Komatsu HM300-5E0 Dump Truck Shop Manual SEN06746-14 PDF

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Komatsu HM300-5E0 Dump Truck Shop Manual SEN06746-14 – PDF DOWNLOAD

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Komatsu HM300-5E0 Dump Truck Shop Manual SEN06746-14 – PDF DOWNLOAD 

Language : English
Pages : 3504
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM300-5E0 Dump Truck Shop Manual SEN06746-14 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 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: HM300-5E0 105
Specifications 107
Specifications: HM300-5E0 107
Weight Table 113
Weight Table: HM300-5E0 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 236
Measurement Principle of Loading Mass 237
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 354
Transmission 357
Transmission Control Valve 379
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 381
Differential Lock Clutch ECMV 386
Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 389
Axle 393
Differential 396
Final Drive 400
Work Equipment System 404
Work Equipment Control 404
Layout Drawing of Work Equipment Control 404
Function of Work Equipment Control 405
Hoist Control 406
Hoist Control System Diagram 406
Function of Hoist Control 406
Component Parts of Work Equipment System 408
Hoist and Radiator Fan Direction Selector Solenoid Valve 408
Dump Lever 409
Dump EPC Valve 413
Steering System 415
Layout Drawing of Steering System 415
Function of Steering System 416
Steering Column 417
Structure of Steering Column 417
Component Parts of Steering System 418
Flow Amplifier Valve 418
Steering Valve 422
Steering Pump Selector Solenoid Valve 427
Secondary Steering Pump 428
Secondary Steering Motor 429
Brake System 430
Layout Drawing of Brake System 430
Retarder Control 431
Retarder Control System Diagram 431
Function of Retarder Control 432
Parking Brake Interlock Function 434
Function of Parking Brake Interlock Function 434
Operation of Parking Brake Interlock Function 434
ARAC System 435
ARAC System Diagram 435
Function of ARAC System 435
Component Parts of Brake System 436
Brake Charge Pump 436
Parking Brake Solenoid Valve and Accumulator Charge Valve 437
Parking Brake Solenoid Valve 438
Accumulator Charge Valve 438
Brake Circuit Accumulator 443
Shut Off Solenoid Valve 445
Brake Valve 446
Proportional Pressure Reducing Valve 449
Slack Adjuster 450
Brake 453
Brake Cooling Oil Control Valve 456
Front Brake Cooling Relief Valve 458
Brake System Tank 459
Parking Brake 460
Spring Cylinder 461
Parking Brake Caliper 463
Undercarriage and Frame 465
Front Suspension 465
Structure of Front Suspension 465
Function of Front Suspension 466
Center and Rear Suspensions 467
Structure of Center and Rear Suspensions 467
Function of Center Suspension 468
Function of Rear Suspension 469
Suspension Cylinder 470
Structure of Suspension Cylinder 470
Function of Suspension Cylinder 471
Operation of Suspension Cylinder 472
Oscillation Hitch 473
Structure of Oscillation Hitch 473
Function of Oscillation Hitch 474
Work Equipment 475
Structure of Work Equipment 475
Function of Work Equipment 476
CAB Related Parts 477
ROPS CAB 477
Structure of ROPS CAB 477
Function of ROPS CAB 478
CAB Tilt 479
Structure of CAB Tilt 479
20 Standard Value Table 481
Table of Contents 482
Abbreviation List 483
Standard Value Table for Engine 489
Standard Value Table for Engine: HM300-5E0 489
Standard Value Table for Machine 493
Standard Value Table for Machine: HM300-5E0 493
Machine Posture and Procedures to Measure Performance 507
Standard Value Table for Electricity 508
Standard Value Table for Electricity 508
30 Testing and Adjusting 523
Table of Contents 524
Precautions Before Work 527
Abbreviation List 528
Related Information on Testing and Adjusting 534
Tools for Testing and Adjusting 534
Sketch of Tools for Testing and Adjusting 542
Engine and Cooling System 543
Examine Engine Speed 543
How to Examine Engine Speed 543
Examine Boost Pressure 546
How to Examine Boost Pressure 546
Examine Exhaust Gas Temperature 548
How to Examine Exhaust Gas Temperature 548
Examine Exhaust Gas Color 551
How to Examine Exhaust Gas Color with the Handy Smoke Checker 551
How to Examine Exhaust Gas Color with Smoke Meter 552
Examine Mass Air Flow and Temperature Sensor 554
How to Examine Mass Air Flow and Temperature Sensor 554
Examine and Adjust Valve Clearance 557
How to Examine Valve Clearance 557
How to Adjust Valve Clearance 558
Examine Compression Pressure 560
How to Examine Compression Pressure 560
