Komatsu HM300-5 Dump Truck Shop Manual SEN06511-24 PDF

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Komatsu HM300-5 Dump Truck Shop Manual SEN06511-24 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HM300-5 Dump Truck Shop Manual SEN06511-24 – PDF DOWNLOAD 

Language : English
Pages : 3506
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM300-5 Dump Truck Shop Manual SEN06511-24 – PDF DOWNLOAD 

SERIAL NUMBERS 10001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 25
Foreword, Safety, Basic Information 31
How to Read the Shop Manual 31
Safety Notice for Operation 33
Precautions to Prevent Fire 41
Procedures If Fire Occurs 43
Precautions for Disposing of Waste Materials 44
Procedures for Exhaust Gas Regulations 45
Precautions for DEF 46
General Character and Precautions for Handling 46
Precautions for Adding 46
Precautions for Storage 46
Precautions for Fire Hazard and Leakage 46
Other Precautions 46
Store DEF 47
Precautions When You Handle Hydraulic Equipment 48
Precautions When You Disconnect and Connect Pipings 51
Precautions When You Handle Electrical Equipment 58
Precautions When You Handle Fuel System Equipment 60
Precautions When You Handle Intake System Equipment 61
Practical Use of KOMTRAX 62
Disconnect and Connect Push-Pull Type Coupler 63
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 63
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 64
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 65
Precautions for Disconnection and Connection of Connectors 67
How to Disconnect and Connect Deutsch Connector 71
How to Disconnect and Connect Slide Lock Type Connector 72
How to Disconnect and Connect Connector with Lock to Pull 74
How to Disconnect and Connect Connector with Lock to Push 75
How to Disconnect and Connect Connector with Housing to Rotate 77
How to Read the Codes for Electric Cable 78
Explanation of Terms for Maintenance Standard 82
Standard Tightening Torque Table 85
Conversion Table 92
01 Specifications 97
Table of Contents 98
Abbreviation List 99
Specifications 105
Specification Drawing 105
Specification Drawing: HM300-5 105
Specifications 107
Specifications: HM300-5 107
Weight Table 113
Weight Table: HM300-5 113
Table of Fuel, Coolant, and Lubricants 115
10 Structure and Function 117
Table of Contents 118
Abbreviation List 122
Urea SCR System 128
Layout Drawing of Urea SCR System 128
Urea SCR System Diagram 131
Function of Urea SCR System 132
Function of DEF System 132
Inducement Strategy 134
Component Parts of Urea SCR System 148
DEF Mixing Tube 148
SCR Assembly 148
DEF Tank 151
DEF Pump 153
DEF Injector 154
DEF Hose 155
DEF Tank Heating Valve 156
Boot-up System 157
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 157
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 159
System Operating Lamp System 161
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 161
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 162
Function of System Operating Lamp System (Machine with Gateway Function Controller) 162
Battery Disconnect Switch 164
Layout Drawing of Battery Disconnect Switch 164
Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal) 164
Function of Battery Disconnect Switch (Machine with Gateway Function Controller) 165
Engine System 166
Layout Drawing of Engine System 166
Function of Engine System 168
Automatic Idle Stop System 169
Function of Automatic Idle Stop System 169
Component Parts of Engine System 171
Damper 171
VGT 172
EGR System 176
EGR Valve 178
EGR Cooler 180
KCCV System 181
KCCV Ventilator 183
KDPF 185
Cooling System 189
Layout Drawing of Cooling System 189
Specifications of Cooling System 190
Radiator Fan Control System 192
Radiator Fan Control System Diagram 192
Function of Radiator Fan Control System 192
Aftercooler Fan Control System 194
Aftercooler Fan Control System Diagram 194
Function of Aftercooler Fan Control System 194
Component Parts of Cooling System 196
Radiator Fan Pump 196
Radiator Fan Motor 204
Aftercooler Fan Motor 209
Hydraulic Oil Cooler Bypass Valve 220
Control System 221
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 221
Layout Drawing of Control System (Machine with Gateway Function Controller) 223
Retarder and Hoist Control System 225
System Diagram of Retarder and Hoist Control System (Machine with KOMTRAX Terminal) 225
System Diagram of Retarder and Hoist Control System (Machine with Gateway Function Controller) 226
Machine Monitor System 227
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 227
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 228
Function of Machine Monitor System 229
Rearview Monitor System 230
System Diagram of Rearview Monitor System 230
Function of Rearview Monitor System 230
KOMTRAX System 231
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 231
Function of KOMTRAX System (Machine with KOMTRAX Terminal) 231
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 232
Function of KOMTRAX System (Machine with Gateway Function Controller) 232
Payload Meter System 233
Layout Drawing of Payload Meter System 233
System Diagram of Payload Meter (Machine with KOMTRAX Terminal) 234
System Diagram of Payload Meter (Machine with Gateway Function Controller) 235
Function of Payload Meter System 235
Measurement Principle of Loading Mass 236
Component Parts of Control System 247
Machine Monitor 247
Switch Panel 269
Rearview Monitor 270
Rearview Camera 272
KOMTRAX Terminal 273
Gateway Function Controller 275
Communication Terminal 278
Transmission Controller 280
Retarder and Hoist Controller 284
Monitor Controller 289
Engine Controller 294
Accelerator Pedal 301
Shift Lever 302
Retarder Control Lever 303
Fuel Feed Pump 304
Fuel Feed Pump Switch 305
Hydraulic System 306
Layout Drawing of Hydraulic System 306
Component Parts of Hydraulic System 308
Hydraulic Tank 308
Steering and Hoist Pump 309
LS Valve 317
PC Valve 318
Power Train and Front Brake Cooling Duplex Pump and Aftercooler Fan Pump 322
Hoist Valve 324
Power Train System 331
Layout Drawing of Power Train System 331
Transmission Control System 334
System Diagram of Transmission Control System (Machine with KOMTRAX Terminal) 334
System Diagram of Transmission Control System (Machine with Gateway Function Controller) 335
Shift Lever Positions and Automatic Gear Shift Range 336
Gear Shift Control System 340
Automatic Gear Shift Control of Gear Shift Control System 340
Shift Hold System 343
Function of Shift Hold System 343
Direction Control System 344
Rim Pull Limit Function for Overload Prevention of Direction Control System 344
Function of Throttle Limit Function at F1 Start at D Position Setting of Direction Control System 344
Komatsu Traction Control System (KTCS) 345
Komatsu Traction Control System (KTCS) System Diagram 345
Function of Komatsu Traction Control System (KTCS) 345
Operation of Komatsu Traction Control System (KTCS) System Logic 346
Component Parts of Power Train System 348
Drive Shaft 348
Torque Converter and PTO 350
Lockup Clutch ECMV 355
Transmission 358
Transmission Control Valve 380
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 382
Differential Lock Clutch ECMV 387
Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 390
Axle 394
Differential 397
Final Drive 401
Work Equipment System 405
Work Equipment Control 405
Layout Drawing of Work Equipment Control 405
Function of Work Equipment Control 406
Hoist Control 407
Hoist Control System Diagram 407
Function of Hoist Control 407
Component Parts of Work Equipment System 409
Hoist and Radiator Fan Direction Selector Solenoid Valve 409
Dump Lever 410
Dump EPC Valve 415
Steering System 417
Layout Drawing of Steering System 417
Function of Steering System 418
Steering Column 419
Structure of Steering Column 419
