 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................................................................3468 A-4 Troubleshooting for Fresh/Recirc Air Changeover.....................................................................................................3470 Troubleshooting by Gauge Pressure.......................................................................................................................3472 Connect Service Tool....................................................................................................................................3475 How to Connect Service Tool.........................................................................................................................3475 Precautions for Disconnection and Connection of Air Conditioner Piping..................................................................................3477 Handle Compressor Oil...................................................................................................................................3479 90 Circuit Diagrams.........................................................................................................................................3481 Table of Contents.......................................................................................................................................3482 Abbreviation List.......................................................................................................................................3484 Hydraulic Circuit Diagram...............................................................................................................................3490 Symbols Used in Hydraulic Circuit Diagram...........................................................................................................3490 Hydraulic Circuit Diagram...........................................................................................................................3495 Power Train Hydraulic Circuit Diagram...............................................................................................................3497 Electrical Circuit Diagram..............................................................................................................................3499 Symbols Used in Electric Circuit Diagram............................................................................................................3499 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (1/8)..............................3503 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (2/8)..............................3505 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (3/8)..............................3507 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (4/8)..............................3509 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (5/8)..............................3511 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (6/8)..............................3513 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (7/8)..............................3515 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10001 to 10171) (8/8)..............................3517 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (1/8)................................3519 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (2/8)................................3521 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (3/8)................................3523 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (4/8)................................3525 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (5/8)................................3527 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (6/8)................................3529 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (7/8)................................3531 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Applicable Machine: 10172 and Up) (8/8)................................3533 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (1/8)....................3535 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (2/8)....................3537 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (3/8)....................3539 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (4/8)....................3541 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (5/8)....................3543 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (6/8)....................3545 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (7/8)....................3547 Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (8/8)....................3549 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (1/9)........................................................3551 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (2/9)........................................................3553 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (3/9)........................................................3555 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (4/9)........................................................3557 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (5/9)........................................................3559 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (6/9)........................................................3561 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (7/9)........................................................3563 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (8/9)........................................................3565 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (9/9)........................................................3567 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (1/9).........3569 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (2/9).........3571 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (3/9).........3573 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (4/9).........3575 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (5/9).........3577 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (6/9).........3579 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (7/9).........3581 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (8/9).........3583 Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (9/9).........3585 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (1/8)..................................................................3587 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (2/8)..................................................................3589 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (3/8)..................................................................3591 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (4/8)..................................................................3593 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (5/8)..................................................................3595 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (6/8)..................................................................3597 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (7/8)..................................................................3599 Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (8/8)..................................................................3601 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (1/8).......................................................3603 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (2/8).......................................................3605 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (3/8).......................................................3607 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (4/8).......................................................3609 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (5/8).......................................................3611 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (6/8).......................................................3613 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (7/8).......................................................3615 Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (8/8).......................................................3617 Index........................................................................................................................................................3619
DESCRIPTION:
KOMATSU HM400-5 ARTICULATED DUMP TRUCK SHOP MANUAL SEN06519-23 – PDF DOWNLOAD
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
S.S 25/12/24
