Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5 Repair Service Manual + Operation & Maintenance Manual + Field Assembly Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 27,061 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
SAFETY ...7
SAFETY NOTICE ...7
FOREWORD ...9
GENERAL ...9
STANDARD TIGHTENING TORQUE ...16
CONVERSION TABLE ...20
01 GENERAL ...27
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...35
RADIATOR, OIL COOLER, AFTERCOOLER ...36
POWER TRAIN SKELETON OUTPUT SHAFT ...40
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING TORQUE CONVERTER ...44
TRANSMISSION ...50
TRANSMISSION VALVE ...70
ECMV ( Electronic Control Modulation Valve) ...71
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE ...78
DRIVE SHAFT ...80
AXLE ...81
DIFFERENTIAL ...84
LIMITED SLIP DIFFERENTIAL ...90
FINAL DRIVE ...96
STEERING COLUMN ...101
BRAKE PIPING BRAKE VALVE ...104
ACCUMULATOR CHARGE VALVE ...107
ACCUMULATOR ...111
SLACK ADJUSTER ...112
BRAKE ...114
PROPORTIONAL REDUCING VALVE ...119
BRAKE SYSTEM TANK ...120
PARKING BRAKE ...122
PARKING BRAKE CALIPER ...124
PARKING BRAKE SOLENOID VALVE ...126
SPRING CYLINDER ...125
SUSPENSION ...128
SUSPENSION CYLINDER ...134
OSCILLATION HITCH ...136
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM ...140
DUMP BODY CONTROL ...141
HYDRAULIC TANK AND FILTER ...142
FLOW AMP VALVE ...143
STEERING CYLINDER ...150
EPC VALVE ...158
HOIST CYLINDER ...161
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP ...162
HYDRAULIC PUMP ...162
STEERING ? HOIST+ PILOT PUMP SAR( 3) 63+ 63+( 1) 6 ...162
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP ...163
TORQUE CONVERTER, TRANSMISSION AND FRONT BRAKE COOLING PUMP SAR( 3) 90 ...163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB TILT ...166
CAB TILT ...166
AIR CONDITIONER ...167
FUNCTION ...167
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...168
AIR CONDITIONER UNIT ...168
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...169
RECEIVER DRYER ...169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...170
CONDENSER ...170
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...171
COMPRESSOR ...171
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM ...172
MACHINE MONITOR SYSTEM ...172
Network data ...172
AUTOMATIC SHIFT CONTROL SYSTEM ...185
TRANSMISSION CONTROLLER ...187
AUTO EMERGENCY STEERING SYSTEM ...193
SENSORS, SWITCHES ...194
20 TESTING AND ADJUSTING ...227
STANDARD VALUE TABLE FOR ENGINE ...228
STANDARD VALUE TABLE FOR CHASSIS ...229
STANDARD VALUE TABLE FOR ELECTRICAL PARTS ...233
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ...246
MEASURING ENGINE SPEED ...248
MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) ...249
MEASURING EXHAUST TEMPERATURE ...250
MEASURING EXHAUST COLOR ...252
MEASURING COMPRESSION PRESSURE ...253
ADJUSTING VALVE CLEARANCE ...254
MEASURING BLOW- BY PRESSURE ...255
MEASURING ENGINE OIL PRESSURE ...256
HANDLING EQUIPMENT IN FUEL CIRCUIT ...257
RELEASING REMAINING PRESSURE IN FUEL SYSTEM ...257
MEASURING FUEL PRESSURE ...258
BLEEDING AIR FROM FUEL CIRCUIT ...259
REDUCED CYLINDER MODE OPERATION FOR ENGINE ...261
CHECKING FOR LEAKAGE IN FUEL CIRCUIT ...262
ADJUSTING ENGINE SPEED SENSOR ...263
TESTING AND ADJUSTING ALTERNATOR BELT TENSION ...264
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION ...264
TESTING TORQUE CONVERTER STALL SPEED ...265
MEASURING POWER TRAIN OIL PRESSURE ...266
ADJUSTING TRANSMISSION SPEED SENSOR ...273
TESTING AND ADJUSTING BRAKE OIL PRESSURE ...274
TESTING BRAKE PERFORMANCE ...278
BLEEDING AIR FROM BRAKE CIRCUIT ...281
TESTING WEAR OF WHEEL BRAKE DISC ...284
TESTING WEAR OF PARKING BRAKE PAD ...285
METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE ...286
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE ...287
TESTING AND ADJUSTING SUSPENSION CYLINDER ...289
METHOD OF TILTING CAB UP ...293
TESTING DUMP CIRCUIT PRESSURE ...294
ADJUSTING BODY POSITIONER SENSOR ...297
HANDLING ENGINE CONTROLLER HIGH- VOLTAGE CIRCUIT ...298
ADJUSTING TRANSMISSION CONTROLLER ...299
METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM ...300
ADJUSTING MACHINE MONITOR ...304
SPECIAL FUNCTIONS OF MACHINE MONITOR ...308
CHECKS BEFORE TROUBLESHOOTING ...358
