Komatsu ARTICULATED DUMP TRUCK Shop Manual SEN06205-19 PDF

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Komatsu ARTICULATED DUMP TRUCK Shop Manual SEN06205-19 – PDF DOWNLOAD

FILE DETAILS:

Komatsu ARTICULATED DUMP TRUCK Shop Manual SEN06205-19 – PDF DOWNLOAD

Language : English
Pages :2314
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu ARTICULATED DUMP TRUCK Shop Manual SEN06205-19 – PDF DOWNLOAD

SERIAL NUMBERS 8001 and up

General precautions

• Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only the approved personnel can do the work in a closed environment or in a prohibited area.
• Only qualified workers must perform the work and operation which require license or qualification. •
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc. •
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc. • Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
• When you work in high places, use a platform.
• Before you start the work, Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
• Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.

TABLE OF CONTENTS:

Komatsu ARTICULATED DUMP TRUCK Shop Manual SEN06205-19 – PDF DOWNLOAD

SERIAL NUMBERS 8001 and up

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 18
Important safety notice 18
How to read the shop manual 25
Explanation of terms for maintenance standard 27
Handling equipment of fuel system devices 29
Handling of intake system parts 30
Handling of hydraulic equipment 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 44
Precautions when performing operation 47
Practical use of KOMTRAX 52
Standard tightening torque table 53
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents 70
Specifications 71
Specification drawing 71
Specifications 73
Weight table 79
Table of fuel, coolant, and lubricants 80
10 Structure and function 83
Table of contents 84
Engine and cooling system 86
Engine related parts 86
Output shaft 87
Turbocharger 88
Muffler 90
Cooling system 91
Radiator fan pump 93
Aftercooler fan motor 101
Radiator fan motor 112
Center brake cooling remote motor 121
Center brake cooling remote pump 125
Oil cooler bypass valve 126
Power train 127
Power train system 127
Drive shaft 129
Torque converter and transmission hydraulic piping 130
Torque converter 131
Transmission 137
Transmission control valve 162
Forward and reverse clutch ECMV and gear speed clutch ECMV 165
Lockup clutch ECMV 172
Differential lock clutch ECMV 176
Main relief valve, torque converter relief valve, and main flow selector valve 180
Axle 186
Differential 189
Final drive 193
Steering system 197
Layout of steering devices 197
Steering column 198
Flow amplifier valve 199
Steering valve 203
Emergency steering pump 209
Emergency steering motor 210
Brake system 211
Layout of brake parts 211
Parking brake solenoid and accumulator charge valve 213
Accumulator 219
Shut off solenoid valve 220
Brake valve 221
Proportional pressure reducing valve 226
Slack adjuster 228
Brake 232
Brake system tank 235
Parking brake 236
Undercarriage and frame 239
Suspension 239
Suspension cylinder 243
Oscillation hitch 246
Hydraulic system 247
Hydraulic component layout 247
Dump body control 249
Hydraulic tank 250
Steering and hoist pump 251
Hoist valve 261
Steering pump selector solenoid valve 267
Dump EPC valve 268
Center brake cooling remote motor 270
Front brake cooling relief valve 279
Center brake cooling relief valve 280
Cab and its attachments 281
ROPS cab 281
Cab tilt 282
Electrical system 283
Electrical control system 283
Machine monitor system 314
KOMTRAX system 337
System component parts 341
Sensor 375
20 Standard value tables 419
Table of contents 420
Standard service value table 421
Standard value table for engine 421
Standard value table for machine 424
30 Testing and adjusting 433
Table of contents 434
Precautions before work 436
Related information on testing and adjusting 437
Tools for testing and adjusting 437
Sketch of tools for testing and adjusting 442
Engine and cooling system 443
Testing engine speed 443
Testing boost pressure 444
Testing exhaust gas temperature 446
Testing exhaust gas color 448
Adjusting valve clearance 450
Testing compression pressure 452
Testing blowby pressure 454
Testing engine oil pressure 455
Testing fuel pressure 457
Handling cylinder cutout mode operation 458
Handling no‐injection cranking operation 459
Testing fuel return rate and leakage 460
Bleeding air from fuel system 462
Testing fuel circuit for leakage 464
Testing radiator fan and aftercooler fan speed 465
Testing and adjusting alternator belt tension 466
Testing and adjusting air conditioner compressor belt tension 467
Power train 468
Testing torque converter stall speed 468
Testing power train oil pressure 470
Adjusting transmission speed sensor 481
Adjusting transmission controller 484
Retrieval of disabled machine that resulted from a trouble in electrical system 485
Retrieval of disabled machine due to traction control system (KTCS) failure 489
Steering system 491
Testing and adjusting steering circuit oil pressure 491