Component Parts of Steering System 420
Flow Amplifier Valve 420
Steering Valve 424
Steering Pump Selector Solenoid Valve 429
Secondary Steering Pump 430
Secondary Steering Motor 431
Brake System 432
Layout Drawing of Brake System 432
Retarder Control 433
Retarder Control System Diagram 433
Function of Retarder Control 434
Parking Brake Interlock Function 436
Function of Parking Brake Interlock Function 436
Operation of Parking Brake Interlock Function 436
ARAC System 437
ARAC System Diagram 437
Function of ARAC System 437
Component Parts of Brake System 438
Brake Charge Pump 438
Parking Brake Solenoid Valve and Accumulator Charge Valve 439
Parking Brake Solenoid Valve 440
Accumulator Charge Valve 440
Brake Circuit Accumulator 445
Shut Off Solenoid Valve 447
Brake Valve 448
Proportional Pressure Reducing Valve 451
Slack Adjuster 452
Brake 455
Brake Cooling Oil Control Valve 458
Front Brake Cooling Relief Valve 460
Brake System Tank 461
Parking Brake 462
Spring Cylinder 463
Parking Brake Caliper 465
Undercarriage and Frame 467
Front Suspension 467
Structure of Front Suspension 467
Function of Front Suspension 468
Center and Rear Suspensions 469
Structure of Center and Rear Suspensions 469
Function of Center Suspension 470
Function of Rear Suspension 471
Suspension Cylinder 472
Structure of Suspension Cylinder 472
Function of Suspension Cylinder 473
Operation of Suspension Cylinder 474
Oscillation Hitch 475
Structure of Oscillation Hitch 475
Function of Oscillation Hitch 476
Work Equipment 477
Structure of Work Equipment 477
Function of Work Equipment 478
CAB Related Parts 479
ROPS CAB 479
Structure of ROPS CAB 479
Function of ROPS CAB 480
CAB Tilt 481
Structure of CAB Tilt 481
20 Standard Value Table 483
Table of Contents 484
Abbreviation List 485
Standard Value Table for Engine 491
Standard Value Table for Engine: HM300-5 491
Standard Value Table for Machine 495
Standard Value Table for Machine: HM300-5 495
Machine Posture and Procedures to Measure Performance 509
Standard Value Table for Electricity 510
Standard Value Table for Electricity 510
30 Testing and Adjusting 525
Table of Contents 526
Precautions Before Work 529
Abbreviation List 530
Related Information on Testing and Adjusting 536
Tools for Testing and Adjusting 536
Sketch of Tools for Testing and Adjusting 544
Engine and Cooling System 545
Examine Engine Speed 545
How to Examine Engine Speed 545
Examine Boost Pressure 548
How to Examine Boost Pressure 548
Examine Exhaust Gas Temperature 550
How to Examine Exhaust Gas Temperature 550
Examine Exhaust Gas Color 553
How to Examine Exhaust Gas Color with the Handy Smoke Checker 553
How to Examine Exhaust Gas Color with Smoke Meter 554
Examine Mass Air Flow and Temperature Sensor 556
How to Examine Mass Air Flow and Temperature Sensor 556
Examine and Adjust Valve Clearance 559
How to Examine Valve Clearance 559
How to Adjust Valve Clearance 560
Examine Compression Pressure 562
How to Examine Compression Pressure 562
Examine Blowby Pressure 565
How to Examine Blowby Pressure 565
Examine Engine Oil Pressure 568
How to Examine Engine Oil Pressure on Machine Monitor 568
How to Examine Engine Oil Pressure by Testing Tool 568
Examine EGR Valve and VGT Oil Pressure 570
How to Examine EGR Valve and VGT Oil Pressure 570
Examine Fuel Pressure 572
How to Examine Fuel Pressure 572
Examine Fuel Return Rate and Leakage 574
How to Examine Fuel Return Rate and Leakage 575
Bleed Air from Fuel System 580
How to Bleed Air from Fuel System 580
Examine Fuel Circuit for Leakage 582
How to Examine Fuel System for Leakage 582
Handle Cylinder Cut-out Mode Operation 584
Handle No-Injection Cranking Operation 585
Examine and Adjust Air Conditioner Compressor Belt Tension 586
How to Examine Air Conditioner Compressor Belt Tension 586
How to Adjust Air Conditioner Compressor Belt Tension 586
Clean Fuel Doser 587
How to Clean Fuel Doser 587
Write Injector Compensation Value to Engine Controller 590
How to Write Injector Compensation Value 590
Write Correction for Ash in Soot Accumulation to Engine Controller 597
How to Write Correction for Ash in Soot Accumulation to Engine Controller 597
Examine SCR Related Functions 598
Examine DEF Pump Raised Pressure 602
Examine Injection Volume from DEF Injector 605
Examine DEF Line Heater Relay 1 610
Examine DEF Line Heater Relay 2 614
Examine DEF Pump Heater Relay 618
Examine DEF Tank Heater Valve 622
Examine SCR Denitration Efficiency 626
Clean DEF Tank 630
How to Clean DEF Tank 630
Clean DEF Pump 635
How to Clean DEF Pump 635
Examine Torque Converter Stall Speed 642
How to Examine Torque Converter Stall Speed 642
Examine Radiator Fan and Aftercooler Fan Speed 647
How to Examine Radiator Fan and Aftercooler Fan Speed 647
Power Train 649
Examine Power Train Oil Pressure 649
How to Examine Power Train Oil Pressure 652
Adjust Transmission Speed Sensor 667
How to Adjust Transmission Speed Sensor 667
Adjust Transmission Controller 670
How to Adjust Transmission Controller 670
Move Machine Which Has a Trouble in Electrical System 671
How to Move Machine Which Has a Trouble in Engine Control System 671
How to Move Machine Which Has a Trouble in Transmission Control System 671
Move Machine Which Has a Trouble in Traction Control System (KTCS) 678
How to Move Machine with Secondary KTCS Operation Connector 680
Steering System 681
Examine and Adjust Steering Circuit Oil Pressure 681
How to Examine Steering Circuit Oil Pressure 681
How to Adjust Steering Circuit Oil Pressure 682
Bleed Air from Steering Cylinder Circuit 683
How to Bleed Air from Steering Cylinder Circuit 683
Brake System 685
Examine and Adjust Brake Oil Pressure 685
How to Examine Brake Oil Pressure 685
How to Adjust Brake Oil Pressure 689
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 690
How to Examine Accumulator Nitrogen Gas Pressure 690
How to Charge Accumulator Nitrogen Gas for Brake 694
Release Remained Pressure in Brake Accumulator Circuit 699
How to Release Remained Pressure in Brake Accumulator Circuit 699
Bleed Air from Brake Circuit 700
How to Bleed Air from Brake Circuit 700
Examine Brake Performance 702
How to Examine Brake Performance 702
Examine Wear of Wheel Brake Disc 706
How to Examine Wear of Wheel Brake Disc 706
Release Parking Brake Manually 708
How to Release Parking Brake Manually 708
Examine and Adjust Wear of Parking Brake Pad 709
How to Examine Wear of Parking Brake Pad 709
How to Adjust Clearance of Parking Brake Pad 710
Hydraulic System 712
Examine and Adjust Suspension Cylinder 712
How to Examine Suspension Cylinder 713
How to Adjust Suspension Cylinder 713
Examine and Adjust Dump Circuit Oil Pressure 718
How to Examine Dump Circuit Oil Pressure 718
How to Adjust Dump Circuit Oil Pressure 719
Work Equipment 721
Examine and Adjust Dump Body Positioner Sensor 721
How to Examine Dump Body Positioner Sensor 721
How to Adjust Dump Body Positioner Sensor 721
Examine and Adjust Dump Body Mount 723
How to Examine Dump Body Mount 723
How to Adjust Dump Body Mount 724
CAB Related Parts 725
CAB Tilt Up 725
How to Tilt Up Cab 726
Adjust Tilt Lock Lever of Steering Wheel 732
How to Adjust Tilt Lock Lever of Steering Wheel 732
Adjust Play of Operator Seat 734
How to Adjust Play of Operator Seat 734
Electrical System 735
Set and Adjust Each Equipment 735
Prepare for Transmission ECMV Current Adjustment 737
How to Adjust Transmission ECMV Current 738
How to Set and Reset Transmission Initial Learning 741
How to Set Property Value of ARAC (Automatic Retarder Accelerator Control) 746
How to Do System Check of KTCS (Komatsu Traction Control System) 749
Set and Operate Machine Monitor 751
Operator Mode 755
Function to Show Technician Identification Status Screen 755
