Komatsu HM300-3 Dump Truck Service Repair Shop Manual (3001 and up) - SEN05629-01

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Articulated Dump Truck HM300-3 (SN: 3001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu Dump Truck HM300-3
Serial Numbers : 3001 and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure and function
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and Assembly
60 Maintenance standard
80 Appendix
90 Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN05629-01
Total Pages : 1977


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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Cover
00 Index and foreword
Index
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
Table of contents
Specifications
Specification drawings
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure and function
Table of contents
Engine and cooling system
Engine related parts
Output shaft
Cooling system
Radiator fan pump
Aftercooler in-fan motor
Radiator in-fan motor
Power train
Power train system
Drive shaft
Torque converter and transmission hydraulic piping
Torque converter
Transmission
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Differential lock clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Axle
Differential
Final drive
Steering system
Layout of steering devices
Steering column
Flow amplifier valve
Steering valve
Emergency steering pump
Brake system
Layout of brake parts
Parking brake solenoid and accumulator charge valve
Accumulator
Brake valve
Proportional pressure reducing valve
Slack adjuster
Brake
Brake system tank
Parking brake
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Layout of hoist hydraulic parts
Dump body control
Hydraulic tank
Steering and hoist control pump
Hoist valve
Dump EPC valve
Brake cooling oil control valve
Cab and its attachments
ROPS cab
Cab tilt
Electrical system
Transmission control system
Retarder and hoist control system
Auto emergency steering system
KTCS
System component parts
Machine monitor system
Rear view monitor system
KOMTRAX system
Sensor

20 Standard value table
Table of contents
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Table of contents
General information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Measuring engine speed
Measuring boost pressure
Measuring exhaust gas temperature
Measuring exhaust gas color
Measuring and adjusting valve clearance
Measuring compression pressure
Measuring blowby pressure
Measuring engine oil pressure
Measuring EGR valve and KVGT driving oil pressure
Measuring fuel pressure
Handling cylinder cutout mode operation
Handling no injection cranking operation
Measuring fuel return rate and leakage
Bleeding air from fuel system
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
Replacing alternator belt
Procedures for cleaning fuel doser
Writing compensation values at replacement of injector and engine controller
Power train
Testing torque converter stall speed
Measuring power train oil pressure
Adjusting transmission speed sensor
Adjusting transmission controller
Retrieval of disabled machine that resulted from a trouble in electrical system
Retrieval of machine that is disabled due to failure in the traction control system (KTCS)
Steering system
Measuring and adjusting steering circuit oil pressure
Brake system
Measuring and adjusting brake oil pressure
Measuring accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas
Testing braking performance
Testing braking performance
Measuring wear of wheel brake disc
Parking brake emergency releasing procedure
Measuring wear of parking brake pad and adjusting clearance
Hydraulic system
Testing and adjusting suspension cylinder
Measuring and adjusting dump circuit oil pressure
Work equipment
Adjusting dump body positioner sensor
Cab and its attachments
Cab tilt-up procedure
Electrical system
Setting and adjusting each equipment
Special functions of machine monitor
Handling voltage circuit of engine controller
Handling battery disconnect switch
Pm Clinic
Pm Clinic service