CONNECTOR TYPES AND MOUNTING LOCATIONS ...359
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ...374
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS ...396
ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...438
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...442
TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...514
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...520
BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...658
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...664
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...720
CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...724
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM ( ENG MODE) ...435
ENG- 1 FAILURE CODE [ A000N1] ( ENGINE: OVERRUN N1)) ...454
ENG- 2 FAILURE CODE [ A570NX] ( ENGINE OIL FILTER: CLOGGED ( NX)) ...455
ENG- 3 FAILURE CODE [ AD00L2] ( COMMON RAIL: * SEE CONTENTS ( L2)) ...456
ENG- 4 FAILURE CODE [ AD00MA] ( COMMON RAIL: FUNCTION IMPOSSIBLE ( MA)) ...456
ENG- 5 FAILURE CODE [ AD10L3] ( FUEL SUPPLY PUMP: * SEE CONTENTS ( L3)) ...457
ENG- 6 FAILURE CODE [ AD10MA] ( FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE ( MA)) ...459
ENG- 7 FAILURE CODE [ AD10MB] ( FUEL SUPPLY PUMP: DROP IN FUNCTION ( MB)) ...459
ENG- 8 FAILURE CODE [ AD11KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION ( KA)) ...460
ENG- 9 FAILURE CODE [ AD11KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT ( KB)) ...461
ENG- 10 FAILURE CODE [ AD51KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION ( KA)) ...462
ENG- 11 FAILURE CODE [ AD51KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT ( KB)) ...463
ENG- 12 FAILURE CODE [ ADA1KA] ( NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...464
ENG- 13 FAILURE CODE [ ADAZKB] ( NO. 1, 2, 3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) ...465
ENG- 14 FAILURE CODE [ ADB1KA] ( NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...469
ENG- 15 FAILURE CODE [ ADC1KA] ( NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...470
ENG- 16 FAILURE CODE [ ADD1KA] ( NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...471
ENG- 17 FAILURE CODE [ ADDZKB] ( NO. 4, 5, 6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) ...472
ENG- 18 FAILURE CODE [ ADE1KA] ( NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...476
ENG- 19 FAILURE CODE [ ADF1KA] ( NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...477
ENG- 20 FAILURE CODE [ B@ BAZG] ( ENGINE OIL: DROP IN OIL PRESSURE ( ZG)) ...478
ENG- 21 FAILURE CODE [ B@ BAZK] ( ENGINE OIL: DROP IN LEVEL ( ZK)) ...479
ENG- 22 FAILURE CODE [ B@ BCNS] ( RADIATOR WATER: OVERHEAT ( NS)) ...480
ENG- 23 FAILURE CODE [ D181KZ] ( PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...481
ENG- 24 FAILURE CODE [ D182KZ] ( PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...483
ENG- 25 FAILURE CODE [ D1D0KB] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT ( KB)) ...484
ENG- 26 FAILURE CODE [ D5ZAKX] ( ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...486
ENG- 27 FAILURE CODE [ DB20KT] ( ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER ( KT)) ...487
ENG- 28 FAILURE CODE [ DB22KK] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...489
ENG- 29 FAILURE CODE [ DB29KQ] ( ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH ( KQ)) ...491
ENG- 30 FAILURE CODE [ DB2AMA] ( ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE ( MA)) ...492
ENG- 31 FAILURE CODE [ DD11KB] ( STARTING SWITCH: SHORT CIRCUIT ( KB)) ...493
ENG- 32 FAILURE CODE [ DDA1L5] ( ACCELERATION SWITCH: * SEE CONTENTS ( L5)) ...494
ENG- 33 FAILURE CODE [ DDE2L6] ( ENGINE OIL PRESSURE SWITCH: * SEE CONTENTS ( L6)) ...496
ENG- 34 FAILURE CODE [ DGE2KX] ( ENGINE WATER TEMPERATURE SENSOR ( FOR HIGH- TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...498
ENG- 35 FAILURE CODE [ DGE3L6] ( ENGINE WATER TEMPERATURE SENSOR ( FOR LOW- TEMPERATURE): * SEE CONTENTS ( L6)) ...499
ENG- 36 FAILURE CODE [ DH30KX] ( BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...500
ENG- 37 FAILURE CODE [ DH40KX] ( COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...502
ENG- 38 FAILURE CODE [ DK10KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...504