Function to Show Operator Identification Input Screen 755
Examine Function by LCD (Liquid Crystal Display) 756
Examine Function of Service Meter and Odometer 757
How to Set Usage Limitation and Change Maintenance Password 757
Service Mode 761
How to Operate Service Mode 761
How to See Pre-defined Monitoring Information 764
How to Examine Self-Define Monitor Information 772
Abnormality Record Menu 789
How to See Maintenance Record 794
Maintenance Mode Setting 796
How to Set Phone Number Entry 800
Default Menu 802
Diagnostic Tests Menu 817
Adjustment Menu 828
No-Injection Cranking Operation 834
Payload Meter Setting 836
KOMTRAX Settings Menu 859
How to Show Service Message 863
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 865
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 869
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 871
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 876
Adjust Optical Axis of Head Lamp 878
How to Adjust Optical Axis of Head Lamp 878
Set Region of Bluetooth(R) Compatible Radio 882
How to Set Region of Bluetooth(R) Compatible Radio 882
Handle Voltage Circuit of Engine Controller 884
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 885
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 886
Examine Diodes 887
How to Examine Diodes by Digital Tester 887
How to Examine Diodes by Analog Tester 887
Pm Clinic 888
Pm Clinic Service 888
Pm Clinic Check Sheet 891
40 Troubleshooting 901
Table of Contents 902
Precautions Before Work 915
Abbreviation List 916
Related Information to Troubleshooting 922
General Troubleshooting Points 922
Troubleshooting Points for Urea SCR System 923
Sequence of Events in Troubleshooting 937
Checks Before Troubleshooting 939
Inspection Procedure Before Troubleshooting 941
Walk-Around Check 941
Test in Accordance with Testing Procedure 943
Examine Fuel Level and Type 943
Examine for Impure Ingredient in Fuel 943
Examine DEF Level and Type 944
Examine Fuel Prefilter 944
Examine Fuel Main Filter 946
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 947
Examine Coolant Level (Reservoir Tank) 948
Examine Air Cleaner Clogging 949
Clean Outer Element 950
Replace Element 952
Examine Hydraulic Oil Level 954
Examine Hydraulic Oil Strainer 954
Examine Hydraulic Oil Filter 955
Examine Oil Level in Transmission Case 955
Examine Oil Level in Differential Case 956
Examine Oil Level in Final Drive Case 957
Bleed Air from Fuel System 957
Bleed Air from Hydraulic System 957
How to Examine Electric Equipment 957
Preparation for Troubleshooting of Electrical System 967
Procedure for Troubleshooting 976
Symptom and Troubleshooting Numbers 978
Information Shown in Troubleshooting Table 981
Connector List and Layout 983
Connector Contact Connection Table 1009
T-Branch Box and T-Branch Adapter Table 1049
Fuse Location Table (Machine with KOMTRAX Terminal) 1055
Fuse Location Table (Machine with Gateway Function Controller) 1059
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1063
Prepare Troubleshoot Machine Monitor 1067
Procedure to Make Harness Checker on Machine Monitor LCD Unit 1069
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1075
Failure Code Table 1077
Troubleshooting by Failure Code (Display of Code) 1103
Failure Code [1500L0] 1103
Failure Code [15B0NX] 1104
Failure Code [15F0KM] 1106
Failure Code [15F0MB] 1107
Failure Code [15F7KM] 1108
Failure Code [15G0MW] 1109
Failure Code [15G7KM] 1112
Failure Code [15H0MW] 1113
Failure Code [15J0MW] 1116
Failure Code [15K0MW] 1119
Failure Code [15L0MW] 1122
Failure Code [15M0MW] 1125
Failure Code [15SBL1] 1128
Failure Code [15SBMA] 1131
Failure Code [15SCL1] 1132
Failure Code [15SCMA] 1136
Failure Code [15SDL1] 1137
Failure Code [15SDMA] 1140
Failure Code [15SEL1] 1141
Failure Code [15SEMA] 1144
Failure Code [15SFL1] 1145
Failure Code [15SFMA] 1148
Failure Code [15SGL1] 1149
Failure Code [15SGMA] 1152
Failure Code [15SJMA] 1153
Failure Code [15SKMA] 1155
Failure Code [2F00KM] 1157
Failure Code [2G42ZG] 1159
Failure Code [2G43ZG] 1160
Failure Code [879AKA] 1161
Failure Code [879AKB] 1162
Failure Code [879BKA] 1163
Failure Code [879BKB] 1165
Failure Code [879CKA] 1167
Failure Code [879CKB] 1168
Failure Code [879EMC] 1169
Failure Code [879FMC] 1170
Failure Code [879GKX] 1171
Failure Code [989D00] 1173
Failure Code [989L00] 1174
Failure Code [989M00] 1175
Failure Code [989N00] 1176
Failure Code [A1U0N3] 1177
Failure Code [A1U0N4] 1179
Failure Code [AA10NX] 1181
Failure Code [AB00KE] 1183
Failure Code [AB00KY] 1185
Failure Code [AQ10N3] 1187
Failure Code [AS00N3] 1189
Failure Code [AS00R2] 1191
Failure Code [AS00R3] 1192
Failure Code [AS00R4] 1193
Failure Code [AS00R5] 1194
Failure Code [AS00R6] 1195
Failure Code [AS00ZK] 1196
Failure Code [AS10KM] 1197
Failure Code [AS10NR] 1198
Failure Code [AS10NT] 1199
Failure Code [B@BAZG] 1200
Failure Code [B@BAZK] 1201
Failure Code [B@BCNS] 1202
Failure Code [B@BCQA] 1203
Failure Code [B@BCZK] 1205
Failure Code [B@C6NS] 1207
Failure Code [B@C8NS] 1208
Failure Code [B@CENS] 1209
Failure Code [B@JANS] 1210
Failure Code [CA115] 1211
Failure Code [CA122] 1212
Failure Code [CA123] 1214
Failure Code [CA131] 1216
Failure Code [CA132] 1218
Failure Code [CA135] 1221
Failure Code [CA141] 1223
Failure Code [CA144] 1225
Failure Code [CA145] 1227
Failure Code [CA153] 1229
Failure Code [CA154] 1232
Failure Code [CA187] 1235
Failure Code [CA221] 1237
Failure Code [CA222] 1239
Failure Code [CA227] 1241
Failure Code [CA234] 1242
Failure Code [CA238] 1243
Failure Code [CA239] 1245
Failure Code [CA249] 1247
Failure Code [CA256] 1249
Failure Code [CA271] 1251
Failure Code [CA272] 1253
Failure Code [CA273] 1254
Failure Code [CA274] 1256
Failure Code [CA322] 1257
Failure Code [CA323] 1259
Failure Code [CA324] 1261
Failure Code [CA325] 1263
Failure Code [CA331] 1265
Failure Code [CA332] 1267
Failure Code [CA343] 1269
Failure Code [CA351] 1270
Failure Code [CA352] 1271
Failure Code [CA356] 1274
Failure Code [CA357] 1276
Failure Code [CA386] 1278
Failure Code [CA431] 1279
Failure Code [CA432] 1282
Failure Code [CA441] 1286
Failure Code [CA442] 1289
Failure Code [CA449] 1290
Failure Code [CA451] 1291
Failure Code [CA452] 1293
Failure Code [CA515] 1295
Failure Code [CA516] 1297
Failure Code [CA553] 1299
Failure Code [CA555] 1300
Failure Code [CA556] 1301
Failure Code [CA559] 1302
Failure Code [CA595] 1307
Failure Code [CA687] 1308
Failure Code [CA689] 1310
Failure Code [CA691] 1312
Failure Code [CA692] 1314
Failure Code [CA697] 1316
Failure Code [CA698] 1317
Failure Code [CA731] 1318
Failure Code [CA778] 1319
Failure Code [CA1117] 1322
Failure Code [CA1664] 1323
Failure Code [CA1669] 1326
Failure Code [CA1673] 1327
Failure Code [CA1677] 1328
Failure Code [CA1678] 1329
Failure Code [CA1682] 1330
Failure Code [CA1683] 1334
Failure Code [CA1684] 1336
Failure Code [CA1686] 1338
Failure Code [CA1691] 1339
Failure Code [CA1694] 1342
Failure Code [CA1695] 1344
Failure Code [CA1696] 1345
Failure Code [CA1712] 1347
Failure Code [CA1713] 1350
Failure Code [CA1714] 1352
Failure Code [CA1715] 1353
Failure Code [CA1776] 1354
Failure Code [CA1777] 1357
Failure Code [CA1843] 1360
Failure Code [CA1844] 1362
Failure Code [CA1879] 1365
Failure Code [CA1881] 1368
Failure Code [CA1883] 1370
Failure Code [CA1885] 1374
Failure Code [CA1887] 1376
Failure Code [CA1921] 1378
Failure Code [CA1922] 1381
Failure Code [CA1923] 1386
Failure Code [CA1924] 1388
Failure Code [CA1925] 1391
Failure Code [CA1927] 1394
Failure Code [CA1928] 1396
Failure Code [CA1942] 1398
Failure Code [CA1963] 1399
Failure Code [CA1977] 1403
Failure Code [CA1993] 1406
Failure Code [CA2185] 1409
Failure Code [CA2186] 1411
Failure Code [CA2249] 1413
Failure Code [CA2265] 1414