Examine Blowby Pressure 563
How to Examine Blowby Pressure 563
Examine Engine Oil Pressure 566
How to Examine Engine Oil Pressure on Machine Monitor 566
How to Examine Engine Oil Pressure by Testing Tool 566
Examine EGR Valve and VGT Oil Pressure 568
How to Examine EGR Valve and VGT Oil Pressure 568
Examine Fuel Pressure 570
How to Examine Fuel Pressure 570
Examine Fuel Return Rate and Leakage 572
How to Examine Fuel Return Rate and Leakage 573
Bleed Air from Fuel System 578
How to Bleed Air from Fuel System 578
Examine Fuel Circuit for Leakage 580
How to Examine Fuel System for Leakage 580
Handle Cylinder Cut-out Mode Operation 582
Handle No-Injection Cranking Operation 583
Examine and Adjust Air Conditioner Compressor Belt Tension 584
How to Examine Air Conditioner Compressor Belt Tension 584
How to Adjust Air Conditioner Compressor Belt Tension 584
Clean Fuel Doser 585
How to Clean Fuel Doser 585
Write Injector Compensation Value to Engine Controller 588
How to Write Injector Compensation Value 588
Write Correction for Ash in Soot Accumulation to Engine Controller 595
How to Write Correction for Ash in Soot Accumulation to Engine Controller 595
Examine SCR Related Functions 596
Examine DEF Pump Raised Pressure 600
Examine Injection Volume from DEF Injector 603
Examine DEF Line Heater Relay 1 608
Examine DEF Line Heater Relay 2 612
Examine DEF Pump Heater Relay 616
Examine DEF Tank Heater Valve 620
Examine SCR Denitration Efficiency 624
Clean DEF Tank 628
How to Clean DEF Tank 628
Clean DEF Pump 633
How to Clean DEF Pump 633
Examine Torque Converter Stall Speed 640
How to Examine Torque Converter Stall Speed 640
Examine Radiator Fan and Aftercooler Fan Speed 645
How to Examine Radiator Fan and Aftercooler Fan Speed 645
Power Train 647
Examine Power Train Oil Pressure 647
How to Examine Power Train Oil Pressure 650
Adjust Transmission Speed Sensor 665
How to Adjust Transmission Speed Sensor 665
Adjust Transmission Controller 668
How to Adjust Transmission Controller 668
Move Machine Which Has a Trouble in Electrical System 669
How to Move Machine Which Has a Trouble in Engine Control System 669
How to Move Machine Which Has a Trouble in Transmission Control System 669
Move Machine Which Has a Trouble in Traction Control System (KTCS) 676
How to Move Machine with Secondary KTCS Operation Connector 678
Steering System 679
Examine and Adjust Steering Circuit Oil Pressure 679
How to Examine Steering Circuit Oil Pressure 679
How to Adjust Steering Circuit Oil Pressure 680
Bleed Air from Steering Cylinder Circuit 681
How to Bleed Air from Steering Cylinder Circuit 681
Brake System 683
Examine and Adjust Brake Oil Pressure 683
How to Examine Brake Oil Pressure 683
How to Adjust Brake Oil Pressure 687
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 688
How to Examine Accumulator Nitrogen Gas Pressure 688
How to Charge Accumulator Nitrogen Gas for Brake 692
Release Remained Pressure in Brake Accumulator Circuit 697
How to Release Remained Pressure in Brake Accumulator Circuit 697
Bleed Air from Brake Circuit 698
How to Bleed Air from Brake Circuit 698
Examine Brake Performance 700
How to Examine Brake Performance 700
Examine Wear of Wheel Brake Disc 704
How to Examine Wear of Wheel Brake Disc 704
Release Parking Brake Manually 706
How to Release Parking Brake Manually 706
Examine and Adjust Wear of Parking Brake Pad 707
How to Examine Wear of Parking Brake Pad 707
How to Adjust Clearance of Parking Brake Pad 708
Hydraulic System 710
Examine and Adjust Suspension Cylinder 710
How to Examine Suspension Cylinder 711
How to Adjust Suspension Cylinder 711
Examine and Adjust Dump Circuit Oil Pressure 716
How to Examine Dump Circuit Oil Pressure 716
How to Adjust Dump Circuit Oil Pressure 717
Work Equipment 719
Examine and Adjust Dump Body Positioner Sensor 719
How to Examine Dump Body Positioner Sensor 719
How to Adjust Dump Body Positioner Sensor 719
Examine and Adjust Dump Body Mount 721
How to Examine Dump Body Mount 721
How to Adjust Dump Body Mount 722
CAB Related Parts 723
CAB Tilt Up 723
How to Tilt Up Cab 724
Adjust Tilt Lock Lever of Steering Wheel 730
How to Adjust Tilt Lock Lever of Steering Wheel 730
Adjust Play of Operator Seat 732
How to Adjust Play of Operator Seat 732
Electrical System 733
Set and Adjust Each Equipment 733
Prepare for Transmission ECMV Current Adjustment 735
How to Adjust Transmission ECMV Current 736
How to Set and Reset Transmission Initial Learning 739
How to Set Property Value of ARAC (Automatic Retarder Accelerator Control) 744