Bleed air from the steering cylinder circuit 493
Testing and adjusting articulate angle sensor 495
Brake system 497
Testing and adjusting brake oil pressure 497
Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas 501
Testing braking performance 509
Releasing remaining pressure in brake circuit 510
Bleeding air from brake circuit 512
Testing wear of wheel brake disc 513
Parking brake emergency releasing procedure 514
Testing wear of parking brake pad and adjusting clearance 515
Hydraulic system 517
Testing and adjusting suspension cylinder 517
Testing and adjusting dump circuit oil pressure 522
Work equipment 525
Adjusting dump body positioner sensor 525
Cab and its attachments 527
Cab tilt up procedure 527
Adjusting steering wheel tilt locklever 531
Electrical system 533
Setting and adjusting each equipment 533
Special functions of machine monitor 544
KOMTRAX terminal start-up procedure 608
Adjusting optical axis of headlamps 612
Handling voltage circuit of engine controller 616
Handling battery disconnect switch 617
Pm clinic 618
Pm Clinic service 618
40 Troubleshooting 625
Table of contents 626
Precautions before work 634
Related information on troubleshooting 636
Troubleshooting points 636
Sequence of events in troubleshooting 638
Check before troubleshooting 640
Inspection procedure before troubleshooting 642
Preparation for troubleshooting of electrical system 651
Classification and procedures for troubleshooting 657
Symptom and troubleshooting numbers 660
Information in troubleshooting table 662
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit 664
Connector list and layout 667
Connector contact identification 683
T-branch box and T-branch adapter table 719
Fuse location table 724
Precautions on troubleshooting of machine monitor 728
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 730
Failure codes table 735
Troubleshooting by failure code (Display of code) 749
Failure code [1500L0] Double Engagement of T/M Clutches 749
Failure code [15B0NX] Transmission Oil Filter Clogging 750
Failure code [15F0KM] Abuse 1 of Gear Shifting from R to F 751
Failure code [15F0MB] Abuse 2 of Gear Shifting from R to F 752
Failure code [15F7KM] Abuse of TM Forward Clutch Disk 753
Failure code [15G0MW] Failure of Clutch (Reverse) 754
Failure code [15G7KM] Abuse of TM Reverse Clutch Disk 757
Failure code [15H0MW] Failure of Clutch (High) 758
Failure code [15J0MW] Failure of Clutch (Low) 761
Failure code [15K0MW] Failure of Clutch (1st) 764
Failure code [15L0MW] Failure of Clutch (2nd) 767
Failure code [15M0MW] Failure of Clutch (3rd) 770
Failure code [15SBL1] Release Trouble of ECMV (Reverse) 773
Failure code [15SBMA] Malfunction of ECMV (Reverse) 776
Failure code [15SCL1] Release Trouble of ECMV (High) 777
Failure code [15SCMA] Malfunction of ECMV (High) 780
Failure code [15SDL1] Release Trouble of ECMV (Low) 781
Failure code [15SDMA] Malfunction of ECMV (Low) 784
Failure code [15SEL1] Release Trouble of ECMV (1st) 785
Failure code [15SEMA] Malfunction of ECMV (1st) 788
Failure code [15SFL1] Release Trouble of ECMV (2nd) 789
Failure code [15SFMA] Malfunction of ECMV (2nd) 792
Failure code [15SGL1] Release Trouble of ECMV (3rd) 793
Failure code [15SGMA] Malfunction of ECMV (3rd) 796
Failure code [15SJMA] Malfunction of ECMV (Lockup) 797
Failure code [15SKMA] Malfunction of ECMV (Inter-Axle Diff) 799
Failure code [2F00KM] Dragging of Parking Brake 801
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 803
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 804
Failure code [879AKA] A/C Inner Sensor Open Circuit 805
Failure code [879AKB] A/C Inner Sensor Short Circuit 806
Failure code [879BKA] A/C Outer Sensor Open Circuit 807
Failure code [879BKB] A/C Outer Sensor Short Circuit 808
Failure code [879CKA] Ventilating Sensor Open Circuit 809
Failure code [879CKB] Ventilating Sensor Short Circuit 810
Failure code [879EMC] Ventilation Damper Abnormality 811
Failure code [879FMC] Air Mix Damper Abnormality 812
Failure code [879GKX] Refrigerant Abnormality 813
Failure code [989D00] Tilt Caution 814
Failure code [989L00] Engine Controller Lock Caution1 815
Failure code [989M00] Engine Controller Lock Caution2 816
Failure code [989N00] Engine Controller Lock Caution3 817
Failure code [AA10NX] Air Cleaner Clogging 818
Failure code [AB00KE] Charge Voltage Low 820
Failure code [AB00KY] Hot Short of Alternator R Terminal 821
Failure code [B@BAZG] Eng Oil Press Low 822
Failure code [B@BAZK] Engine Oil Level Low 823
Failure code [B@BCNS] Eng Water Overheat 824
Failure code [B@BCZK] Eng Water Level Low 825
Failure code [B@C6NS] Retarder Oil Overheat (Front) 827
Failure code [B@C8NS] Retarder Oil Overheat (Center) 828
Failure code [B@CENS] T/C Oil Temp Overheat 829
Failure code [B@JANS] Steering Oil Overheat 830
Failure code [CA111] ECM Critical Internal Failure 831
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 832
Failure code [CA122] Chg Air Press Sensor High Error 833
Failure code [CA123] Chg Air Press Sensor Low Error 835