ENG- 39 FAILURE CODE [ DLE3LC] ( ENGINE NE SPEED SENSOR: * SEE CONTENTS ( LC)) ...506
ENG- 40 FAILURE CODE [ DLH1LC] ( ENGINE G SPEED SENSOR: * SEE CONTENTS ( LC)) ...507
ENG- 41 ENGINE DOES NOT START ( STARTING MOTOR DOES NOT TURN) ...508
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM ( TM MODE) ...511
TM- 1 FAILURE CODE [ 1380MW] ( LOCK- UP CLUTCH: SLIPPING ( MW)) ...546
TM- 2 FAILURE CODE [ 1500LO] ( TRANSMISSION CLUTCH: * SEE THE TABLE IN CONTENTS. ( LO)) ...547
TM- 3 FAILURE CODE [ 15BONX] ( TRANSMISSION OIL FILTER: CLOGGED ( NX)) ...548
TM- 4 FAILURE CODE [ 15GOMW] ( R CLUTCH: SLIPPING ( MW)) ...549
TM- 5 FAILURE CODE [ 15HOMW] ( HI CLUTCH: SLIPPING ( MW)) ...550
TM- 6 FAILURE CODE [ 15JOMW] ( LO CLUTCH: SLIPPING ( MW)) ...551
TM- 7 ...552
TM- 8 FAILURE CODE [ 15LOMW] ( 2ND CLUTCH: SLIPPING ( MW)) ...553
TM- 9 FAILURE CODE [ 15MOMW] ( 3RD CLUTCH: SLIPPING ( MW)) ...554
TM- 10 FAILURE CODE [ 15SBL1] ( ECMV FOR R CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...555
TM- 11 FAILURE CODE [ 15SBMA] ( ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...556
TM- 12 FAILURE CODE [ 15SCL1] ( ECMV FOR HI CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...557
TM- 13 FAILURE CODE [ 15SCMA] ( ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...558
TM- 14 FAILURE CODE [ 15SDL1] ( ECMV FOR LO CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...559
TM- 15 FAILURE CODE [ 15SDMA] ( ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...560
TM- 16 FAILURE CODE [ 15SEL1] ( ECMV FOR 1ST CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...561
TM- 17 FAILURE CODE [ 15SEMA] ( ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...562
TM- 18 FAILURE CODE [ 15SFL1] ( ECMV FOR 2ND CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...563
TM- 19 FAILURE CODE [ 15SFMA] ( ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...564
TM- 20 FAILURE CODE [ 15SGL1] ( ECMV FOR 3RD CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...565
TM- 21 FAILURE CODE [ 15SGMA] ( ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...566
TM- 22 FAILURE CODE [ 15SJL1] ( ECMV FOR LOCK- UP CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...567
TM- 23 FAILURE CODE [ 15SJMA] ( ECMV FOR LOCK- UP CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...568
TM- 24 FAILURE CODE [ 15SKL1] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...569
TM- 25 FAILURE CODE [ 15SKMA] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...570
TM- 26 FAILURE CODE [ 2B61MW] ( INTER- AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING ( MW)) ...571
TM- 27 FAILURE CODE [ 2F00KM] ( PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...572
TM- 28 FAILURE CODE [ 989A00] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED ( 00)) ...574
TM- 29 FAILURE CODE [ 989AKZ] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...575
TM- 30 FAILURE CODE [ 989D00] ( REAR OVERTURN SIGNAL: ACTUATED ( 00)) ...576
TM- 31 FAILURE CODE [ AA10NX] ( AIR CLEANER ELEMENT: CLOGGED ( NX)) ...578
TM- 32 FAILURE CODE [ AB00MA] ( ALTERNATOR: FUNCTION IMPOSSIBLE ( MA)) ...580
TM- 33 FAILURE CODE [ B@ BCZK] ( RADIATOR COOLING WATER: DROP IN LEVEL ( ZK)) ...581
TM- 34 FAILURE CODE [ B@ HAZK] ( HYDRAULIC TANK OIL: DROP IN LEVEL ( ZK)) ...582
TM- 35 FAILURE CODE [ B@ JANS] ( STEERING OIL: OVERHEAT ( NS)) ...583
TM- 36 FAILURE CODE [ D1B0KZ] ( TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...584
TM- 37 FAILURE CODE [ D5ZBKX] ( INTER- AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...586
TM- 38 FAILURE CODE [ D5ZCKZ] ( EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...588
TM- 39 FAILURE CODE [ D5ZDL4] ( FORCED NEUTRAL DEMAND SIGNAL: * SEE THE TABLE IN CONTENTS. ( L4)) ...589
TM- 40 FAILURE CODE [ D5ZEKX] ( ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...591
TM- 41 FAILURE CODE [ DAQ0KK] ( TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...592
TM- 42 FAILURE CODE [ DAQ1KK] ( TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...594
TM- 43 FAILURE CODE [ DAQ2KK] ( TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...595
TM- 44 FAILURE CODE [ DAQ3KK] ( TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...596