40 Troubleshooting
Table of contents
General information on troubleshooting
Instruction on troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Testing procedure before troubleshooting
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Table of fuse locations
Precautions for cleaning and replacing KDPF (KCSF, KDOC)
Precautions on troubleshooting of machine monitor
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
Dummy temperature sensor (for KDOC and KDPF temperature sensors)
Short-circuit connector (for CA1883 and CA3135)
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [1500L0] Double Engagement of T/M Clutches
Failure code [15B0NX] Transmission Oil Filter Clogging
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F
Failure code [15F7KM] Abuse of TM Forward Clutch Disk
Failure code [15G0MW] Failure of Clutch (Reverse)
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk
Failure code [15H0MW] Failure of Clutch (High)
Failure code [15J0MW] Failure of Clutch (Low)
Failure code [15K0MW] Failure of Clutch (1st)
Failure code [15L0MW] Failure of Clutch (2nd)
Failure code [15M0MW] Failure of Clutch (3rd)
Failure code [15SBL1] Release Trouble of ECMV (Reverse)
Failure code [15SBMA] Malfunction of ECMV (Reverse)
Failure code [15SCL1] Release Trouble of ECMV (High)
Failure code [15SCMA] Malfunction of ECMV (High)
Failure code [15SDL1] Release Trouble of ECMV (Low)
Failure code [15SDMA] Malfunction of ECMV (Low)
Failure code [15SEL1] Release Trouble of ECMV (1st)
Failure code [15SEMA] Malfunction of ECMV (1st)
Failure code [15SFL1] Release Trouble of ECMV (2nd)
Failure code [15SFMA] Malfunction of ECMV (2nd)
Failure code [15SGL1] Release Trouble of ECMV (3rd)
Failure code [15SGMA] Malfunction of ECMV (3rd)
Failure code [15SJMA] Malfunction of ECMV (Lockup)
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff.)
Failure code [2F00KM] Dragging of Parking Brake
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front)
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989D00] Tilt Caution
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A1U0N3] HC desorb request 1
Failure code [A1U0N4] HC desorb request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [AB00KY] Hot Short of Alternator R Terminal
Failure code [B@BAZK] Engine Oil Level Low
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@C6NS] Retarder Oil Overheat (Front)
Failure code [B@C8NS] Retarder Oil Overheat (Center)
Failure code [B@CENS] T/C Oil Temp. Overheat
Failure code [B@JANS] Steering Oil Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sensor 2 Supply Volt Low Error
Failure code [CA221] Ambient Press Sensor High Error
Failure code [CA222] Ambient Press Sensor Low Error
Failure code [CA227] Sensor 2 Supply Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sensor Supply Volt Error
Failure code [CA239] Ne Speed Sens Supply Volt High Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA343] ECM Critical Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor 1 Supply Volt Low Error
Failure code [CA356] Mass Air Flow Sensor High Error
Failure code [CA357] Mass Air Flow Sensor Low Error
Failure code [CA386] Sensor 1 Supply Volt High Error
Failure code [CA431] Idle Validation Sw Error
Failure code [CA432] Idle Validation Process Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA515] Rail Press Sens Sup Volt High Error
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA555] Crankcase Press High Error 1
Failure code [CA556] Crankcase Press High Error 2
Failure code [CA559] Rail Press Low Error
Failure code [CA595] Turbo Speed High Error 2
Failure code [CA687] Turbo Speed Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA691] Intake Air Temp Sens High Error
Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Internal Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1664] KDOC Malfunction
Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sensor 5 Supply Volt High Error
Failure code [CA1696] Sensor 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1923] Dosing Fuel Valve 1 High Error
Failure code [CA1924] Dosing Fuel Valve 1 Low Error
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
Failure code [CA1927] Dosing Fuel Press Sens High Error
Failure code [CA1928] Dosing Fuel Press Sens Low Error
Failure code [CA1942] Crankcase Press Sensor In Range Error
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
Failure code [CA1977] Fuel Doser Open/Short Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2732] Dosing Fuel Valve 2 High Error
Failure code [CA2733] Dosing Fuel Valve 2 Low Error
Failure code [CA2741] Dosing Fuel Valve Swap Error
Failure code [CA2765] Inj Trim Data Error
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
Failure code [CA2881] Dosing Fuel Pressure Low Error 1
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [D150KB] Ground Fault of Emerg. Steering Relay
Failure code [D150KZ] Failure of Emerg. Steering Relay
Failure code [D164KY] Hot Short of Head Light High Selector
Failure code [D19HKZ] Failure of Stop Lamp (R&L)
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D1EHKA] Disconnection of Engine Start Relay
Failure code [D1EHKB] Ground Fault of Engine Start Relay
Failure code [D1EHKY] Hot Short of Engine Start Relay
Failure code [D1EMKA] Disconnection of Parking Interlock Relay
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay
Failure code [D1EMKY] Hot Short of Parking Interlock Relay
Failure code [D1FBKB] Ground Fault of Sol. Self-Holding Relay
Failure code [D5ZHL6] Disconnection of Key SW C
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF3KK] Controller Power Source Low (MON)
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit
Failure code [DAFGMC] GPS Module Error
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)
Failure code [DAFQKR] CAN2 Discon (Monitor)
Failure code [DAQ0KK] Controller Power Source Low (T/M)
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M)
Failure code [DAQ0MC] T/M Con Error
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M)
Failure code [DAQ2KK] Solenoid Power Source Low (T/M)
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M)
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M)
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M)
Failure code [DAQQKR] CAN2 Discon (Transmission Con)
Failure code [DAQRKR] CAN1 Discon (Transmission Con)
Failure code [DAQRMA] Inconsistency of Option Selection (T/M)
Failure code [DAZ9KQ] A/C Model Selection Abnormality
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC)
Failure code [DB10MC] RHC Error
Failure code [DB11KA] Disconnection of Key SW ACC (RHC)
Failure code [DB12KK] Solenoid Power Source Low (RHC)
Failure code [DB13KK] Controller Power Source Low (RHC)
Failure code [DB19KQ] Inconsistency of Model Selection (RHC)
Failure code [DB1LKA] Disconnection of System Ope. Lamp (RHC)
Failure code [DB1LKB] Short Circuit of System Ope. Lamp (RHC)
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con)
Failure code [DB1QMA] Inconsistency of Option Selection (RHC)
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con)
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DB2RKR] CAN1 Discon (Engine Con)
Failure code [DD1ML4] Failure of ARAC SW
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch
Failure code [DDTHKA] Disconnection of Fill Switch (High)
Failure code [DDTJKA] Disconnection of Fill Switch (Low)
Failure code [DDTKKA] Disconnection of Fill Switch (1st)
Failure code [DDTLKA] Disconnection of Fill Switch (2nd)
Failure code [DDTMKA] Disconnection of Fill Switch (3rd)
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse)
Failure code [DF10KA] Disconnection of Shift Lever Input
Failure code [DF10KB] Ground Fault of Shift Lever Input
Failure code [DGF1KX] Out oF Range of T/M Oil Temp. Sensor
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp. S.(C)
Failure code [DGR3L8] Failure of Retarder Oil Temp. Sensor (C)
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp. S.(F)
Failure code [DGR4L8] Failure of Retarder Oil Temp. Sensor (F)
Failure code [DGR6KB] Ground Fault of Steering Oil Temp. S.
Failure code [DGR6L8] Failure of Steering Oil Temp. Sensor
Failure code [DGT1KX] Out of Range of T/C Oil Temp. Sensor
Failure code [DHQ2KX] Out of Range of Main Flow Sel. Valve S.
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor
Failure code [DHT5L6] Failure of T/C Oil Press Sensor
Failure code [DHT8KX] Out of Range of Steering Oil Press. S.
Failure code [DHT8ZG] Steering Oil Pressure Low
Failure code [DHU2KX] Out of Range of Acc. Oil Press. S. (F)
Failure code [DHU3KX] Out of Range of Acc. Oil Press. S. (R)
Failure code [DHUAKX] Out of Range of Retarder Press. S. (CR)
Failure code [DHUBKX] Out of Range of Retarder Press. S. (FR)
Failure code [DHUCKX] Out of Range of Parking Brake Press. S.
Failure code [DHUDKX] Out of Range of Emerg. Steering Press. S.1
Failure code [DHUQKX] Out of Range of Retarder Press. S. (FL)
Failure code [DHURKX] Out of Range of Retarder Press. S. (CL)
Failure code [DJF1KA] Disconnection of Fuel Level Sensor
Failure code [DK30KX] Out of Range of Steering Angle Pot.
Failure code [DK51L5] Failure of Retarder Lever Pot. and RVS
Failure code [DK52KX] Out of Range of Hoist Lever Potentio.
Failure code [DK53L8] Failure of Hoist Lever Potentio.
Failure code [DK54KX] Out of Range of Body Potentio.
Failure code [DK60KX] Out of Range of Acceleration Sensor
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor
Failure code [DLF1LC] Failure of T/M Input Speed Sensor
Failure code [DLF2KA] Disconnection of T/M Inter. Speed Sensor