Failure code [CA131] Throttle Sensor High Error 837
Failure code [CA132] Throttle Sensor Low Error 839
Failure code [CA135] Eng Oil Press Sensor High Error 841
Failure code [CA141] Eng Oil Press Sensor Low Error 843
Failure code [CA144] Coolant Temp Sens High Error 845
Failure code [CA145] Coolant Temp Sens Low Error 847
Failure code [CA153] Chg Air Temp Sensor High Error 849
Failure code [CA154] Chg Air Temp Sensor Low Error 851
Failure code [CA187] Sensor 2 Supply Volt Low Error 853
Failure code [CA221] Ambient Press Sensor High Error 855
Failure code [CA222] Ambient Press Sensor Low Error 857
Failure code [CA227] Sensor 2 Supply Volt High Error 859
Failure code [CA234] Eng Overspeed 860
Failure code [CA238] Ne Speed Sensor Supply Volt Error 861
Failure code [CA263] Fuel Temp Sensor High Error 862
Failure code [CA265] Fuel Temp Sensor Low Error 864
Failure code [CA271] IMV/PCV1 Short Error 866
Failure code [CA272] IMV/PCV1 Open Error 867
Failure code [CA273] PCV2 Short Error 868
Failure code [CA274] PCV2 Open Error 869
Failure code [CA322] Inj #1(L#1) Open/Short Error 870
Failure code [CA323] Inj #5(L#5) Open/Short Error 872
Failure code [CA324] Inj #3(L#3) Open/Short Error 874
Failure code [CA325] Inj #6(L#6) Open/Short Error 876
Failure code [CA331] Inj #2(L#2) Open/Short Error 878
Failure code [CA332] Inj #4(L#4) Open/Short Error 880
Failure code [CA342] Calibration Code Incompatibility 882
Failure code [CA351] Injectors Drive Circuit Error 883
Failure code [CA352] Sensor 1 Supply Volt Low Error 884
Failure code [CA386] Sensor 1 Supply Volt High Error 886
Failure code [CA431] Idle Validation Sw Error 887
Failure code [CA432] Idle Validation Process Error 890
Failure code [CA441] Battery Voltage Low Error 893
Failure code [CA442] Battery Voltage High Error 895
Failure code [CA449] Rail Press Very High Error 896
Failure code [CA451] Rail Press Sensor High Error 897
Failure code [CA452] Rail Press Sensor Low Error 899
Failure code [CA553] Rail Press High Error 901
Failure code [CA554] Rail Press Sensor In Range Error 902
Failure code [CA559] Rail Press Low Error 903
Failure code [CA689] Eng Ne Speed Sensor Error 907
Failure code [CA731] Eng Bkup Speed Sens Phase Error 909
Failure code [CA757] All Continuous Data Lost Error 910
Failure code [CA778] Eng Bkup Speed Sensor Error 911
Failure code [CA2185] Throt Sensor Sup Volt High Error 913
Failure code [CA2186] Throt Sensor Sup Volt Low Error 915
Failure code [CA2249] Rail Press Very Low Error 917
Failure code [CA2555] Grid Htr Relay Volt Low Error 918
Failure code [CA2556] Grid Htr Relay Volt High Error 920
Failure code [D150KB] Ground Fault of Emerg Steering Relay 922
Failure code [D150KZ] Failure of Emerg Steering Relay 923
Failure code [D151KB] Ground Fault of Emerg Steering Relay 2 924
Failure code [D151KZ] Failure of Emerg Steering Relay 2 925
Failure code [D164KY] Hot Short of Head Light High Selector 926
Failure code [D19HKZ] Failure of Stop Lamp (R&L) 927
Failure code [D19JKZ] Personal Code Relay Abnormality 929
Failure code [D1EHKA] Disconnection of Engine Start Relay 930
Failure code [D1EHKB] Ground Fault of Engine Start Relay 931
Failure code [D1EHKY] Hot Short of Engine Start Relay 932
Failure code [D1EMKA] Disconnection of Parking Interlock Relay 933
Failure code [D1EMKB] Ground Fault of Parking Interlock Relay 934
Failure code [D1EMKY] Hot Short of Parking Interlock Relay 935
Failure code [D1FBKB] Ground Fault of Sol Self-Holding Relay 936
Failure code [D5ZHL6] Disconnection of Key SW C 937
Failure code [D811MC] KOMTRAX Error 939
Failure code [D862KA] GPS Antenna Open Circuit 940
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 941
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 943
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 945
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 946
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) 947
Failure code [DAF0MB] Monitor ROM Abnormality 948
Failure code [DAF0MC] Monitor Error 949
Failure code [DAF3KK] Controller Power Source Low (MON) 950
Failure code [DAF8KB] Camera Power Supply Short Circuit 952
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit 953
Failure code [DAFGMC] GPS Module Error 955
Failure code [DAFLKA] Operating Lamp Open Circuit (MON) 956
Failure code [DAFLKB] Operating Lamp Short Circuit (MON) 958
Failure code [DAFQKR] CAN2 Discon (Monitor) 960
Failure code [DAQ0KK] Controller Power Source Low (T/M) 961
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) 963
Failure code [DAQ0MC] T/M Con Error 964
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) 965
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) 967
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) 969
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) 970
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) 972
Failure code [DAQQKR] CAN2 Discon (Transmission Con) 974
Failure code [DAQRKR] CAN1 Discon (Transmission Con) 975
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) 979
Failure code [DAQV00] Neutral Coast Caution 980