How to Do System Check of KTCS (Komatsu Traction Control System) 747
Set and Operate Machine Monitor 749
Operator Mode 753
Function to Show Technician Identification Status Screen 753
Function to Show Operator Identification Input Screen 753
Examine Function by LCD (Liquid Crystal Display) 754
Examine Function of Service Meter and Odometer 755
How to Set Usage Limitation and Change Maintenance Password 755
Service Mode 759
How to Operate Service Mode 759
How to See Pre-defined Monitoring Information 762
How to Examine Self-Define Monitor Information 770
Abnormality Record Menu 787
How to See Maintenance Record 792
Maintenance Mode Setting 794
How to Set Phone Number Entry 798
Default Menu 800
Diagnostic Tests Menu 815
Adjustment Menu 826
No-Injection Cranking Operation 832
Payload Meter Setting 834
KOMTRAX Settings Menu 857
How to Show Service Message 861
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 863
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 867
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 869
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 874
Adjust Optical Axis of Head Lamp 876
How to Adjust Optical Axis of Head Lamp 876
Set Region of Bluetooth(R) Compatible Radio 880
How to Set Region of Bluetooth(R) Compatible Radio 880
Handle Voltage Circuit of Engine Controller 882
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 883
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 884
Examine Diodes 885
How to Examine Diodes by Digital Tester 885
How to Examine Diodes by Analog Tester 885
Pm Clinic 886
Pm Clinic Service 886
Pm-Clinic Check Sheet: HM300-5E0 889
40 Troubleshooting 899
Table of Contents 900
Precautions Before Work 913
Abbreviation List 914
Related Information to Troubleshooting 920
General Troubleshooting Points 920
Troubleshooting Points for Urea SCR System 921
Sequence of Events in Troubleshooting 935
Checks Before Troubleshooting 937
Inspection Procedure Before Troubleshooting 939
Walk-Around Check 939
Test in Accordance with Testing Procedure 941
Examine Fuel Level and Type 941
Examine for Impure Ingredient in Fuel 941
Examine DEF Level and Type 942
Examine Fuel Prefilter 942
Examine Fuel Main Filter 944
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 945
Examine Coolant Level (Reservoir Tank) 946
Examine Air Cleaner Clogging 947
Clean Outer Element 948
Replace Element 950
Examine Hydraulic Oil Level 952
Examine Hydraulic Oil Strainer 952
Examine Hydraulic Oil Filter 953
Examine Oil Level in Transmission Case 953
Examine Oil Level in Differential Case 954
Examine Oil Level in Final Drive Case 955
Bleed Air from Fuel System 955
Bleed Air from Hydraulic System 955
How to Examine Electric Equipment 955
Preparation for Troubleshooting of Electrical System 965
Procedure for Troubleshooting 974
Symptom and Troubleshooting Numbers 976
Information Shown in Troubleshooting Table 979
Connector List and Layout 981
Connector Contact Connection Table 1007
T-Branch Box and T-Branch Adapter Table 1047
Fuse Location Table (Machine with KOMTRAX Terminal) 1053
Fuse Location Table (Machine with Gateway Function Controller) 1057
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1061
Prepare Troubleshoot Machine Monitor 1065
Procedure to Make Harness Checker on Machine Monitor LCD Unit 1067
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1073
Failure Code Table 1075
Troubleshooting by Failure Code (Display of Code) 1101
Failure Code [1500L0] 1101
Failure Code [15B0NX] 1102
Failure Code [15F0KM] 1104
Failure Code [15F0MB] 1105
Failure Code [15F7KM] 1106
Failure Code [15G0MW] 1107
Failure Code [15G7KM] 1110
Failure Code [15H0MW] 1111
Failure Code [15J0MW] 1114
Failure Code [15K0MW] 1117
Failure Code [15L0MW] 1120
Failure Code [15M0MW] 1123
Failure Code [15SBL1] 1126
Failure Code [15SBMA] 1129
Failure Code [15SCL1] 1130
Failure Code [15SCMA] 1134
Failure Code [15SDL1] 1135
Failure Code [15SDMA] 1138
Failure Code [15SEL1] 1139
Failure Code [15SEMA] 1142
Failure Code [15SFL1] 1143
Failure Code [15SFMA] 1146
Failure Code [15SGL1] 1147
Failure Code [15SGMA] 1150
Failure Code [15SJMA] 1151
Failure Code [15SKMA] 1153
Failure Code [2F00KM] 1155
Failure Code [2G42ZG] 1157
Failure Code [2G43ZG] 1158
Failure Code [879AKA] 1159
Failure Code [879AKB] 1160
Failure Code [879BKA] 1161
Failure Code [879BKB] 1163
Failure Code [879CKA] 1165
Failure Code [879CKB] 1166
Failure Code [879EMC] 1167
Failure Code [879FMC] 1168
Failure Code [879GKX] 1169
Failure Code [989D00] 1171