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor
Failure code [DLF400] T/M Diff. Overrun Prevention Activated
Failure code [DLF4KA] Disconnection of T/M Diff. Speed Sensor
Failure code [DLF4LC] Failure of T/M Diff. Speed Sensor
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR)
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL)
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR)
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL)
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front)
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center)
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor
Failure code [DLM3MB] Radiator Fan Control Mismatch
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor
Failure code [DLM4MB] CAC Fan Control Mismatch
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main)
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)
Failure code [DPQ1KR] LIN Discon (Switch Panel)
Failure code [DPQ2KR] LIN Discon (LED Unit)
Failure code [DPQ3KR] LIN Discon (Rear View Monitor)
Failure code [DSJ0KR] CAN2 Discon (Meter Unit)
Failure code [DV00KB] Ground Fault of Buzzer Output
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol.
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol.
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol.
Failure code [DW2BL1] Release Trouble of Main Flow Sel. Valve
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve
Failure code [DW4BK4] Release Trouble of Parking Brake Valve
Failure code [DW4BMA] Malfunction of Parking Brake Valve
Failure code [DW72KZ] Failure of Kick out Solenoid
Failure code [DW73KA] Disconnection of Hoist Selector Sol.
Failure code [DW73KB] Ground Fault of Hoist Selector Sol.
Failure code [DW73KY] Hot Short of Hoist Selector Sol.
Failure code [DW78KZ] Failure of Brake Cooling Sol. (Rear)
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol.
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol.
Failure code [DW7BKZ] Failure of Radiator Fan Rev. Sol.
Failure code [DW7LKB] Ground Fault of CAC Fan Rev. Sol.
Failure code [DW7LKY] Hot Short of CAC Fan Rev. Sol.
Failure code [DW7LKZ] Failure of CAC Fan Rev. Sol.
Failure code [DW7MKB] Ground Fault of Fan/Hoist Selector Sol.
Failure code [DW7MKY] Hot Short of Fan/Hoist Selector Sol.
Failure code [DW7MKZ] Failure of Fan/Hoist Selector Sol.
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol.
Failure code [DWNJKZ] Failure of TCS Shut off Sol. (Front)
Failure code [DWNKKZ] Failure of TCS Shut off Sol. (Center)
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol.
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol.
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol.
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol.
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol.
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol.
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL)
Failure code [DX30KA] Disconnection of Retarder EPC Sol. (FL)
Failure code [DX30KB] Ground Fault of Retarder EPC Sol. (FL)
Failure code [DX30KY] Hot Short of Retarder EPC Sol. (FL)
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL)
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR)
Failure code [DX31KA] Disconnection of Retarder EPC Sol. (CR)
Failure code [DX31KB] Ground Fault of Retarder EPC Sol. (CR)
Failure code [DX31KY] Hot Short of Retarder EPC Sol. (CR)
Failure code [DX31MA] Malfunction of Retarder Valve (CR)
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL)
Failure code [DX32KA] Disconnection of Retarder EPC Sol. (CL)
Failure code [DX32KB] Ground Fault of Retarder EPC Sol. (CL)
Failure code [DX32KY] Hot Short of Retarder EPC Sol. (CL)
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL)
Failure code [DX33K4] Release Trouble of Retarder EPC Valve(FR)
Failure code [DX33KA] Disconnection of Retarder EPC Sol. (FR)
Failure code [DX33KB] Ground Fault of Retarder EPC Sol. (FR)
Failure code [DX33KY] Hot Short of Retarder EPC Sol. (FR)
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR)
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff.)
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff.)
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff.)
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup)
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup)
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup)
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High)
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High)
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High)
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low)
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low)
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low)
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st)
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd)
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd)
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd)
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd)
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd)
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse)
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse)
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor
Failure code [DY30ME] Emerg. Steering Long-Time Activated
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not rotate)
E-2 Manual preheating system does not work
E-3 Automatic preheating system does not work
E-4 While preheating is working, preheating monitor does not light up
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing
E-6 LCD unit on machine monitor displays nothing
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers)
E-8 LCD on machine monitor does not display properly
E-9 Meter unit display on machine monitor is abnormal
E-10 Night lighting lamp of meter unit on machine monitor is abnormal
E-11 Caution LED on machine monitor is abnormal
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate properly
E-13 2 switches operation of switch panel on machine monitor does not function
E-14 Switch panel buzzer of machine monitor is abnormal
E-15 Rear view monitor does not light up or backlight flickers
E-16 Rear view monitor images are not displayed clearly
E-17 Rear view monitor brightness cannot be adjusted
E-18 Night lighting lamp of rear view monitor is abnormal
E-19 Rear view monitor does not display images while R-linked display function is enabled
E-20 Guide line on rear view monitor is not displayed while guide line is set
E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly
E-22 Fuel level gauge does not indicate correct level
E-23 Seat belt caution lamp indication is abnormal
E-24 Machine monitor cannot be operated when starting switch is in OFF position
E-25 Alarm buzzer does not sound
E-26 Alarm buzzer does not stop sounding
E-27 Engine mode selector function does not operate properly
E-28 AISS function does not operate properly
E-29 Hoist lever does not operate properly
E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly
E-31 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up
E-32 Small lamp (clearance lamp) does not light up
E-33 Tail lamp does not light up
E-34 "Low beam" head lamp does not light up
E-35 "High beam" head lamp does not light up
E-36 Neither "Low beam" nor "High beam" head lamps lights up
E-37 Passing lamp does not light up
E-38 KOMTRAX does not operate properly
Troubleshooting of hydraulic and mechanical system (H-mode)
Information mentioned in troubleshooting table (H mode)
System diagram of hydraulic and mechanical systems
Failure mode and cause table
H-1 Machine does not start
H-2 Machine does not travel smoothly (machine hunts)
H-3 Lockup is not released
H-4 Start shock and gear shift shock are abnormally large
H-5 Gear is not shifted up
H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds
H-7 Machine lacks travel speed or power when traveling in torque converter drive mode
H-8 Machine lacks travel speed or power when traveling at some gear speed
H-9 Large time lag is observed when machine starts and gear is shifted
H-10 Oil temperature of torque converter is high
H-11 Oil pressure of torque converter is low
H-12 Front brake does not work enough
H-13 Center brake does not work enough
H-14 Steering wheel is heavy
H-15 Steering wheel does not turn
H-16 Steering wheel waggles
H-17 Dump body rising speed is low
H-18 Dump body does not move
H-19 Dump body hydraulic drift is large
H-20 Radiator fan speed is unusual (excessively high or low, or fan stops)
H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops)
H-22 Unusual noise is heard from around radiator fan
H-23 Unusual noise is heard from around aftercooler fan
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
S-1 When starting switch is turned to START position, engine is not cranked
S-2 The engine cranks but exhaust smoke does not come out
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not)
S-4 Startability is poor
S-5 Engine does not pick-up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 Exhaust gas is black (KDPF gets clogged in a short time)
S-10 Engine oil consumption is excessive
S-11 Engine oil becomes contaminated early
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Oil pressure drops
S-15 Fuel mixes into engine oil
S-16 Water mixes into engine oil (milky)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is made
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit
S-21 Active regeneration is executed frequently
S-22 Active regeneration takes a long time
S-23 White smoke is exhausted during active regeneration