TM- 45 FAILURE CODE [ DAQ5KP] ( TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE ( KP)) ...597
TM- 46 FAILURE CODE [ DAQ9KM] ( TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...598
TM- 47 FAILURE CODE [ DAQ9KQ] ( TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...599
TM- 48 FAILURE CODE [ DAQAKQ] ( TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...600
TM- 49 FAILURE CODE [ DAQSMA] ( TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE ( MA) ...600
TM- 50 FAILURE CODE [ DDTFKA] ( FILL SWITCH FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION ( KA)) ...601
TM- 51 FAILURE CODE [ DDTGKA] ( FILL SWITCH FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) ...602
TM- 52 FAILURE CODE [ DDTHKA] ( FILL SWITCH FOR HI CLUTCH: DISCONNECTION ( KA)) ...603
TM- 53 FAILURE CODE [ DDTJKA] ( FILL SWITCH FOR LO CLUTCH: DISCONNECTION ( KA)) ...604
TM- 54 FAILURE CODE [ DDTKKA] ( FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION ( KA)) ...605
TM- 55 FAILURE CODE [ DDTLKA] ( FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION ( KA)) ...606
TM- 56 FAILURE CODE [ DDTMKA] ( FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION ( KA)) ...607
TM- 57 FAILURE CODE [ DDTNKA] ( FILL SWITCH FOR R CLUTCH: DISCONNECTION ( KA)) ...608
TM- 58 FAILURE CODE [ DF10KA] ( GEARSHIFT LEVER: DISCONNECTION ( KA)) ...609
TM- 59 FAILURE CODE [ DF10KB] ( GEARSHIFT LEVER: SHORT CIRCUIT ( KB)) ...611
TM- 60 FAILURE CODE [ DGF1KX] ( TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...613
TM- 61 FAILURE CODE [ DGR3L8] ( BRAKE OIL TEMPERATURE SENSOR ( CENTER): * SEE THE TABLE IN CONTENTS. ( L8)) ...615
TM- 62 FAILURE CODE [ DGR4L8] ( BRAKE OIL TEMPERATURE SENSOR ( FRONT): * SEE THE TABLE IN CONTENTS. ( L8)) ...617
TM- 63 FAILURE CODE [ DGT1LX] ( TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...619
TM- 64 FAILURE CODE [ DHT5KX] ( TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...621
TM- 65 FAILURE CODE [ DHT5L6] ( TORQUE CONVERTER OIL PRESSURE SENSOR: * SEE THE TABLE IN CONTENTS. ( L6)) ...623
TM- 66 FAILURE CODE [ DJF1KA] ( FUEL LEVEL SENSOR: DISCONNECTION ( KA)) ...624
TM- 67 FAILURE CODE [ DK11KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...625
TM- 68 FAILURE CODE [ DLE2KA] ( ENGINE SPEED SENSOR: DISCONNECTION ( KA)) ...627
TM- 69 FAILURE CODE [ DLE2LC] ( ENGINE SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...628
TM- 70 FAILURE CODE [ DLF1KA] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION ( KA)) ...629
TM- 71 FAILURE CODE [ DLF1LC] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...630
TM- 72 FAILURE CODE [ DLF2KA] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...631
TM- 73 FAILURE CODE [ DLF2LC] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...632
TM- 74 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...633
TM- 75 FAILURE CODE [ DLT3LC] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...634
TM- 76 FAILURE CODE [ DXH0KA] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: DISCONNECTION ( KA)) ...636
TM- 77 FAILURE CODE [ DXH0KB] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT ( KB)) ...637
TM- 78 FAILURE CODE [ DXH1KA] ( SOLENOID FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) ...638
TM- 79 FAILURE CODE [ DXH1KB] ( SOLENOID FOR LOCK- UP CLUTCH: SHORT CIRCUIT ( KB)) ...639
TM- 80 FAILURE CODE [ DXH2KA] ( SOLENOID FOR HI CLUTCH: DISCONNECTION ( KA)) ...640
TM- 81 FAILURE CODE [ DXH2KB] ( SOLENOID FOR HI CLUTCH: SHORT CIRCUIT ( KB)) ...641
TM- 82 FAILURE CODE [ DXH3KA] ( SOLENOID FOR LO CLUTCH: DISCONNECTION ( KA)) ...642
TM- 83 FAILURE CODE [ DXH3KB] ( SOLENOID FOR LO CLUTCH: SHORT CIRCUIT ( KB)) ...643
TM- 84 FAILURE CODE [ DXH4KA] ( SOLENOID FOR 1ST CLUTCH: DISCONNECTION ( KA)) ...644
TM- 85 FAILURE CODE [ DXH4KB] ( SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT ( KB)) ...645
TM- 86 FAILURE CODE [ DXH5KA] ( SOLENOID FOR 2ND CLUTCH: DISCONNECTION ( KA)) ...646
TM- 87 FAILURE CODE [ DXH5KB] ( SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT ( KB)) ...647
TM- 88 FAILURE CODE [ DXH6KA] ( SOLENOID FOR 3RD CLUTCH: DISCONNECTION ( KA)) ...648
TM- 89 FAILURE CODE [ DXH6KB] ( SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT ( KB)) ...649