Failure Code [989L00] 1172
Failure Code [989M00] 1173
Failure Code [989N00] 1174
Failure Code [A1U0N3] 1175
Failure Code [A1U0N4] 1177
Failure Code [AA10NX] 1179
Failure Code [AB00KE] 1181
Failure Code [AB00KY] 1183
Failure Code [AQ10N3] 1185
Failure Code [AS00N3] 1187
Failure Code [AS00R2] 1189
Failure Code [AS00R3] 1190
Failure Code [AS00R4] 1191
Failure Code [AS00R5] 1192
Failure Code [AS00R6] 1193
Failure Code [AS00ZK] 1194
Failure Code [AS10KM] 1195
Failure Code [AS10NR] 1196
Failure Code [AS10NT] 1197
Failure Code [B@BAZG] 1198
Failure Code [B@BAZK] 1199
Failure Code [B@BCNS] 1200
Failure Code [B@BCQA] 1201
Failure Code [B@BCZK] 1203
Failure Code [B@C6NS] 1205
Failure Code [B@C8NS] 1206
Failure Code [B@CENS] 1207
Failure Code [B@JANS] 1208
Failure Code [CA115] 1209
Failure Code [CA122] 1210
Failure Code [CA123] 1212
Failure Code [CA131] 1214
Failure Code [CA132] 1216
Failure Code [CA135] 1219
Failure Code [CA141] 1221
Failure Code [CA144] 1223
Failure Code [CA145] 1225
Failure Code [CA153] 1227
Failure Code [CA154] 1230
Failure Code [CA187] 1233
Failure Code [CA221] 1235
Failure Code [CA222] 1237
Failure Code [CA227] 1239
Failure Code [CA234] 1240
Failure Code [CA238] 1241
Failure Code [CA239] 1243
Failure Code [CA249] 1245
Failure Code [CA256] 1247
Failure Code [CA271] 1249
Failure Code [CA272] 1251
Failure Code [CA273] 1252
Failure Code [CA274] 1254
Failure Code [CA322] 1255
Failure Code [CA323] 1257
Failure Code [CA324] 1259
Failure Code [CA325] 1261
Failure Code [CA331] 1263
Failure Code [CA332] 1265
Failure Code [CA343] 1267
Failure Code [CA351] 1268
Failure Code [CA352] 1269
Failure Code [CA356] 1272
Failure Code [CA357] 1274
Failure Code [CA386] 1276
Failure Code [CA431] 1277
Failure Code [CA432] 1280
Failure Code [CA441] 1284
Failure Code [CA442] 1287
Failure Code [CA449] 1288
Failure Code [CA451] 1289
Failure Code [CA452] 1291
Failure Code [CA515] 1293
Failure Code [CA516] 1295
Failure Code [CA553] 1297
Failure Code [CA555] 1298
Failure Code [CA556] 1299
Failure Code [CA559] 1300
Failure Code [CA595] 1305
Failure Code [CA687] 1306
Failure Code [CA689] 1308
Failure Code [CA691] 1310
Failure Code [CA692] 1312
Failure Code [CA697] 1314
Failure Code [CA698] 1315
Failure Code [CA731] 1316
Failure Code [CA778] 1317
Failure Code [CA1117] 1320
Failure Code [CA1664] 1321
Failure Code [CA1669] 1324
Failure Code [CA1673] 1325
Failure Code [CA1677] 1326
Failure Code [CA1678] 1327
Failure Code [CA1682] 1328
Failure Code [CA1683] 1332
Failure Code [CA1684] 1334
Failure Code [CA1686] 1336
Failure Code [CA1691] 1337
Failure Code [CA1694] 1340
Failure Code [CA1695] 1342
Failure Code [CA1696] 1343
Failure Code [CA1712] 1345
Failure Code [CA1713] 1348
Failure Code [CA1714] 1350
Failure Code [CA1715] 1351
Failure Code [CA1776] 1352
Failure Code [CA1777] 1355
Failure Code [CA1843] 1358
Failure Code [CA1844] 1360
Failure Code [CA1879] 1363
Failure Code [CA1881] 1366
Failure Code [CA1883] 1368
Failure Code [CA1885] 1372
Failure Code [CA1887] 1374
Failure Code [CA1921] 1376
Failure Code [CA1922] 1379
Failure Code [CA1923] 1384
Failure Code [CA1924] 1386
Failure Code [CA1925] 1389
Failure Code [CA1927] 1392
Failure Code [CA1928] 1394
Failure Code [CA1942] 1396
Failure Code [CA1963] 1397
Failure Code [CA1977] 1401
Failure Code [CA1993] 1404
Failure Code [CA2185] 1407
Failure Code [CA2186] 1409
Failure Code [CA2249] 1411
Failure Code [CA2265] 1412
Failure Code [CA2266] 1414
Failure Code [CA2271] 1417
Failure Code [CA2272] 1419
Failure Code [CA2349] 1422
Failure Code [CA2353] 1424
Failure Code [CA2357] 1426
Failure Code [CA2381] 1427
Failure Code [CA2382] 1429
Failure Code [CA2383] 1431
Failure Code [CA2386] 1433
Failure Code [CA2387] 1435
Troubleshooting Flowchart 1439
Failure Code [CA2555] 1440
Failure Code [CA2556] 1442
Failure Code [CA2637] 1444
Failure Code [CA2639] 1446
Failure Code [CA2732] 1449
Failure Code [CA2733] 1451
Failure Code [CA2741] 1453
Failure Code [CA2765] 1454
Failure Code [CA2771] 1455
Failure Code [CA2777] 1461
Failure Code [CA2878] 1464
Failure Code [CA2881] 1467
Failure Code [CA2976] 1470
Failure Code [CA3133] 1472
Failure Code [CA3134] 1474
Failure Code [CA3135] 1476
Failure Code [CA3142] 1480
Failure Code [CA3143] 1481
Failure Code [CA3144] 1482
Failure Code [CA3146] 1484
Failure Code [CA3147] 1485
Failure Code [CA3148] 1486
Failure Code [CA3151] 1488
Failure Code [CA3165] 1494
Failure Code [CA3167] 1496
Failure Code [CA3229] 1499
Failure Code [CA3231] 1501
Failure Code [CA3232] 1503
Failure Code [CA3235] 1507
Failure Code [CA3239] 1509