Failure Code [CA2266] 1416
Failure Code [CA2271] 1419
Failure Code [CA2272] 1421
Failure Code [CA2349] 1424
Failure Code [CA2353] 1426
Failure Code [CA2357] 1428
Failure Code [CA2381] 1429
Failure Code [CA2382] 1431
Failure Code [CA2383] 1433
Failure Code [CA2386] 1435
Failure Code [CA2387] 1437
Troubleshooting Flowchart 1441
Failure Code [CA2555] 1442
Failure Code [CA2556] 1444
Failure Code [CA2637] 1446
Failure Code [CA2639] 1448
Failure Code [CA2732] 1451
Failure Code [CA2733] 1453
Failure Code [CA2741] 1455
Failure Code [CA2765] 1456
Failure Code [CA2771] 1457
Failure Code [CA2777] 1463
Failure Code [CA2878] 1466
Failure Code [CA2881] 1469
Failure Code [CA2976] 1472
Failure Code [CA3133] 1474
Failure Code [CA3134] 1476
Failure Code [CA3135] 1478
Failure Code [CA3142] 1482
Failure Code [CA3143] 1483
Failure Code [CA3144] 1484
Failure Code [CA3146] 1486
Failure Code [CA3147] 1487
Failure Code [CA3148] 1488
Failure Code [CA3151] 1490
Failure Code [CA3165] 1496
Failure Code [CA3167] 1498
Failure Code [CA3229] 1501
Failure Code [CA3231] 1503
Failure Code [CA3232] 1505
Failure Code [CA3235] 1509
Failure Code [CA3239] 1511
Failure Code [CA3241] 1514
Failure Code [CA3242] 1517
Failure Code [CA3251] 1520
Failure Code [CA3253] 1522
Failure Code [CA3254] 1526
Failure Code [CA3255] 1529
Failure Code [CA3256] 1533
Failure Code [CA3311] 1535
Failure Code [CA3312] 1537
Failure Code [CA3313] 1540
Failure Code [CA3314] 1541
Failure Code [CA3315] 1542
Failure Code [CA3316] 1545
Failure Code [CA3317] 1546
Failure Code [CA3318] 1547
Failure Code [CA3319] 1550
Failure Code [CA3321] 1551
Failure Code [CA3322] 1553
Failure Code [CA3419] 1556
Failure Code [CA3421] 1558
Failure Code [CA3497] 1560
Failure Code [CA3498] 1561
Failure Code [CA3543] 1562
Failure Code [CA3545] 1569
Failure Code [CA3547] 1571
Failure Code [CA3558] 1572
Failure Code [CA3559] 1574
Failure Code [CA3562] 1576
Failure Code [CA3563] 1578
Failure Code [CA3567] 1581
Failure Code [CA3568] 1584
Failure Code [CA3571] 1590
Failure Code [CA3572] 1592
Failure Code [CA3574] 1594
Failure Code [CA3575] 1597
Failure Code [CA3577] 1599
Failure Code [CA3578] 1601
Failure Code [CA3582] 1603
Failure Code [CA3583] 1610
Failure Code [CA3596] 1612
Failure Code [CA3649] 1617
Failure Code [CA3681] 1619
Failure Code [CA3682] 1624
Failure Code [CA3713] 1630
Failure Code [CA3717] 1633
Failure Code [CA3718] 1634
Failure Code [CA3725] 1635
Failure Code [CA3748] 1638
Failure Code [CA3751] 1641
Failure Code [CA3755] 1643
Failure Code [CA3866] 1645
Failure Code [CA3867] 1649
Failure Code [CA3868] 1652
Failure Code [CA3899] 1656
Failure Code [CA3911] 1658
Failure Code [CA3912] 1662
Failure Code [CA3932] 1664
Failure Code [CA3933] 1666
Failure Code [CA3934] 1668
Failure Code [CA3935] 1671
Failure Code [CA3936] 1673
Failure Code [CA4151] 1675
Failure Code [CA4152] 1679
Failure Code [CA4155] 1683
Failure Code [CA4156] 1686
Failure Code [CA4157] 1689
Failure Code [CA4158] 1691
Failure Code [CA4159] 1692
Failure Code [CA4161] 1693
Failure Code [CA4162] 1696
Failure Code [CA4163] 1699
Failure Code [CA4164] 1701
Failure Code [CA4165] 1703
Failure Code [CA4166] 1705
Failure Code [CA4168] 1707
Failure Code [CA4169] 1710
Failure Code [CA4171] 1714
Failure Code [CA4249] 1718
Failure Code [CA4251] 1722
Failure Code [CA4259] 1726
Failure Code [CA4261] 1729
Failure Code [CA4277] 1731
Failure Code [CA4281] 1735
Failure Code [CA4459] 1738
Failure Code [CA4461] 1741
Failure Code [CA4658] 1744
Failure Code [CA4731] 1748
Failure Code [CA4732] 1749
Failure Code [CA4739] 1750
Failure Code [CA4768] 1751
Failure Code [CA4769] 1753
Failure Code [CA4842] 1756
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1760
Failure Code [CA4952] (Machine with Gateway Function Controller) 1762
Failure Code [CA5115] 1764
Failure Code [CA5179] 1767
Failure Code [CA5181] 1769
Failure Code [CA5383] 1771
Failure Code [D150KB] 1773
Failure Code [D150KZ] 1774
Failure Code [D164KY] 1775
Failure Code [D19HKZ] 1777
Failure Code [D19JKZ] 1779
Failure Code [D1EHKA] 1781
Failure Code [D1EHKB] 1782
Failure Code [D1EHKY] 1783
Failure Code [D1EMKA] 1784
Failure Code [D1EMKB] 1785
Failure Code [D1EMKY] 1786
Failure Code [D1FBKB] 1787
Failure Code [D5ZHL6] 1789
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1791
Failure Code [D811MC] (Machine with Gateway Function Controller) 1792
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1793
Failure Code [D862KA] (Machine with Gateway Function Controller) 1794
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1795
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1797
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1799
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1801
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal) 1803
Failure Code [D8AQK4] (Machine with Gateway Function Controller) 1804
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1805
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1807
Failure Code [D8G1KT] 1809
Failure Code [D8G6KT] 1810
Failure Code [DAF0KT] 1811
Failure Code [DAF0MB] 1812
Failure Code [DAF0MC] 1813
Failure Code [DAF3KK] 1814
Failure Code [DAF8KB] 1816
Failure Code [DAFDKB] 1818
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1820
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1821
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1822
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1824
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1826
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1828
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1830
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1831
Failure Code [DAQ0KK] 1832
Failure Code [DAQ0KT] 1834
Failure Code [DAQ0MC] 1835
Failure Code [DAQ1KA] 1836
Failure Code [DAQ2KK] 1839
Failure Code [DAQ9KQ] 1841
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal) 1842
Failure Code [DAQLKA] (Machine with Gateway Function Controller) 1844
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal) 1846
Failure Code [DAQLKB] (Machine with Gateway Function Controller) 1848
Failure Code [DAQQKR] 1850
Failure Code [DAQRKR] 1851
Failure Code [DAQRMA] 1852
Failure Code [DAQV00] 1853
Failure Code [DAQW00] 1854
Failure Code [DAZ9KQ] 1855
Failure Code [DAZQKR] 1856
Failure Code [DB10KT] 1857
Failure Code [DB10MC] 1858
Failure Code [DB11KA] 1859
Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch) 1861
Failure Code [DB12KK] 1864
Failure Code [DB13KK] 1866
Failure Code [DB19KQ] 1868
Failure Code [DB1LKA] (Machine with KOMTRAX Terminal) 1869
Failure Code [DB1LKA] (Machine with Gateway Function Controller) 1871
Failure Code [DB1LKB] (Machine with KOMTRAX Terminal) 1873
Failure Code [DB1LKB] (Machine with Gateway Function Controller) 1875
Failure Code [DB1QKR] 1877
Failure Code [DB1QMA] 1878
Failure Code [DB1RKR] 1879
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1880
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1886
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1892
Failure Code [DB2QKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1898
Failure Code [DB2RKR] 1904
Failure Code [DBS0KK] 1910
Failure Code [DBS0KK] (Machine with Payload Meter Controller: CR720) 1913
Failure Code [DBS6KP] 1916
Failure Code [DBS6KP] (Machine with Payload Meter Controller: CR720) 1919
Failure Code [DBSQKQ] 1922
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) 1923
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1928
Failure Code [DBSQKR] (Machine with Gateway Function Controller) 1933
Failure Code [DBSQKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1938
Failure Code [DD1ML4] 1943
Failure Code [DDAAL6] 1946
Failure Code [DDAAL6] (Machine with Emergency Engine Stop Switch) 1948
Failure Code [DDTHKA] 1951