TM- 90 FAILURE CODE [ DXH7KA] ( SOLENOID FOR R CLUTCH: DISCONNECTION ( KA)) ...650
TM- 91 FAILURE CODE [ DXH7KB] ( SOLENOID FOR R CLUTCH: SHORT CIRCUIT ( KB)) ...651
TM- 92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY ...652
TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM ( BK MODE) ...655
BK- 1 FAILURE CODE [ 2G42ZG] ( ACCUMULATOR ( FRONT): DROP IN OIL PRESSURE ( ZG)) ...676
BK- 2 FAILURE CODE [ 2G43ZG] ( ACCUMULATOR ( REAR): DROP IN OIL PRESSURE ( ZG)) ...676
BK- 3 FAILURE CODE [ D1C0KZ] ( BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...677
BK- 4 FAILURE CODE [ D5ZFKZ] ( NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...679
BK- 5 FAILURE CODE [ D5ZGKZ] ( NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...680
BK- 6 FAILURE CODE [ DB10KK] ( RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...681
BK- 7 FAILURE CODE [ DB11KK] ( RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...683
BK- 8 FAILURE CODE [ DB12KK] ( RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...684
BK- 9 FAILURE CODE [ DB13KK] ( RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...685
BK- 10 FAILURE CODE [ DB19KM] ( RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...686
BK- 11 FAILURE CODE [ DB1SKQ] ( RETARDER CONTROLLER S- NET LINE: MODEL SELECTION SIGNAL MISMATCH ( KQ)) ...687
BK- 12 FAILURE CODE [ DHU2KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( FRONT): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...688
BK- 13 FAILURE CODE [ DHU3KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( REAR): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...690
BK- 14 FAILURE CODE [ DK51L5] ( RETARDER LEVER POTENTIOMETER: * SEE SEPARATE TABLE ( L5)) ...692
BK- 15 FAILURE CODE [ DK52KX] ( DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...695
BK- 16 FAILURE CODE [ DK53L8] ( DUMP LEVER POTENTIOMETER 2: * SEE THE TABLE IN CONTENTS. ( L8)) ...697
BK- 17 FAILURE CODE [ DK54KX] ( BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...698
BK- 18 FAILURE CODE [ DLF4KA] ( TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION ( KA)) ...700
BK- 19 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...701
BK- 20 FAILURE CODE [ DW71KZ] ( EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...702
BK- 21 FAILURE CODE [ DW72KZ] ( DUMP LEVER KICK- OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...703
BK- 22 FAILURE CODE [ DW73KZ] ( DUMP SELECTOR VALVE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...705
BK- 23 FAILURE CODE [ DX11KA] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) ...707
BK- 24 FAILURE CODE [ DX11KB] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...708
BK- 25 FAILURE CODE [ DX11KY] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...709
BK- 26 FAILURE CODE [ DX12KA] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) ...710
BK- 27 FAILURE CODE [ DX12KB] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...711
BK- 28 FAILURE CODE [ DX12KY] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...712
BK- 29 FAILURE CODE [ DX13KA] ( DUMP EPC VALVE SOLENOID: DISCONNECTION ( KA)) ...713
BK- 30 FAILURE CODE [ DX13KB] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...714
BK- 31 FAILURE CODE [ DX13KY] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...715
BK- 32 PARKING BRAKE DOES NOT WORK PROPERLY ...716
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM ( MON MODE) ...719
MON- 1 FAILURE CODE [ B@ C6NS] ( FRONT BRAKE OIL: OVERHEAT ( NS)) ...728
MON- 2 FAILURE CODE [ B@ C8NS] ( CENTER BRAKE OIL: OVERHEAT ( NS)) ...728
MON- 3 FAILURE CODE [ B@ CENS] ( TORQUE CONVERTER: OVERHEAT ( NS)) ...728
MON- 4 FAILURE CODE [ DAF0KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...729
MON- 5 FAILURE CODE [ DAF9KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...730
MON- 6 FAILURE CODE [ DAFSKQ] ( MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...731
MON- 7 FAILURE CODE [ DAQSKR] ( TRANSMISSION CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...732
MON- 8 FAILURE CODE [ DB1SKR] ( RETARDER CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...734
MON- 9 FAILURE CODE [ DB2SKR] ( ENGINE CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...736