Failure Code [CA3241] 1512
Failure Code [CA3242] 1515
Failure Code [CA3251] 1518
Failure Code [CA3253] 1520
Failure Code [CA3254] 1524
Failure Code [CA3255] 1527
Failure Code [CA3256] 1531
Failure Code [CA3311] 1533
Failure Code [CA3312] 1535
Failure Code [CA3313] 1538
Failure Code [CA3314] 1539
Failure Code [CA3315] 1540
Failure Code [CA3316] 1543
Failure Code [CA3317] 1544
Failure Code [CA3318] 1545
Failure Code [CA3319] 1548
Failure Code [CA3321] 1549
Failure Code [CA3322] 1551
Failure Code [CA3419] 1554
Failure Code [CA3421] 1556
Failure Code [CA3497] 1558
Failure Code [CA3498] 1559
Failure Code [CA3543] 1560
Failure Code [CA3545] 1567
Failure Code [CA3547] 1569
Failure Code [CA3558] 1570
Failure Code [CA3559] 1572
Failure Code [CA3562] 1574
Failure Code [CA3563] 1576
Failure Code [CA3567] 1579
Failure Code [CA3568] 1582
Failure Code [CA3571] 1588
Failure Code [CA3572] 1590
Failure Code [CA3574] 1592
Failure Code [CA3575] 1595
Failure Code [CA3577] 1597
Failure Code [CA3578] 1599
Failure Code [CA3582] 1601
Failure Code [CA3583] 1608
Failure Code [CA3596] 1610
Failure Code [CA3649] 1615
Failure Code [CA3681] 1617
Failure Code [CA3682] 1622
Failure Code [CA3713] 1628
Failure Code [CA3717] 1631
Failure Code [CA3718] 1632
Failure Code [CA3725] 1633
Failure Code [CA3748] 1636
Failure Code [CA3751] 1639
Failure Code [CA3755] 1641
Failure Code [CA3866] 1643
Failure Code [CA3867] 1647
Failure Code [CA3868] 1650
Failure Code [CA3899] 1654
Failure Code [CA3911] 1656
Failure Code [CA3912] 1660
Failure Code [CA3932] 1662
Failure Code [CA3933] 1664
Failure Code [CA3934] 1666
Failure Code [CA3935] 1669
Failure Code [CA3936] 1671
Failure Code [CA4151] 1673
Failure Code [CA4152] 1677
Failure Code [CA4155] 1681
Failure Code [CA4156] 1684
Failure Code [CA4157] 1687
Failure Code [CA4158] 1689
Failure Code [CA4159] 1690
Failure Code [CA4161] 1691
Failure Code [CA4162] 1694
Failure Code [CA4163] 1697
Failure Code [CA4164] 1699
Failure Code [CA4165] 1701
Failure Code [CA4166] 1703
Failure Code [CA4168] 1705
Failure Code [CA4169] 1708
Failure Code [CA4171] 1712
Failure Code [CA4249] 1716
Failure Code [CA4251] 1720
Failure Code [CA4259] 1724
Failure Code [CA4261] 1727
Failure Code [CA4277] 1729
Failure Code [CA4281] 1733
Failure Code [CA4459] 1736
Failure Code [CA4461] 1739
Failure Code [CA4658] 1742
Failure Code [CA4731] 1746
Failure Code [CA4732] 1747
Failure Code [CA4739] 1748
Failure Code [CA4768] 1749
Failure Code [CA4769] 1751
Failure Code [CA4842] 1754
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1758
Failure Code [CA4952] (Machine with Gateway Function Controller) 1760
Failure Code [CA5115] 1762
Failure Code [CA5179] 1765
Failure Code [CA5181] 1767
Failure Code [CA5383] 1769
Failure Code [D150KB] 1771
Failure Code [D150KZ] 1772
Failure Code [D164KY] 1773
Failure Code [D19HKZ] 1775
Failure Code [D19JKZ] 1777
Failure Code [D1EHKA] 1779
Failure Code [D1EHKB] 1780
Failure Code [D1EHKY] 1781
Failure Code [D1EMKA] 1782
Failure Code [D1EMKB] 1783
Failure Code [D1EMKY] 1784
Failure Code [D1FBKB] 1785
Failure Code [D5ZHL6] 1787
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1789
Failure Code [D811MC] (Machine with Gateway Function Controller) 1790
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1791
Failure Code [D862KA] (Machine with Gateway Function Controller) 1792
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1793
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1795
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1797
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1799
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal) 1801
Failure Code [D8AQK4] (Machine with Gateway Function Controller) 1802
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1803
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1805
Failure Code [D8G1KT] 1807
Failure Code [D8G6KT] 1808
Failure Code [DAF0KT] 1809
Failure Code [DAF0MB] 1810
Failure Code [DAF0MC] 1811
Failure Code [DAF3KK] 1812
Failure Code [DAF8KB] 1814
Failure Code [DAFDKB] 1816
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1818
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1819
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1820
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1822
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1824
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1826
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1828
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1829
Failure Code [DAQ0KK] 1830