Failure Code [DDTJKA] 1953
Failure Code [DDTKKA] 1955
Failure Code [DDTLKA] 1957
Failure Code [DDTMKA] 1959
Failure Code [DDTNKA] 1961
Failure Code [DF10KA] 1963
Failure Code [DF10KB] 1967
Failure Code [DGF1KX] 1972
Failure Code [DGR3KB] 1974
Failure Code [DGR3L8] 1975
Failure Code [DGR4KB] 1977
Failure Code [DGR4L8] 1978
Failure Code [DGR6KB] 1980
Failure Code [DGR6L8] 1981
Failure Code [DGT1KX] 1983
Failure Code [DHAAMA] 1985
Failure Code [DHACMA] 1987
Failure Code [DHP4KY] 1989
Failure Code [DHP4KY] (Machine with Payload Meter Controller: CR720) 1991
Failure Code [DHP4KZ] 1993
Failure Code [DHP4KZ] (Machine with Payload Meter Controller: CR720) 1995
Failure Code [DHP5KY] 1997
Failure Code [DHP5KY] (Machine with Payload Meter Controller: CR720) 1999
Failure Code [DHP5KZ] 2001
Failure Code [DHP5KZ] (Machine with Payload Meter Controller: CR720) 2003
Failure Code [DHP6KY] 2005
Failure Code [DHP6KY] (Machine with Payload Meter Controller: CR720) 2007
Failure Code [DHP6KZ] 2009
Failure Code [DHP6KZ] (Machine with Payload Meter Controller: CR720) 2011
Failure Code [DHP7KY] 2013
Failure Code [DHP7KY] (Machine with Payload Meter Controller: CR720) 2015
Failure Code [DHP7KZ] 2017
Failure Code [DHP7KZ] (Machine with Payload Meter Controller: CR720) 2019
Failure Code [DHQ2KX] 2021
Failure Code [DHT5KX] 2023
Failure Code [DHT5L6] 2025
Failure Code [DHT8KX] 2027
Failure Code [DHT8ZG] 2029
Failure Code [DHU2KX] 2031
Failure Code [DHU3KX] 2033
Failure Code [DHUAKX] 2035
Failure Code [DHUBKX] 2037
Failure Code [DHUCKX] 2039
Failure Code [DHUDKX] 2041
Failure Code [DHUQKX] 2043
Failure Code [DHURKX] 2045
Failure Code [DJF1KA] 2047
Failure Code [DK30KX] 2049
Failure Code [DK51L5] 2051
Failure Code [DK52KX] 2054
Failure Code [DK53L8] 2056
Failure Code [DK54KX] 2058
Failure Code [DK60KX] 2060
Failure Code [DKH0KX] 2062
Failure Code [DKH1KX] 2064
Failure Code [DKH1KX] (Machine with Payload Meter Controller: CR720) 2066
Failure Code [DLF1KA] 2068
Failure Code [DLF1LC] 2070
Failure Code [DLF2KA] 2072
Failure Code [DLF2LC] 2074
Failure Code [DLF400] 2076
Failure Code [DLF4KA] 2077
Failure Code [DLF4LC] 2079
Failure Code [DLF6LC] 2081
Failure Code [DLF7LC] 2083
Failure Code [DLFDLC] 2085
Failure Code [DLFELC] 2087
Failure Code [DLFFLC] 2089
Failure Code [DLFGLC] 2090
Failure Code [DLM3KA] 2091
Failure Code [DLM3LC] 2093
Failure Code [DLM3MB] 2095
Failure Code [DLM4KA] 2096
Failure Code [DLM4LC] 2098
Failure Code [DLM4MB] 2100
Failure Code [DLT3KA] 2102
Failure Code [DLT3LC] 2104
Failure Code [DPQ1KR] 2106
Failure Code [DPQ2KR] 2109
Failure Code [DPQ3KR] 2112
Failure Code [DSJ0KR] 2116
Failure Code [DV00KB] 2117
Failure Code [DW2BKA] 2119
Failure Code [DW2BKB] 2120
Failure Code [DW2BKY] 2121
Failure Code [DW2BL1] 2122
Failure Code [DW2BLH] 2123
Failure Code [DW4BK4] 2124
Failure Code [DW4BMA] 2127
Failure Code [DW72KZ] 2130
Failure Code [DW73KA] 2132
Failure Code [DW73KB] 2134
Failure Code [DW73KY] 2136
Failure Code [DW78KZ] 2138
Failure Code [DW7BKB] 2140
Failure Code [DW7BKY] 2142
Failure Code [DW7BKZ] 2143
Failure Code [DW7LKB] 2145
Failure Code [DW7LKY] 2146
Failure Code [DW7LKZ] 2147
Failure Code [DW7MKB] 2148
Failure Code [DW7MKY] 2150
Failure Code [DW7MKZ] 2151
Failure Code [DW7NKZ] 2153
Failure Code [DWNJKZ] 2155
Failure Code [DWNKKZ] 2157
Failure Code [DX13KA] 2159
Failure Code [DX13KB] 2161
Failure Code [DX13KY] 2163
Failure Code [DX16KA] 2165
Failure Code [DX16KB] 2166
Failure Code [DX16KY] 2168
Failure Code [DX29KA] 2169
Failure Code [DX29KB] 2171
Failure Code [DX29KY] 2173
Failure Code [DX30K4] 2174
Failure Code [DX30KA] 2176
Failure Code [DX30KB] 2178
Failure Code [DX30KY] 2180
Failure Code [DX30MA] 2182
Failure Code [DX31K4] 2184
Failure Code [DX31KA] 2186
Failure Code [DX31KB] 2188
Failure Code [DX31KY] 2190
Failure Code [DX31MA] 2192
Failure Code [DX32K4] 2194
Failure Code [DX32KA] 2196
Failure Code [DX32KB] 2198
Failure Code [DX32KY] 2200
Failure Code [DX32MA] 2202
Failure Code [DX33K4] 2204
Failure Code [DX33KA] 2206
Failure Code [DX33KB] 2208
Failure Code [DX33KY] 2210
Failure Code [DX33MA] 2212
Failure Code [DXH0KA] 2214
Failure Code [DXH0KB] 2216
Failure Code [DXH0KY] 2218
Failure Code [DXH1KA] 2220
Failure Code [DXH1KB] 2222
Failure Code [DXH1KY] 2224
Failure Code [DXH2KA] 2226
Failure Code [DXH2KB] 2229
Failure Code [DXH2KY] 2232
Failure Code [DXH3KA] 2235
Failure Code [DXH3KB] 2238
Failure Code [DXH3KY] 2241
Failure Code [DXH4KA] 2244
Failure Code [DXH4KB] 2246
Failure Code [DXH4KY] 2248
Failure Code [DXH5KA] 2251
Failure Code [DXH5KB] 2253
Failure Code [DXH5KY] 2255
Failure Code [DXH6KA] 2258
Failure Code [DXH6KB] 2260
Failure Code [DXH6KY] 2262
Failure Code [DXH7KA] 2265
Failure Code [DXH7KB] 2267
Failure Code [DXH7KY] 2269
Failure Code [DY30MA] 2272
Failure Code [DY30MC] 2274
Failure Code [DY30ME] 2277
Failure Code [F313KA] 2279
Failure Code [F313KB] 2281
Failure Code [F318KB] 2282
Failure Code [F318KY] 2284
Troubleshooting of Electrical System (E-Mode) 2285
Engine Does Not Start (Engine Does Not Crank) 2285
Manual Preheating System Does Not Operate 2291
Automatic Preheating System Does Not Operate 2294
While Preheating is in Operation, Preheating Monitor Does Not Come On 2296
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 2298
All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed) 2301
LCD Unit on Machine Monitor Shows Nothing 2304
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 2307
LCD Screen on Machine Monitor Does Not Show Correctly 2310
Meter Unit Display on Machine Monitor is Abnormal 2313
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 2316
LED Unit Lamp on Machine Monitor is Abnormal 2320
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly 2322
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 2325
Switch Panel Buzzer of Machine Monitor is Abnormal 2328
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 2331
DEF Level is Not Shown Correctly 2332
Rearview Monitor Does Not Come On or Backlight Flickers 2335
Rearview Monitor Images are Not Shown Clearly 2338
Rearview Monitor Brightness Cannot be Adjusted 2342
Night Mode Lamp of Rearview Monitor is Abnormal 2345
Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled 2347
Guide Line on Rearview Monitor is Not Shown While Guide Line is Set 2350
Fuel Gauge Does Not Show Normally 2352
Seatbelt Caution Lamp Does Not Show Normally 2354
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 2355
Alarm Buzzer Does Not Operate 2356
Alarm Buzzer Does Not Stop 2357
Engine Mode Selector Function Does Not Operate Correctly 2359
AISS Function Does Not Operate Correctly 2361
Hoist Lever Does Not Operate Correctly 2363
Fuel Feed Pump Does Not Operate or Stop Automatically 2365
Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly 2368
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 2372
Clearance Lamp Does Not Come On 2374
Tail Lamp Does Not Come On 2376
Headlamp (Low Beam) Does Not Come On 2378
Headlamp (High Beam) Does Not Come On 2380
Head Lamps (Low Beam) and (High Beam) Do Not Come on 2382
Passing Lamp Does Not Come On 2384
KOMTRAX System Does Not Operate Correctly (Machine with KOMTRAX Terminal) 2386
KOMTRAX System Does Not Operate Correctly (Machine with Gateway Function Controller) 2388
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2390
Information Shown in Troubleshooting Table (H-Mode) 2390
System Chart of Hydraulic and Mechanical Systems 2391
Failure Mode and Cause Table 2393
Machine Does Not Start 2403
Machine Does Not Travel Smoothly (Machine Hunts) 2406
Lockup is Not Released 2407
Strong Shock is Made When You Start Machine or Shift Gears 2408
Shiftup Does Not Operate 2410
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 2413