Failure code [DAQW00] Neutral Over Speed Caution 981
Failure code [DAZ9KQ] A/C Model Selection Abnormality 982
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 983
Failure code [DB10KT] Abnormality of Non-volatile Memory (RHC) 984
Failure code [DB10MC] RHC Error 985
Failure code [DB11KA] Disconnection of Key SW ACC (RHC) 986
Failure code [DB12KK] Solenoid Power Source Low (RHC) 988
Failure code [DB13KK] Controller Power Source Low (RHC) 990
Failure code [DB19KQ] Inconsistency of Model Selection (RHC) 992
Failure code [DB1LKA] Disconnection of System Ope Lamp (RHC) 993
Failure code [DB1LKB] Short Circuit of System Ope Lamp (RHC) 995
Failure code [DB1QKR] CAN2 Discon (Retarder Hoist Con) 997
Failure code [DB1QMA] Inconsistency of Option Selection (RHC) ( 998
Failure code [DB1RKR] CAN1 Discon (Retarder Hoist Con) 999
Failure code [DB1Z00] Rollover Caution1000
Failure code [DB1ZKM] Occurrence of Large Lateral Acceleration1001
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1002
Failure code [DB2QKR] CAN2 Discon (Engine Con) (Machine with payload meter controller: CR720)1007
Failure code [DBSQKQ] Inconsistency of Model Selection (PLM) 1013
Failure code [DBSQKR] CAN2 Discon (PLM) 1014
Failure code [DBSQKR] CAN2 Discon (PLM) (Machine with payload meter controller: CR720)1018
Failure code [DD1ML4] Failure of ARAC SW 1022
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch 1025
Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No: 8001 to 82031027
Failure code [DDTHKA] Disconnection of Fill Switch (High) Serial No: 8204 and up1029
Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No: 8001 to 82031031
Failure code [DDTJKA] Disconnection of Fill Switch (Low) Serial No: 8204 and up1033
Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No: 8001 to 82031035
Failure code [DDTKKA] Disconnection of Fill Switch (1st) Serial No: 8204 and up1037
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No: 8001 to 82031039
Failure code [DDTLKA] Disconnection of Fill Switch (2nd) Serial No: 8204 and up1041
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No: 8001 to 82031043
Failure code [DDTMKA] Disconnection of Fill Switch (3rd) Serial No: 8204 and up1045
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No: 8001 to 82031047
Failure code [DDTNKA] Disconnection of Fill Switch (Reverse) Serial No: 8204 and up1049
Failure code [DF10KA] Disconnection of Shift Lever Input 1051
Failure code [DF10KB] Ground Fault of Shift Lever Input 1054
Failure code [DGF1KX] Out of Range of T/M Oil Temp Sensor 1058
Failure code [DGR3KB] Ground Fault of Retarder Oil Temp S(C) 1060
Failure code [DGR3L8] Failure of Retarder Oil Temp Sensor (C) 1061
Failure code [DGR4KB] Ground Fault of Retarder Oil Temp S(F) 1062
Failure code [DGR4L8] Failure of Retarder Oil Temp Sensor (F) 1063
Failure code [DGR6KB] Ground Fault of Steering Oil Temp S 1065
Failure code [DGR6L8] Failure of Steering Oil Temp Sensor 1066
Failure code [DGR7KX] Out of Range of Piston Pump Oil Temp S 1068
Failure code [DGR8KX] Out of Range of CAC Output Temp S 1070
Failure code [DGT1KX] Out of Range of T/C Oil Temp Sensor 1072
Failure code [DHP4KY] Hot Short of Suspension Press S (FR) 1074
Failure code [DHP4KY] Hot Short of Suspension Press S (FR) (Machine with payload meter controller: CR720)1076
Failure code [DHP4KZ] Failure of Suspension Press S (FR) 1078
Failure code [DHP4KZ] Failure of Suspension Press S (FR) (Machine with payload meter controller: CR720)1080
Failure code [DHP5KY] Hot Short of Suspension Press S (FL) 1082
Failure code [DHP5KY] Hot Short of Suspension Press S (FL) (Machine with payload meter controller: CR720)1084
Failure code [DHP5KZ] Failure of Suspension Press S (FL) 1086
Failure code [DHP5KZ] Failure of Suspension Press S (FL) (Machine with payload meter controller: CR720)1088
Failure code [DHP6KY] Hot Short of Suspension Press S (RR) 1090
Failure code [DHP6KY] Hot Short of Suspension Press S (RR) (Machine with payload meter controller: CR720)1092
Failure code [DHP6KZ] Failure of Suspension Press S (RR) 1094
Failure code [DHP6KZ] Failure of Suspension Press S (RR) (Machine with payload meter controller: CR720)1096
Failure code [DHP7KY] Hot Short of Suspension Press S (RL) 1098
Failure code [DHP7KY] Hot Short of Suspension Press S (RL) (Machine with payload meter controller: CR720)1100
Failure code [DHP7KZ] Failure of Suspension Press S (RL) 1102
Failure code [DHP7KZ] Failure of Suspension Press S (RL) (Machine with payload meter controller: CR720)1104
Failure code [DHQ2KX] Out of Range of Main Flow Sel Valve S 1106
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor 1108
Failure code [DHT5L6] Failure of T/C Oil Press Sensor 1110
Failure code [DHT8KX] Out of Range of Steering Oil Press S 1112
Failure code [DHT8ZG] Steering Oil Pressure Low 1114
Failure code [DHU2KX] Out of Range of Acc Oil Press S (F) 1115
Failure code [DHU3KX] Out of Range of Acc Oil Press S (R) 1117
Failure code [DHUAKX] Out of Range of Retarder Press S (CR) 1119