Failure Code [DAQ0KT] 1832
Failure Code [DAQ0MC] 1833
Failure Code [DAQ1KA] 1834
Failure Code [DAQ2KK] 1837
Failure Code [DAQ9KQ] 1839
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal) 1840
Failure Code [DAQLKA] (Machine with Gateway Function Controller) 1842
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal) 1844
Failure Code [DAQLKB] (Machine with Gateway Function Controller) 1846
Failure Code [DAQQKR] 1848
Failure Code [DAQRKR] 1849
Failure Code [DAQRMA] 1850
Failure Code [DAQV00] 1851
Failure Code [DAQW00] 1852
Failure Code [DAZ9KQ] 1853
Failure Code [DAZQKR] 1854
Failure Code [DB10KT] 1855
Failure Code [DB10MC] 1856
Failure Code [DB11KA] 1857
Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch) 1859
Failure Code [DB12KK] 1862
Failure Code [DB13KK] 1864
Failure Code [DB19KQ] 1866
Failure Code [DB1LKA] (Machine with KOMTRAX Terminal) 1867
Failure Code [DB1LKA] (Machine with Gateway Function Controller) 1869
Failure Code [DB1LKB] (Machine with KOMTRAX Terminal) 1871
Failure Code [DB1LKB] (Machine with Gateway Function Controller) 1873
Failure Code [DB1QKR] 1875
Failure Code [DB1QMA] 1876
Failure Code [DB1RKR] 1877
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1878
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1884
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1890
Failure Code [DB2QKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1896
Failure Code [DB2RKR] 1902
Failure Code [DBS0KK] 1908
Failure Code [DBS0KK] (Machine with Payload Meter Controller: CR720) 1911
Failure Code [DBS6KP] 1914
Failure Code [DBS6KP] (Machine with Payload Meter Controller: CR720) 1917
Failure Code [DBSQKQ] 1920
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) 1921
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1926
Failure Code [DBSQKR] (Machine with Gateway Function Controller) 1931
Failure Code [DBSQKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1936
Failure Code [DD1ML4] 1941
Failure Code [DDAAL6] 1944
Failure Code [DDAAL6] (Machine with Emergency Engine Stop Switch) 1946
Failure Code [DDTHKA] 1949
Failure Code [DDTJKA] 1951
Failure Code [DDTKKA] 1953
Failure Code [DDTLKA] 1955
Failure Code [DDTMKA] 1957
Failure Code [DDTNKA] 1959
Failure Code [DF10KA] 1961
Failure Code [DF10KB] 1965
Failure Code [DGF1KX] 1970
Failure Code [DGR3KB] 1972
Failure Code [DGR3L8] 1973
Failure Code [DGR4KB] 1975
Failure Code [DGR4L8] 1976
Failure Code [DGR6KB] 1978
Failure Code [DGR6L8] 1979
Failure Code [DGT1KX] 1981
Failure Code [DHAAMA] 1983
Failure Code [DHACMA] 1985
Failure Code [DHP4KY] 1987
Failure Code [DHP4KY] (Machine with Payload Meter Controller: CR720) 1989
Failure Code [DHP4KZ] 1991
Failure Code [DHP4KZ] (Machine with Payload Meter Controller: CR720) 1993
Failure Code [DHP5KY] 1995
Failure Code [DHP5KY] (Machine with Payload Meter Controller: CR720) 1997
Failure Code [DHP5KZ] 1999
Failure Code [DHP5KZ] (Machine with Payload Meter Controller: CR720) 2001
Failure Code [DHP6KY] 2003
Failure Code [DHP6KY] (Machine with Payload Meter Controller: CR720) 2005
Failure Code [DHP6KZ] 2007
Failure Code [DHP6KZ] (Machine with Payload Meter Controller: CR720) 2009
Failure Code [DHP7KY] 2011
Failure Code [DHP7KY] (Machine with Payload Meter Controller: CR720) 2013
Failure Code [DHP7KZ] 2015
Failure Code [DHP7KZ] (Machine with Payload Meter Controller: CR720) 2017
Failure Code [DHQ2KX] 2019
Failure Code [DHT5KX] 2021
Failure Code [DHT5L6] 2023
Failure Code [DHT8KX] 2025
Failure Code [DHT8ZG] 2027
Failure Code [DHU2KX] 2029
Failure Code [DHU3KX] 2031
Failure Code [DHUAKX] 2033
Failure Code [DHUBKX] 2035
Failure Code [DHUCKX] 2037
Failure Code [DHUDKX] 2039
Failure Code [DHUQKX] 2041
Failure Code [DHURKX] 2043
Failure Code [DJF1KA] 2045
Failure Code [DK30KX] 2047
Failure Code [DK51L5] 2049
Failure Code [DK52KX] 2052
Failure Code [DK53L8] 2054
Failure Code [DK54KX] 2056
Failure Code [DK60KX] 2058
Failure Code [DKH0KX] 2060
Failure Code [DKH1KX] 2062
Failure Code [DKH1KX] (Machine with Payload Meter Controller: CR720) 2064
Failure Code [DLF1KA] 2066
Failure Code [DLF1LC] 2068
Failure Code [DLF2KA] 2070
Failure Code [DLF2LC] 2072
Failure Code [DLF400] 2074
Failure Code [DLF4KA] 2075
Failure Code [DLF4LC] 2077
Failure Code [DLF6LC] 2079
Failure Code [DLF7LC] 2081
Failure Code [DLFDLC] 2083
Failure Code [DLFELC] 2085
Failure Code [DLFFLC] 2087
Failure Code [DLFGLC] 2088
Failure Code [DLM3KA] 2089
Failure Code [DLM3LC] 2091
Failure Code [DLM3MB] 2093
Failure Code [DLM4KA] 2094
Failure Code [DLM4LC] 2096
Failure Code [DLM4MB] 2098