Travel Speed is Low or Power is Low During Travel with Torque Converter 2414
Travel Speed is Low or Power is Low in Specified Gear Speed 2415
Time Lag is Large When You Start Machine or Shift Gears 2417
Torque Converter Oil Temperature is High 2420
Torque Converter Oil Pressure is Low 2422
Steering Wheel is Heavy to Operate 2424
Steering Wheel is Disabled 2425
Steering Wheel Waggles 2426
Front Brake Does Not Operate Sufficiently 2427
Center Brake Does Not Work Sufficiently 2428
Speed is Low When Dump Body is Raised 2429
Hydraulic Drift of Dump Body is Large 2431
Dump Body is Disabled 2432
Radiator Fan Speed is Unusual (Too High or Low, or Fan Stops) 2434
Aftercooler Fan Speed is Unusual (Too Much High or Low, or Fan Stops) 2435
Unusual Noise is Heard from Around Radiator Fan 2436
Unusual Noise is Heard from Around Aftercooler Fan 2437
Troubleshooting of Engine (S-Mode) 2438
Information Shown in Troubleshooting Table (S-Mode) 2438
Engine Does Not Crank When Starting Switch is Turned to Start Position 2439
Engine Cranks but No Exhaust Smoke Comes Out 2440
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2441
Engine Startability is Unsatisfactory 2442
Engine Does Not Pick Up Smoothly 2444
Engine Stops During Operation 2446
Engine Does Not Rotate Smoothly 2448
Engine Lacks Output (or Lacks Power) 2449
KDPF Becomes Clogged in a Short Time 2451
Engine Oil Consumption is Excessive 2453
Engine Oil Becomes Dirty Quickly 2454
Fuel Consumption is Excessive 2455
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2456
Engine Oil Pressure Drops 2457
Fuel Mixes Into Engine Oil 2459
Water Mixes Into Engine Oil (Milky) 2460
Coolant Temperature Increases Too High (Overheat) 2461
Unusual Noise is Heard 2462
Vibration is Excessive 2463
Air Cannot be Bled from Fuel Circuit 2464
Active Regeneration is Done Frequently 2465
Active Regeneration Continues Long 2467
White Smoke is Exhausted During Active Regeneration 2468
DEF Consumption is Excessive 2469
There is an Unusual Smell (Irritating Odor) 2471
Foreign Materials Enter DEF (DEF Increases) 2472
50 Disassembly and Assembly 2473
Table of Contents 2474
Precautions Before Work 2479
Abbreviation List 2480
Related Information on Disassembly and Assembly 2486
How to Read This Manual 2486
Coating Materials List 2487
Special Tool List 2492
Sketches of Special Tools 2512
Engine and Cooling System 2530
Remove and Install Supply Pump Assembly 2530
How to Remove Supply Pump Assembly 2531
How to Install Supply Pump Assembly 2537
Remove and Install Injector Assembly 2543
How to Remove Injector Assembly 2544
How to Install Injector Assembly 2554
Remove and Install Fuel Doser Assembly 2568
How to Remove Fuel Doser Assembly 2568
How to Install Fuel Doser Assembly 2569
Remove and Install Cylinder Head Assembly 2571
How to Remove Cylinder Head Assembly 2572
How to Install Cylinder Head Assembly 2583
Remove and Install EGR Valve Assembly 2598
How to Remove EGR Valve Assembly 2598
How to Install EGR Valve Assembly 2599
Remove and Install EGR Cooler Assembly 2601
How to Remove EGR Cooler Assembly 2601
How to Install EGR Cooler Assembly 2606
Remove and Install Starter Assembly 2610
How to Remove Starting Motor Assembly 2610
How to Install Starting Motor Assembly 2612
Remove and Install Alternator Belt 2615
How to Remove Alternator Belt 2615
How to Install Alternator Belt 2617
Remove and Install Radiator Assembly 2619
How to Remove Radiator Assembly 2619
How to Install Radiator Assembly 2622
Remove and Install Cooling Fan and Fan Motor Assembly 2627
How to Remove Cooling Fan and Fan Motor Assembly 2627
How to Install Cooling Fan and Fan Motor Assembly 2631
Remove and Install Aftercooler Assembly 2637
How to Remove Aftercooler Assembly 2638
How to Install Aftercooler Assembly 2641
Remove and Install Aftercooler Fan and Fan Motor Assembly 2645
How to Remove Aftercooler Fan and Fan Motor Assembly 2645
How to Install Aftercooler Fan and Fan Motor Assembly 2646
Remove and Install Engine Assembly 2650
How to Remove Engine Assembly 2652
How to Install Engine Assembly 2658
Remove and Install Engine Front Oil Seal 2666
How to Remove Engine Front Oil Seal 2666
How to Install Engine Front Oil Seal 2670
Remove and Install Engine Rear Oil Seal 2676
How to Remove Engine Rear Oil Seal 2676
How to Install Engine Rear Oil Seal 2678
Remove and Install Output Shaft 2684
How to Remove Output Shaft 2685
How to Install Output Shaft 2688
Disassemble and Assemble Output Shaft 2694
How to Disassemble Output Shaft 2694
How to Assemble Output Shaft 2696
Remove and Install DEF Tank Assembly 2699
How to Remove DEF Tank Assembly 2699
How to Install DEF Tank Assembly 2705
Remove and Install DEF Tank Sensor Flange Assembly 2709
How to Remove DEF Tank Sensor Flange Assembly 2709
How to Install DEF Tank Sensor Flange Assembly 2714
Remove and Install DEF Tank Sensor 2719
How to Remove DEF Tank Sensor 2719
How to Install DEF Tank Sensor 2720
Remove and Install DEF Tank Strainer 2722
How to Remove DEF Tank Strainer 2722
How to Install DEF Tank Strainer 2722
Remove and Install KDPF Assembly 2723
How to Remove KDPF Assembly 2724
How to Install KDPF Assembly 2727
Disassemble and Assemble KDPF Assembly 2731
How to Disassemble KDPF Assembly 2731
How to Assemble KDPF Assembly 2735
Remove and Install SCR Assembly 2740
How to Remove SCR Assembly 2740
How to Install SCR Assembly 2744
Remove and Install KCCV Assembly 2749
How to Remove KCCV Assembly 2749
How to Install KCCV Assembly 2750
Remove and Install DEF Mixing Tube 2751
How to Remove DEF Mixing Tube 2751
How to Install DEF Mixing Tube 2757
Remove and Install DEF Injector 2764
How to Remove DEF Injector 2764
How to Install DEF Injector 2767
Remove and Install DEF Pump 2770
How to Remove DEF Pump 2770
How to Install DEF Pump 2774
Remove and Install DEF Hose 2778
How to Remove DEF Hose 2778
How to Install DEF Hose 2782
Remove and Install Air Cleaner Assembly 2786
How to Remove Air Cleaner Assembly 2786
How to Install Air Cleaner Assembly 2789
Remove and Install Air Conditioner Compressor Assembly 2792
How to Remove Air Conditioner Compressor Assembly 2792
How to Install Air Conditioner Compressor Assembly 2794
Remove and Install Air Conditioner Condenser Assembly 2796
How to Remove Air Conditioner Condenser Assembly 2796
How to Install Air Conditioner Condenser Assembly 2797
Power Train 2798
Remove and Install Transmission and Front Differential Assembly 2798
How to Remove Transmission and Front Differential Assembly 2799
How to Install Transmission and Front Differential Assembly 2811
Disconnect and Connect Transmission and Front Differential Assembly 2825
How to Disconnect Transmission and Front Differential Assembly 2825
How to Connect Transmission and Front Differential Assembly 2826
Disassemble and Assemble Front Differential Assembly 2828
How to Disassemble Front Differential Assembly 2828
How to Assemble Front Differential Assembly 2833
Disassemble and Assemble Torque Converter Assembly 2844
How to Disassemble Torque Converter Assembly 2845
How to Assemble Torque Converter Assembly 2849
Disassemble and Assemble Transmission Assembly 2854
How to Disassemble Transmission Assembly 2855
How to Assemble Transmission Assembly 2880
Remove and Install Center Differential Assembly 2907
How to Remove Center Differential Assembly 2907
How to Install Center Differential Assembly 2910
Disassemble and Assemble Center Differential Assembly 2914
How to Disassemble Center Differential Assembly 2915
How to Assemble Center Differential Assembly 2920
Remove and Install Rear Differential Assembly 2931
How to Remove Rear Differential Assembly 2931
How to Install Rear Differential Assembly 2933
Disassemble and Assemble Rear Differential Assembly 2935