Failure code [DHUBKX] Out of Range of Retarder Press S (FR) 1121
Failure code [DHUCKX] Out of Range of Parking Brake Press S1123
Failure code [DHUDKX] Out of Range of Emerg Steering Press S1 1125
Failure code [DHUEKX] Out of Range of Emerg Steering Press S2 1127
Failure code [DHUQKX] Out of Range of Retarder Press S (FL) 1129
Failure code [DHURKX] Out of Range of Retarder Press S (CL) 1131
Failure code [DJF1KA] Disconnection of Fuel Level Sensor 1133
Failure code [DK30KX] Out of Range of Steering Angle Pot 1135
Failure code [DK51L5] Failure of Retarder Lever Pot and RVS 1137
Failure code [DK52KX] Out of Range of Hoist Lever Potentio 1140
Failure code [DK53L8] Failure of Hoist Lever Potentio 1142
Failure code [DK54KX] Out of Range of Body Potentio 1143
Failure code [DK60KX] Out of Range of Acceleration Sensor 1145
Failure code [DK80KT] IMU Internal Error1147
Failure code [DK80KR] CAN J1939 Communication Error (IMU)1148
Failure code [DKH0KX] Out of Range of Inclination Angle Sensor 1151
Failure code [DKH1KX] Out of Range of Long Inclination Angle S 1153
Failure code [DKH1KX] Out of Range of Long Inclination Angle S (Machine with payload meter controller: CR720)1155
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor 1157
Failure code [DLF1LC] Failure of T/M Input Speed Sensor 1159
Failure code [DLF2KA] Disconnection of T/M Inter Speed Sensor 1161
Failure code [DLF2LC] Failure of T/M Intermediate Speed Sensor 1163
Failure code [DLF400] T/M Diff Overrun Prevention Activated 1165
Failure code [DLF4KA] Disconnection of T/M Diff Speed Sensor 1166
Failure code [DLF4LC] Failure of T/M Diff Speed Sensor 1168
Failure code [DLF6LC] Failure of Wheel Speed Sensor (FR) 1170
Failure code [DLF7LC] Failure of Wheel Speed Sensor (FL) 1172
Failure code [DLFDLC] Failure of Wheel Speed Sensor (CR) 1174
Failure code [DLFELC] Failure of Wheel Speed Sensor (CL) 1176
Failure code [DLFFLC] Failure of Wheel Speed Sensor (Front) 1178
Failure code [DLFGLC] Failure of Wheel Speed Sensor (Center) 1179
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor 1180
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor 1182
Failure code [DLM3MB] Radiator Fan Control Mismatch 1184
Failure code [DLM4KA] Disconnection of CAC Fan Speed Sensor 1185
Failure code [DLM4LC] Failure of CAC Fan Speed Sensor 1187
Failure code [DLM4MB] CAC Fan Control Mismatch 1189
Failure code [DLT3KA] Disconnection of Output Speed Sens (Main) 1190
Failure code [DLT3LC] Failure of Output Speed Sensor (Main) 1192
Failure code [DPQ1KR] LIN Discon (Switch Panel) 1194
Failure code [DPQ2KR] LIN Discon (LED Unit) 1197
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) 1200
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) 1203
Failure code [DV00KB] Ground Fault of Buzzer Output 1204
Failure code [DW2BKA] Disconnection of Main Flow Selector Sol 1206
Failure code [DW2BKB] Ground Fault of Main Flow Selector Sol 1207
Failure code [DW2BKY] Hot Short of Main Flow Selector Sol 1208
Failure code [DW2BL1] Release Trouble of Main Flow Sel Valve 1209
Failure code [DW2BLH] Malfunction of Main Flow Selector Valve 1210
Failure code [DW4BK4] Release Trouble of Parking Brake Valve 1211
Failure code [DW4BMA] Malfunction of Parking Brake Valve 1213
Failure code [DW72KZ] Failure of Kick out Solenoid 1214
Failure code [DW73KA] Disconnection of Hoist Selector Sol 1216
Failure code [DW73KB] Ground Fault of Hoist Selector Sol 1218
Failure code [DW73KY] Hot Short of Hoist Selector Sol 1220
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev Sol 1222
Failure code [DW7BKY] Hot Short of Radiator Fan Rev Sol 1224
Failure code [DW7BKZ] Failure of Radiator Fan Rev Sol 1225
Failure code [DW7LKB] Ground Fault of CAC Fan Rev Sol 1227
Failure code [DW7LKY] Hot Short of CAC Fan Rev Sol 1228
Failure code [DW7LKZ] Failure of CAC Fan Rev Sol 1229
Failure code [DW7NKZ] Failure of Steering Pump Selector Sol 1230
Failure code [DWNJKZ] Failure of TCS Shut off Sol (Front) 1232
Failure code [DWNKKZ] Failure of TCS Shut off Sol (Center) 1234
Failure code [DX13KA] Disconnection of Hoist EPC Solenoid 1236
Failure code [DX13KB] Ground Fault of Hoist EPC Solenoid 1238
Failure code [DX13KY] Hot Short of Hoist EPC Solenoid 1240
Failure code [DX16KA] Disconnection of Rad Fan Pump EPC Sol 1242
Failure code [DX16KB] Ground Fault of Rad Fan Pump EPC Sol 1243
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol 1245
Failure code [DX29KA] Disconnection of CAC Fan Pump EPC Sol 1246
Failure code [DX29KB] Ground Fault of CAC Fan Pump EPC Sol 1247
Failure code [DX29KY] Hot Short of CAC Fan Pump EPC Sol 1248
Failure code [DX30K4] Release Trouble of Retarder EPC Valve(FL) 1249
Failure code [DX30KA] Disconnection of Retarder EPC Sol (FL) 1251
Failure code [DX30KB] Ground Fault of Retarder EPC Sol (FL) 1253
Failure code [DX30KY] Hot Short of Retarder EPC Sol (FL) 1255
Failure code [DX30MA] Malfunction of Retarder EPC Valve (FL) 1257
Failure code [DX31K4] Release Trouble of Retarder EPC Valve(CR) 1259
Failure code [DX31KA] Disconnection of Retarder EPC Sol (CR) 1261