Failure Code [DLT3KA] 2100
Failure Code [DLT3LC] 2102
Failure Code [DPQ1KR] 2104
Failure Code [DPQ2KR] 2107
Failure Code [DPQ3KR] 2110
Failure Code [DSJ0KR] 2114
Failure Code [DV00KB] 2115
Failure Code [DW2BKA] 2117
Failure Code [DW2BKB] 2118
Failure Code [DW2BKY] 2119
Failure Code [DW2BL1] 2120
Failure Code [DW2BLH] 2121
Failure Code [DW4BK4] 2122
Failure Code [DW4BMA] 2125
Failure Code [DW72KZ] 2128
Failure Code [DW73KA] 2130
Failure Code [DW73KB] 2132
Failure Code [DW73KY] 2134
Failure Code [DW78KZ] 2136
Failure Code [DW7BKB] 2138
Failure Code [DW7BKY] 2140
Failure Code [DW7BKZ] 2141
Failure Code [DW7LKB] 2143
Failure Code [DW7LKY] 2144
Failure Code [DW7LKZ] 2145
Failure Code [DW7MKB] 2146
Failure Code [DW7MKY] 2148
Failure Code [DW7MKZ] 2149
Failure Code [DW7NKZ] 2151
Failure Code [DWNJKZ] 2153
Failure Code [DWNKKZ] 2155
Failure Code [DX13KA] 2157
Failure Code [DX13KB] 2159
Failure Code [DX13KY] 2161
Failure Code [DX16KA] 2163
Failure Code [DX16KB] 2164
Failure Code [DX16KY] 2166
Failure Code [DX29KA] 2167
Failure Code [DX29KB] 2169
Failure Code [DX29KY] 2171
Failure Code [DX30K4] 2172
Failure Code [DX30KA] 2174
Failure Code [DX30KB] 2176
Failure Code [DX30KY] 2178
Failure Code [DX30MA] 2180
Failure Code [DX31K4] 2182
Failure Code [DX31KA] 2184
Failure Code [DX31KB] 2186
Failure Code [DX31KY] 2188
Failure Code [DX31MA] 2190
Failure Code [DX32K4] 2192
Failure Code [DX32KA] 2194
Failure Code [DX32KB] 2196
Failure Code [DX32KY] 2198
Failure Code [DX32MA] 2200
Failure Code [DX33K4] 2202
Failure Code [DX33KA] 2204
Failure Code [DX33KB] 2206
Failure Code [DX33KY] 2208
Failure Code [DX33MA] 2210
Failure Code [DXH0KA] 2212
Failure Code [DXH0KB] 2214
Failure Code [DXH0KY] 2216
Failure Code [DXH1KA] 2218
Failure Code [DXH1KB] 2220
Failure Code [DXH1KY] 2222
Failure Code [DXH2KA] 2224
Failure Code [DXH2KB] 2227
Failure Code [DXH2KY] 2230
Failure Code [DXH3KA] 2233
Failure Code [DXH3KB] 2236
Failure Code [DXH3KY] 2239
Failure Code [DXH4KA] 2242
Failure Code [DXH4KB] 2244
Failure Code [DXH4KY] 2246
Failure Code [DXH5KA] 2249
Failure Code [DXH5KB] 2251
Failure Code [DXH5KY] 2253
Failure Code [DXH6KA] 2256
Failure Code [DXH6KB] 2258
Failure Code [DXH6KY] 2260
Failure Code [DXH7KA] 2263
Failure Code [DXH7KB] 2265
Failure Code [DXH7KY] 2267
Failure Code [DY30MA] 2270
Failure Code [DY30MC] 2272
Failure Code [DY30ME] 2275
Failure Code [F313KA] 2277
Failure Code [F313KB] 2279
Failure Code [F318KB] 2280
Failure Code [F318KY] 2282
Troubleshooting of Electrical System (E-Mode) 2283
Engine Does Not Start (Engine Does Not Crank) 2283
Manual Preheating System Does Not Operate 2289
Automatic Preheating System Does Not Operate 2292
While Preheating is in Operation, Preheating Monitor Does Not Come On 2294
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 2296
All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed) 2299
LCD Unit on Machine Monitor Shows Nothing 2302
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 2305
LCD Screen on Machine Monitor Does Not Show Correctly 2308
Meter Unit Display on Machine Monitor is Abnormal 2311
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 2314
LED Unit Lamp on Machine Monitor is Abnormal 2318
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly 2320
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 2323
Switch Panel Buzzer of Machine Monitor is Abnormal 2326
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 2329
DEF Level is Not Shown Correctly 2330
Rearview Monitor Does Not Come On or Backlight Flickers 2333
Rearview Monitor Images are Not Shown Clearly 2336
Rearview Monitor Brightness Cannot be Adjusted 2340
Night Mode Lamp of Rearview Monitor is Abnormal 2343
Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled 2345
Guide Line on Rearview Monitor is Not Shown While Guide Line is Set 2348
Fuel Gauge Does Not Show Normally 2350
Seatbelt Caution Lamp Does Not Show Normally 2352
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 2353
Alarm Buzzer Does Not Operate 2354
Alarm Buzzer Does Not Stop 2355
Engine Mode Selector Function Does Not Operate Correctly 2357
AISS Function Does Not Operate Correctly 2359
Hoist Lever Does Not Operate Correctly 2361
Fuel Feed Pump Does Not Operate or Stop Automatically 2363
Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly 2366
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 2370
Clearance Lamp Does Not Come On 2372
Tail Lamp Does Not Come On 2374
Headlamp (Low Beam) Does Not Come On 2376
Headlamp (High Beam) Does Not Come On 2378