How to Disassemble Rear Differential Assembly 2935
How to Assemble Rear Differential Assembly 2939
Remove and Install Front Final Drive and Brake Assembly 2948
How to Remove Front Final Drive and Brake Assembly 2948
How to Install Front Final Drive and Brake Assembly 2953
Disassemble and Assemble Front Final Drive and Brake Assembly 2958
How to Disassemble Front Final Drive and Brake Assembly 2959
How to Assemble Front Final Drive and Brake Assembly 2965
Remove and Install Center Final Drive and Brake Assembly 2974
How to Remove Center Final Drive and Brake Assembly 2974
How to Install Center Final Drive and Brake Assembly 2976
Disassemble and Assemble Center Final Drive and Brake Assembly 2978
How to Disassemble Center Final Drive and Brake Assembly 2979
How to Assemble Center Final Drive and Brake Assembly 2982
Disassemble and Assemble Rear Final Drive Assembly 2989
How to Disassemble Rear Final Drive Assembly 2989
How to Assemble Rear Final Drive Assembly 2993
Remove and Install Center Axle Assembly 2998
How to Remove Center Axle Assembly 2998
How to Install Center Axle Assembly 3001
Remove and Install Rear Axle Assembly 3004
How to Remove Rear Axle Assembly 3004
How to Install Rear Axle Assembly 3006
Steering System 3009
Disassemble and Assemble Steering Cylinder Assembly 3009
How to Disassemble Steering Cylinder Assembly 3010
How to Assemble Steering Cylinder Assembly 3013
Undercarriage and Frame 3018
Remove and Install Front Suspension Cylinder Assembly 3018
How to Remove Front Suspension Cylinder Assembly 3019
How to Install Front Suspension Cylinder Assembly 3022
Remove and Install Rear Suspension Cylinder Assembly 3027
How to Remove Rear Suspension Cylinder Assembly 3027
How to Install Rear Suspension Cylinder Assembly 3028
Disassemble and Assemble Suspension Cylinder Assembly 3030
How to Disassemble Suspension Cylinder Assembly 3030
How to Assemble Suspension Cylinder Assembly 3030
Remove and Install Equalizer Bar Assembly 3032
How to Remove Equalizer Bar Assembly 3032
How to Install Equalizer Bar Assembly 3034
Remove and Install Hitch Frame Assembly 3036
How to Remove Hitch Frame Assembly 3037
How to Install Hitch Frame Assembly 3046
Disassemble and Assemble Hitch Frame Assembly 3057
How to Disassemble Hitch Frame Assembly 3057
How to Assemble Hitch Frame Assembly 3059
Hydraulic System 3064
Remove and Install Hydraulic Tank Assembly 3064
How to Remove Hydraulic Tank Assembly 3064
How to Install Hydraulic Tank Assembly 3069
Remove and Install Flow Amplifier Valve Assembly 3073
How to Remove Flow Amplifier Valve Assembly 3073
How to Install Flow Amplifier Valve Assembly 3075
Remove and Install Hoist Valve Assembly 3078
How to Remove Hoist Valve Assembly 3078
How to Install Hoist Valve Assembly 3081
Disassemble and Assemble Hoist Cylinder Assembly 3083
How to Disassemble Hoist Cylinder Assembly 3083
How to Assemble Hoist Cylinder Assembly 3086
Work Equipment 3092
Remove and Install Dump Body Assembly 3092
How to Remove Body Assembly 3092
How to Install Body Assembly 3094
CAB Related Parts 3096
Remove and Install Operator Cab Assembly 3096
How to Remove Operator Cab Assembly 3097
How to Install Operator Cab Assembly 3099
Remove and Install Operator Cab Glass (Adhered Glass) 3103
How to Remove Operator Cab Glass (Adhered Glass) 3104
How to Install Operator Cab Glass (Adhered Glass) 3104
Remove and Install Air Conditioner Unit Assembly 3109
How to Remove Air Conditioner Unit Assembly 3110
How to Install Air Conditioner Unit Assembly 3116
Remove and Install Operator Seat Assembly (Made by GRAMMER) 3123
How to Remove Operator Seat Assembly 3123
How to Install Operator Seat Assembly 3124
Remove and Install Operator Seat Assembly (Made by SEARS) 3126
How to Remove Operator Seat Assembly 3126
How to Install Operator Seat Assembly 3128
How to Remove and Install Seat Belt 3131
How to Remove Seat Belt 3131
How to Install Seatbelt 3132
Electrical System 3133
Remove and Install Engine Controller Assembly 3133
How to Remove Engine Controller Assembly 3133
How to Install Engine Controller Assembly 3135
Remove and Install Retarder and Hoist Controller Assembly 3138
How to Remove Retarder and Hoist Controller Assembly 3138
How to Install Retarder and Hoist Controller Assembly 3139
Remove and Install Transmission Controller Assembly 3140
How to Remove Transmission Controller Assembly 3140
How to Install Transmission Controller Assembly 3141
Remove and Install Machine Monitor Assembly 3142
How to Remove Machine Monitor Assembly 3142
How to Install Machine Monitor Assembly 3144
Remove and Install Mass Air Flow and Temperature Sensor 3147
How to Remove Mass Air Flow and Temperature Sensor 3147
How to Install Mass Air Flow and Temperature Sensor 3149
Remove and Install SCR Temperature Sensor 3151
How to Remove SCR Temperature Sensor 3151
How to Install SCR Temperature Sensor 3153
Remove and Install KOMTRAX Terminal Assembly 3155
How to Remove KOMTRAX Terminal Assembly 3155
How to Install KOMTRAX Terminal Assembly 3156
Remove and Install Gateway Function Controller Assembly 3157
How to Remove Gateway Function Controller Assembly 3157
How to Install Gateway Function Controller Assembly 3159
Remove and Install Communication Terminal Wiring Harness 3163
How to Remove Communication Terminal Wiring Harness 3163
How to Install Communication Terminal Wiring Harness 3170
Remove and Install Communication Terminal 3176
How to Remove Communication Terminal 3176
How to Install Communication Terminal 3182
60 Maintenance Standard 3189
Table of Contents 3190
Abbreviation List 3191
Engine and Cooling System 3197
Maintenance Standard for Engine Mount 3197
Maintenance Standard for Damper 3198
Maintenance Standard for Radiator Fan Pump 3199
Maintenance Standard for Servo Valve of Radiator Fan Pump 3200
Maintenance Standard for Radiator Fan Motor 3201
Maintenance Standard for Aftercooler Fan Motor 3203
Power Train 3206
Maintenance Standard for Drive Shaft 3206
Maintenance Standard for Torque Converter and Transmission Mount 3207
Maintenance Standard for Torque Converter and PTO 3208
Maintenance Standard for Lockup Clutch ECMV 3211
Maintenance Standard for Transmission 3212
Maintenance Standard for FL, R Clutch 3216
Maintenance Standard for FH, 1st Clutch 3217
Maintenance Standard for 2nd, 3rd Clutch 3218
Maintenance Standard for Differential Lock Clutch 3220
Maintenance Standard for Transmission Control Valve 3222
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 3223
Maintenance Standard for Differential Lock Clutch ECMV 3224
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 3225
Maintenance Standard for Front Axle 3227
Maintenance Standard for Center Axle 3228
Maintenance Standard for Rear Axle 3229
Maintenance Standard for Front Differential 3230
Maintenance Standard for Center Differential 3231
Maintenance Standard for Rear Differential 3232
Maintenance Standard for Front Final Drive 3233
Maintenance Standard for Center Final Drive 3235
Maintenance Standard for Rear Final Drive 3236
Steering System 3237
Maintenance Standard for Steering Column 3237
Maintenance Standard for Steering Cylinder 3238
Brake System 3239
Maintenance Standard for Front Slack Adjuster 3239
Maintenance Standard for Center Slack Adjuster 3240
Maintenance Standard for Front Brake 3241
Maintenance Standard for Center Brake 3243
Maintenance Standard for Parking Brake 3245
Undercarriage and Frame 3247
Maintenance Standard for Front Suspension 3247
Maintenance Standard for Center and Rear Suspensions 3249
Maintenance Standard for Suspension Cylinder 3252
Maintenance Standard for Oscillation Hitch 3254
Hydraulic System 3256
Maintenance Standard for Steering and Hoist Pump 3256
Maintenance Standard for Servo Valve for Steering and Hoist Pump 3257