Failure code [DX31KB] Ground Fault of Retarder EPC Sol (CR) 1263
Failure code [DX31KY] Hot Short of Retarder EPC Sol (CR) 1265
Failure code [DX31MA] Malfunction of Retarder Valve (CR) 1267
Failure code [DX32K4] Release Trouble of Retarder EPC Valve(CL) 1269
Failure code [DX32KA] Disconnection of Retarder EPC Sol (CL) 1271
Failure code [DX32KB] Ground Fault of Retarder EPC Sol (CL) 1273
Failure code [DX32KY] Hot Short of Retarder EPC Sol (CL) 1275
Failure code [DX32MA] Malfunction of Retarder EPC Valve (CL) 1277
Failure code [DX33K4] Release Trouble of Retarder EPC Valve (FR) 1279
Failure code [DX33KA] Disconnection of Retarder EPC Sol (FR) 1281
Failure code [DX33KB] Ground Fault of Retarder EPC Sol (FR) 1283
Failure code [DX33KY] Hot Short of Retarder EPC Sol (FR) 1285
Failure code [DX33MA] Malfunction of Retarder EPC Valve (FR) 1287
Failure code [DX34KA] Disconnection of Remote Cooling EPC Sol 1289
Failure code [DX34KB] Ground Fault of Remote Cooling EPC Sol 1290
Failure code [DX34KY] Hot Short of Remote Cooling EPC Sol 1292
Failure code [DXH0KA] Disconnection of ECMV (Inter-Axle Diff) 1293
Failure code [DXH0KB] Ground Fault of ECMV (Inter-Axle Diff) 1295
Failure code [DXH0KY] Hot Short of ECMV (Inter-Axle Diff) 1297
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) 1299
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) 1301
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) 1303
Failure code [DXH2KA] Disconnection of ECMV Solenoid (High) 1305
Failure code [DXH2KB] Ground Fault of ECMV Solenoid (High) 1307
Failure code [DXH2KY] Hot Short of ECMV Solenoid (High) 1309
Failure code [DXH3KA] Disconnection of ECMV Solenoid (Low) 1310
Failure code [DXH3KB] Ground Fault of ECMV Solenoid (Low) 1312
Failure code [DXH3KY] Hot Short of ECMV Solenoid (Low) 1314
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) 1317
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) 1319
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) 1321
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) 1324
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) 1326
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) 1328
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) 1331
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) 1333
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) 1335
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse) 1338
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) 1340
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) 1342
Failure code [DY30MA] Malfunction 1 of Emerg Steering Motor 1345
Failure code [DY30MC] Malfunction 2 of Emerg Steering Motor 1348
Failure code [DY30ME] Emerg Steering Long-Time Activated 1351
Failure code [DY32MC] Malfunction 2 of Emerg Steering Motor 2 1353
Troubleshooting of electrical system (E-mode) 1356
E-1 Engine does not start (Engine does not crank) 1356
E-2 Manual preheating system does not work 1361
E-3 Automatic preheating system does not work 1364
E-4 While preheating is working, preheating monitor does not light up 1366
E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing 1368
E-6 LCD unit on machine monitor displays nothing 1371
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) 1373
E-8 LCD on machine monitor does not display properly 1375
E-9 Meter unit display on machine monitor is abnormal 1377
E-10 Night lighting lamp of meter unit on machine monitor is abnormal 1380
E-11 LED unit lamp on machine monitor is abnormal 1383
E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly 1385
E-13 2 switches operation of switch panel on machine monitor does not function 1387
E-14 Switch panel buzzer of machine monitor is abnormal 1389
E-15 Some items of gauges and caution lamps on machine monitor are not displayed properly 1391
E-16 Fuel level gauge does not indicate correct level 1392
E-17 Seat belt caution lamp indication is abnormal 1394
E-18 Machine monitor cannot be operated when starting switch is in OFF position 1395
E-19 Alarm buzzer does not sound 1396
E-20 Alarm buzzer does not stop sounding 1398
E-21 Engine mode selector function does not operate properly 1400
E-22 AISS function does not operate properly 1401
E-23 Hoist lever does not operate properly 1402
E-24 Turn signal lamp and winker lamp (hazard lamp) do not operate properly 1404
E-25 All of small lamp (clearance lamp and tail lamp) and head lamp do not light up 1408
E-26 Small lamp (clearance lamp) does not light up 1410
E-27 Tail lamp does not light up 1412
E-28 Low beam head lamp does not light up 1414
E-29 High beam head lamp does not light up 1416
E-30 Neither Low beam nor High beam head lamps lights up 1418
E-31 High beams do not light up while passing switch is operated 1420
E-32 KOMTRAX does not operate properly 1422
Troubleshooting of hydraulic and mechanical system (H-mode) 1423
Information described in troubleshooting table (H-mode) 1423
System chart of hydraulic and mechanical systems 1424
Failure mode and cause table 1426
H-1 Machine does not start 1430