MON- 10 FAILURE CODE [ DV00KB] ( ALARM BUZZER: SHORT CIRCUIT ( KB)) ...738
MON- 11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY ...739
MON- 12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED ...740
MON- 13 ALARM BUZZER DOES NOT SOUND ...741
MON- 14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY ...742
MON- 15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY ...743
MON- 16 ...744
MON- 17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY ...747
MON- 18 AISS FUNCTION DOES NOT WORK PROPERLY ...748
MON- 19 EXHAUST BRAKE DOES NOT WORK PROPERLY ( MACHINES EQUIPPED WITH EXHAUST BRAKE) ...749
MON- 20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY ...751
MON- 21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY ...753
MON- 22 NIGHT LIGHTING IS NOT NORMAL ...758
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ( H MODE) ...765
H- 1 MACHINE DOES NOT START ...766
H- 2 MACHINE DOES NOT TRAVEL SMOOTHLY ( MACHINE JERKS) H- 3 LOCK- UP CLUTCH CANNOT BE DISENGAGED ( ENGINE STALLS) ...767
H- 4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING ...768
H- 5 ...769
H- 6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING ...770
H- 7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR ...773
H- 8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ...774
H- 9 TORQUE CONVERTER OIL PRESSURE IS LOW ...775
H- 10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE ...776
H- 11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE ...777
H- 12 STEERING WHEEL IS HEAVY ...778
H- 13 STEERING WHEEL DOES NOT WORK ...779
H- 14 STEERING WHEEL VIBRATES ...780
H- 15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER ...781
H- 16 DUMP DOES NOT WORK ...782
H- 17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY ...783
30 DISASSEMBLY AND ASSEMBLY ...809
HOW TO READ THIS MANUAL ...811
REMOVAL AND INSTALLATION OF ASSEMBLIES ...811
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES ...812
2. Precautions when carrying out installation work ...814
3. Precautions when completing the operation ...814
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY ...819
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ...822
REMOVAL AND INSTALLATION OF NOZZLE TIP ...826
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY ...829
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY ...837
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ...842
REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY ...845
ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY ...848
REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY ...851
CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY ...858
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY ...860
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY ...869
DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY ...915
REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY ...930
DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY ...934
REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY ...954
DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY ...956
REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ...971
DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ...973
REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY ...987
DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY ...989
DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY ...1000
REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY ...1008
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY ...1010
REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY ...1013
INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY ...1015
REMOVAL AND INSTALLATION OF EQUALIZER BAR ...1016
REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY ...1018
DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY ...1028
DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY ...1035
REMOVAL AND INSTALLATION OF FLOW AMP VALVE ...1045
REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY ...1046
DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY ...1048
DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY ...1051
REMOVAL AND INSTALLATION OF BODY ASSEMBLY ...1055
90 OTHERS ...1069