50 Disassembly and Assembly
Table of contents
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of radiator fan and fan motor
Removal and installation of aftercooler assembly
Removal and installation of aftercooler fan and fan motor
Removal and installation of engine assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of output shaft assembly
Disassembly and assembly of output shaft
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Power train
Removal and installation of transmission and front differential assembly
Disconnection and connection of front differential assembly and transmission assembly
Disassembly and assembly of front differential
Disassembly and assembly of torque converter
Disassembly and assembly of transmission
Removal and installation of center differential assembly
Disassembly and assembly of center differential
Removal and installation of rear differential assembly
Disassembly and assembly of rear differential
Removal and installation of front final drive and brake assembly
Disassembly and assembly of front final drive and brake
Removal and installation of center final drive and brake
Disassembly and assembly center final drive and brake
Disassembly and assemble rear final drive
Removal and installation of center axle assembly
Removal and installation of rear axle assembly
Undercarriage and frame
Removal and installation of front suspension cylinder assembly
Removal and installation of rear suspension assembly
Disassembly and assembly of suspension cylinder
Removal and installation of equalizer bar assembly
Removal and installation of hitch frame assembly
Disassembly and assembly of hitch frame
Hydraulic system
Removal and installation of flow amplifier valve assembly
Removal and installation of hoist valve assembly
Disassembly and assembly of steering cylinder
Disassembly and assembly of hoist cylinder
Body
Removal and installation of body assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (adhered window glass)
Removal and installation of operator seat assembly
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of retarder and hoist controller assembly
Removal and installation of transmission controller assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly
Air conditioner components
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly

60 Maintenance standard
Table of contents
Engine and cooling system
Output shaft
Radiator fan pump
Radiator in-fan motor
Aftercooler in-fan motor
Power train
Drive shaft
Torque converter
Transmission
Transmission control valve
Forward and reverse clutch ECMV and gear speed clutch ECMV
Lockup clutch ECMV
Differential lock clutch ECMV
Main relief valve, torque converter relief valve, and main flow selector valve
Axle
Differential
Final drive
Steering system
Steering column
Steering cylinder
Brake system
Slack adjuster
Brake
Parking brake
Undercarriage and frame
Suspension
Suspension cylinder
Oscillation hitch
Hydraulic system
Steering and hoist control pump
Front brake cooling duplex pump and aftercooler fan pump
Center brake cooling pump
Brake charge pump
Hoist valve
Hoist cylinder

80 Appendix
Table of contents
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Air conditioner compressor
Condenser
Receiver drier
Outside air temperature sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Parts and connectors layout
Layout of air conditioner related parts and connectors
Testing air leakage (duct)
Testing with self-diagnosis function
How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information mentioned in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil

90 Diagrams and drawings
Table of contents
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Power train hydraulic circuit diagram
Steering and hoist hydraulic circuit diagram
Brake hydraulic circuit diagram
Brake cooling system hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Inside cab electric circuit diagram
Outside cab electric circuit diagram

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