H-2 Machine does not travel smoothly (engine hunts) 1432
H-3 Lockup clutch is not disengaged 1433
H-4 Abnormally large shocks result from starting of machine and gear shifting 1434
H-5 Machine does not upshift 1435
H-6 Machine lacks travel speed or power during travel in lockup drive mode through all gear speeds 1437
H-7 Machine lacks travel speed or power during travel in torque converter drive mode 1438
H-8 Machine lacks travel speed or power during travel in specific gear speed 1439
H-9 Machine starts or gear speed shifts with long time lag 1440
H-10 Torque converter oil temperature is high 1442
H-11 Torque converter oil pressure is low 1443
H-12 Front brake does not work sufficiently 1444
H-13 Center brake does not work sufficiently 1445
H-14 Steering wheel is heavy to turn 1446
H-15 Steering wheel does not move 1447
H-16 Steering wheel swings 1448
H-17 Dump body raise speed or power is slow 1449
H-18 Dump body does not move 1451
H-19 Hydraulic drift of dump body is large 1452
H-20 Radiator fan speed is abnormal (high, low, or stationary) 1453
H-21 Aftercooler fan speed is abnormal (high, low, or stationary) 1454
H-22 Unusual noise is heard from around radiator fan 1455
H-23 Unusual noise is heard from around aftercooler fan 1456
Troubleshooting of engine (S-mode) 1457
Information mentioned in troubleshooting table (S mode) 1457
S-1 Engine does not crank when starting switch is turned to START position 1458
S-2 The engine cranks but exhaust smoke does not come out 1459
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) 1460
S-4 Engine startability is poor 1461
S-5 Engine does not pick up smoothly 1463
S-6 Engine stops during operation 1465
S-7 Engine runs rough or is unstable 1467
S-8 Engine lacks power 1468
S-9 Exhaust smoke is black 1470
S-10 Engine oil consumption is excessive 1472
S-11 Oil becomes contaminated quickly 1473
S-12 Fuel consumption is excessive 1474
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1475
S-14 Oil pressure drops 1476
S-15 Fuel mixes into engine oil 1477
S-16 Water mixes into engine oil (milky) 1478
S-17 Coolant temperature rises too high (overheating) 1479
S-18 Unusual noise is heard 1480
S-19 Vibration is excessive 1481
S-20 Air cannot be bled from fuel circuit 1482
50 Disassembly and assembly 1483
Table of contents 1484
Precautions before work1486
Related information on disassembly and assembly1488
How to read this manual1488
Coating materials list1490
Special tools list1495
Sketches of special tools1517
Engine and cooling system1541
Removal and installation of supply pump assembly1541
Removal and installation of injector assembly1547
Removal and installation of cylinder head assembly1558
Removal and installation of radiator assembly1577
Removal and installation of radiator core assembly1586
Removal and installation of cooling fan and fan motor assembly for radiator1589
Removal and installation of aftercooler assembly1593
Removal and installation of cooling fan and fan motor assembly foraftercooler1600
Removal and installation of engine assembly1603
Removal and installation of engine front oil seal1618
Removal and installation of engine rear oil seal1624
Removal and installation of output shaft assembly1634
Disassembly and assembly of output shaft assembly1643
Removal and installation of air cleaner assembly1646
Removal and installation of fire prevention cover on exhaust pipe1649
Power train1654
Removal and installation of transmission and front differential assembly1654
Disconnection and connection of front differential assembly andtransmission assembly1676
Disassembly and assembly of front differential assembly1679
Disassembly and assembly of torque converter assembly1714
Disassembly and assembly of transmission assembly1725
Removal and installation of center differential assembly1789
Disassembly and assembly of center differential assembly1795
Removal and installation of rear differential assembly1829
Disassembly and assembly of rear differential assembly1833
Removal and installation of front final drive and brake assembly1852
Disassembly and assembly of front final drive and brake assembly1856
Removal and installation of center final drive and brake assembly1889
Disassembly and assembly of center final drive and brake assembly1894
Removal and installation of rear final drive assembly1923
Disassembly and assembly of rear final drive assembly1928
Removal and installation of center axle assembly1937
Removal and installation of rear axle assembly1943
Steering system1947
Disassembly and assembly of steering cylinder assembly1947
Undercarriage and frame1956
Removal and installation of front suspension cylinder assembly1956
Removal and installation of rear suspension cylinder assembly1958
Disassembly and assembly of suspension cylinder assembly1960
Removal and installation of equalizer bar assembly1962
Removal and installation of front wheel assembly1966
Removal and installation of rear (front side) wheel assembly1973
Removal and installation of rear (rear side) wheel assembly1974
Removal and installation of hitch frame assembly1975