Maintenance Standard for Power Train and Front Brake Cooling Duplex Pump and Aftercooler Fan Pump 3259
Maintenance Standard for Center Brake Cooling Pump 3261
Maintenance Standard for Brake Charge Pump 3262
Maintenance Standard for Hoist Valve 3263
Work Equipment 3265
Maintenance Standard for Hoist Cylinder 3265
80 Appendix 3267
Table of Contents 3268
Precautions Before Work 3270
Abbreviation List 3271
Air Conditioner System 3277
Precautions for Refrigerant 3277
Air Conditioner Component 3278
Specifications of Air Conditioner 3280
Structure and Function of Refrigeration Cycle 3281
Outline of Refrigeration Cycle 3282
Component Parts of Air Conditioner System 3284
Air Conditioner Unit 3284
Configuration Diagram of Air Conditioner Unit 3284
Function of Air Conditioner Unit 3286
Component Parts of Air Conditioner Unit 3288
Function of Evaporator as Air Conditioner Unit Component 3289
Function of Heater Core as Air Conditioner Unit Component 3289
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3289
Function of Servo Motor as Air Conditioner Unit Component 3289
Structure of Expansion Valve as Air Conditioner Unit Component 3290
Function of Expansion Valve as Air Conditioner Unit Component 3290
Operate Expansion Valve as Air Conditioner Unit Component 3290
Function of Dual Pressure Switch 3291
Air Conditioner Controller 3292
Structure of Air Conditioner Controller 3292
Compressor 3293
Structure of Compressor 3293
Specifications of Compressor 3293
Function of Compressor 3293
Condenser 3294
Structure of Condenser 3294
Specifications of Condenser 3294
Function of Condenser 3294
Receiver Drier 3295
Structure of Receiver Dryer 3295
Specifications of Receiver Dryer 3295
Function of Receiver Dryer 3295
Air Conditioner Related Sensors 3296
Structure of Outside Temperature Sensor 3296
Function of Outside Air Temperature Sensor 3296
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3297
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3299
System Diagram of Air Conditioner 3301
Input and Output Signals of Air Conditioner Controller 3302
Function of Air Conditioner Controller 3303
Locations of Air Conditioner Parts and Layout of Connectors 3304
Examine Air Leakage (Duct) 3307
How to Examine Air Leakage (Duct) 3307
Examine Air Conditioner with Self-Diagnosis Function 3311
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3312
Examine Vent (Mode) Changeover 3314
How to Examine Vent (Mode) Changeover 3314
Examine Fresh/Recirc Air Changeover 3315
How to Examine Fresh/Recirc Air Changeover 3315
Examine Refrigerant (Dual) Pressure Switch 3316
How to Examine Refrigerant (Dual) Pressure Switch 3316
Examine Relay 3317
How to Examine Relay 3317
Air Conditioner Troubleshooting Chart 1 3319
Air Conditioner Troubleshooting Chart 2 3320
Information Shown in Troubleshooting Table 3323
Failure Code [879AKA] 3324
Failure Code [879AKB] 3325
Failure Code [879BKA] 3326
Failure Code [879BKB] 3328
Failure Code [879CKA] 3330
Failure Code [879CKB] 3331
Failure Code [879EMC] 3332
Failure Code [879FMC] 3333
Failure Code [879GKX] 3334
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3336
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3338
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3341
Troubleshooting for Fresh/Recirc Air Changeover 3343
Troubleshooting by Gauge Pressure 3345
Connect Service Tool 3348
How to Connect Service Tool 3348
Precautions for Disconnection and Connection of Air Conditioner Piping 3350
Handle Compressor Oil 3352
90 Circuit Diagrams 3355
Table of Contents 3356
Abbreviation List 3358
Hydraulic Circuit Diagram 3364
Symbols Used in Hydraulic Circuit Diagram 3364
Hydraulic Circuit Diagram 3369
Power Train Hydraulic Circuit Diagram 3371
Hydraulic Circuit Diagram of Steering, Hoist (at Reverse 1st, Right Turn, Brake Operation) 3373
Hydraulic Circuit Diagram of Brake (at Reverse 1st + Right Turn + Brake Operation) 3374
Hydraulic Circuit Diagram of Power Train (at Reverse 1st + Right Turn + Brake Operation) 3375
Hydraulic Circuit Diagram of Steering, Hoist (at Dump Body RAISE, Forward 2nd Operation) 3377
Hydraulic Circuit Diagram of Power Train (at Dump Body RAISE, Forward 2nd Operation) 3379
Electrical Circuit Diagram 3381
Symbols Used in Electric Circuit Diagram 3381
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (1/8) 3385
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (2/8) 3387
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (3/8) 3389
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (4/8) 3391
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (5/8) 3393
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (6/8) 3395
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (7/8) 3397
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (8/8) 3399
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (1/8) 3401
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (2/8) 3403
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (3/8) 3405
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (4/8) 3407
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (5/8) 3409
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (6/8) 3411
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (7/8) 3413
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (8/8) 3415
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (1/9) 3417
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (2/9) 3419
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (3/9) 3421
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (4/9) 3423
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (5/9) 3425
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (6/9) 3427
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (7/9) 3429
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (8/9) 3431
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (9/9) 3433
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (1/9) 3435
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (2/9) 3437
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (3/9) 3439
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (4/9) 3441
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (5/9) 3443
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (6/9) 3445
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (7/9) 3447
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (8/9) 3449
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (9/9) 3451
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (1/8) 3453
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (2/8) 3455
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (3/8) 3457
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (4/8) 3459
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (5/8) 3461
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (6/8) 3463
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (7/8) 3465
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (8/8) 3467
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (1/8) 3469
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (2/8) 3471
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (3/8) 3473
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (4/8) 3475
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (5/8) 3477
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (6/8) 3479
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (7/8) 3481
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (8/8) 3483
Index 3485

DESCRIPTION:

Komatsu HM300-5 Dump Truck Shop Manual SEN06511-24 – PDF DOWNLOAD 

SERIAL NUMBERS 10001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.

Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

S.V 30/12/24