Disassembly and assembly of hitch frame assembly1987
Hydraulic system1993
Removal and installation of flow amplifier valve assembly1993
Removal and installation of hoist valve assembly1999
Disassembly and assembly of hoist valve assembly2006
Disassembly and assembly of hoist cylinder assembly2009
Disassembly and assembly of hoist cylinder assembly2017
Body2025
Removal and installation of dump body assembly2025
Cab and its attachments2029
Removal and installation of operator’s cab assembly2029
Removal and installation of operator’s cab glass (adhered glass)2035
Removal and installation of operator’s seat assembly2043
Removal and installation of seat belt2045
Electrical system2047
Removal and installation of machine monitor assembly2047
Removal and installation of engine controller assembly2050
Removal and installation of retarder and hoist controller assembly2053
Removal and installation of transmission controller assembly2055
Removal and installation of KOMTRAX terminal assembly2057
Air conditioner system2059
Removal and installation of air conditioner unit assembly2059
Removal and installation of air conditioner compressor assembly2068
Removal and installation of air conditioner condenser2071
60 Maintenance standard 2073
Table of contents 2074
Engine and cooling system 2075
Engine mount 2075
Output shaft 2076
Radiator fan pump 2077
Aftercooler fan motor 2079
Radiator fan motor 2081
Power train 2082
Drive shaft 2082
Torque converter and transmission mount 2084
Torque converter 2085
Transmission 2088
Transmission control valve 2096
Forward and reverse clutch ECMV and gear speed clutch ECMV 2097
Lockup clutch ECMV 2098
Differential lock clutch ECMV 2099
Main relief valve, torque converter relief valve, and main flow selector valve 2100
Differential 2102
Axle 2105
Final drive 2107
Steering system 2112
Steering column 2112
Steering cylinder 2113
Emergency steering pump 2114
Brake system 2115
Slack adjuster 2115
Brake 2117
Parking brake 2120
Undercarriage and frame 2122
Suspension 2122
Suspension cylinder 2126
Oscillation hitch 2128
Hydraulic system 2130
Steering and hoist pump 2130
Pump for driving torque converter, transmission, aftercooler fan, and center brake cooling motors 2133
Center brake cooling pump 2135
Brake charge pump 2136
Center brake cooling remote pump 2137
Center brake cooling remote motor 2138
Hoist valve 2140
Hoist cylinder 2142
80 Appendix 2143
Table of contents 2144
Precautions before work2145
Air conditioner components 2147
Precautions for refrigerant 2147
Air conditioner component 2148
Configuration and function of refrigeration cycle 2151
Air conditioner unit 2154
Dual pressure switch 2159
Air conditioner controller 2160
Compressor 2161
Condenser 2162
Receiver drier 2163
Outer temperature sensor (outside air temperature sensor) 2164
Procedure for testing and troubleshooting 2165
Circuit diagram and arrangement of connector pins 2167
System diagram 2169
Input and output signals of the air conditioner controller 2170
Parts and connectors layout 2172
Testing air leakage (duct) 2177
Testing with self-diagnosis function 2180
How to open the electrical system abnormality record screen in service mode of the machine monitor 2181
Testing vent (mode) changeover 2183
Testing FRESH/RECIRC air changeover 2184
Testing (dual) pressure switch for refrigerant 2185
Testing relays 2187
Troubleshooting chart 1 2189
Troubleshooting chart 2 2190
Information in troubleshooting table 2193
Failure code list related to air conditioner 2194
Failure code [879AKA] A/C Inner sensor Open Circuit 2195
Failure code [879AKB] A/C Inner sensor Short Circuit 2196
Failure code [879BKA] A/C Outer sensor Open Circuit 2197
Failure code [879BKB] A/C Outer sensor Short Circuit 2199
Failure code [879CKA] Ventilating sensor Open Circuit 2201
Failure code [879CKB] Ventilating sensor Short Circuit 2202
Failure code [879EMC] Ventilating Damper Abnormality 2203
Failure code [879FMC] Air Mix Damper Abnormality 2204
Failure code [879GKX] Refrigerant Abnormality 2205
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 2207
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 2209
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2212
A-4 Troubleshooting for FRESH/RECIRC air changeover 2214
Troubleshooting with gauge pressure 2216
Connection of service tool 2219
Precautions for disconnecting and connecting air conditioner piping 2221
Handling of compressor oil 2223
90 Diagrams and drawings 2225
Table of contents 2226
Hydraulic circuit diagram 2227
Symbols in hydraulic circuit diagram 2227
Power train hydraulic circuit diagram2231
Hydraulic circuit diagram 2233
Electric circuit diagram 2235
Symbols in electric circuit diagram 2235
Inside cab electrical circuit diagram (Serial No: 8001 to 8203)2239
Inside cab electrical circuit diagram (Serial No: 8204 and up)2255
Inside cab electrical circuit diagram (Machine with payload meter controller: CR720)2271
Outside cab electrical circuit diagram 2287
Electrical circuit diagram of engine 2301
INDEX2303

S.M 29/12/24