Head Lamps (Low Beam) and (High Beam) Do Not Come on 2380
Passing Lamp Does Not Come On 2382
KOMTRAX System Does Not Operate Correctly (Machine with KOMTRAX Terminal) 2384
KOMTRAX System Does Not Operate Correctly (Machine with Gateway Function Controller) 2386
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2388
Information Shown in Troubleshooting Table (H-Mode) 2388
System Chart of Hydraulic and Mechanical Systems 2389
Failure Mode and Cause Table 2391
Machine Does Not Start 2401
Machine Does Not Travel Smoothly (Machine Hunts) 2404
Lockup is Not Released 2405
Strong Shock is Made When You Start Machine or Shift Gears 2406
Shiftup Does Not Operate 2408
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 2411
Travel Speed is Low or Power is Low During Travel with Torque Converter 2412
Travel Speed is Low or Power is Low in Specified Gear Speed 2413
Time Lag is Large When You Start Machine or Shift Gears 2415
Torque Converter Oil Temperature is High 2418
Torque Converter Oil Pressure is Low 2420
Steering Wheel is Heavy to Operate 2422
Steering Wheel is Disabled 2423
Steering Wheel Waggles 2424
Front Brake Does Not Operate Sufficiently 2425
Center Brake Does Not Work Sufficiently 2426
Speed is Low When Dump Body is Raised 2427
Hydraulic Drift of Dump Body is Large 2429
Dump Body is Disabled 2430
Radiator Fan Speed is Unusual (Too High or Low, or Fan Stops) 2432
Aftercooler Fan Speed is Unusual (Too Much High or Low, or Fan Stops) 2433
Unusual Noise is Heard from Around Radiator Fan 2434
Unusual Noise is Heard from Around Aftercooler Fan 2435
Troubleshooting of Engine (S-Mode) 2436
Information Shown in Troubleshooting Table (S-Mode) 2436
Engine Does Not Crank When Starting Switch is Turned to Start Position 2437
Engine Cranks but No Exhaust Smoke Comes Out 2438
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2439
Engine Startability is Unsatisfactory 2440
Engine Does Not Pick Up Smoothly 2442
Engine Stops During Operation 2444
Engine Does Not Rotate Smoothly 2446
Engine Lacks Output (or Lacks Power) 2447
KDPF Becomes Clogged in a Short Time 2449
Engine Oil Consumption is Excessive 2451
Engine Oil Becomes Dirty Quickly 2452
Fuel Consumption is Excessive 2453
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2454
Engine Oil Pressure Drops 2455
Fuel Mixes Into Engine Oil 2457
Water Mixes Into Engine Oil (Milky) 2458
Coolant Temperature Increases Too High (Overheat) 2459
Unusual Noise is Heard 2460
Vibration is Excessive 2461
Air Cannot be Bled from Fuel Circuit 2462
Active Regeneration is Done Frequently 2463
Active Regeneration Continues Long 2465
White Smoke is Exhausted During Active Regeneration 2466
DEF Consumption is Excessive 2467
There is an Unusual Smell (Irritating Odor) 2469
Foreign Materials Enter DEF (DEF Increases) 2470
50 Disassembly and Assembly 2471
Table of Contents 2472
Precautions Before Work 2477
Abbreviation List 2478
Related Information on Disassembly and Assembly 2484
How to Read This Manual 2484
Coating Materials List 2485
Special Tool List 2490
Sketches of Special Tools 2510
Engine and Cooling System 2528
Remove and Install Supply Pump Assembly 2528
How to Remove Supply Pump Assembly 2529
How to Install Supply Pump Assembly 2535
Remove and Install Injector Assembly 2541
How to Remove Injector Assembly 2542
How to Install Injector Assembly 2552
Remove and Install Fuel Doser Assembly 2566
How to Remove Fuel Doser Assembly 2566
How to Install Fuel Doser Assembly 2567
Remove and Install Cylinder Head Assembly 2569
How to Remove Cylinder Head Assembly 2570
How to Install Cylinder Head Assembly 2581
Remove and Install EGR Valve Assembly 2596
How to Remove EGR Valve Assembly 2596
How to Install EGR Valve Assembly 2597
Remove and Install EGR Cooler Assembly 2599
How to Remove EGR Cooler Assembly 2599
How to Install EGR Cooler Assembly 2604
Remove and Install Starter Assembly 2608
How to Remove Starting Motor Assembly 2608
How to Install Starting Motor Assembly 2610
Remove and Install Alternator Belt 2613
How to Remove Alternator Belt 2613
How to Install Alternator Belt 2615
Remove and Install Radiator Assembly 2617
How to Remove Radiator Assembly 2617
How to Install Radiator Assembly 2620
Remove and Install Cooling Fan and Fan Motor Assembly 2625
How to Remove Cooling Fan and Fan Motor Assembly 2625
How to Install Cooling Fan and Fan Motor Assembly 2629
Remove and Install Aftercooler Assembly 2635
How to Remove Aftercooler Assembly 2636
How to Install Aftercooler Assembly 2639
Remove and Install Aftercooler Fan and Fan Motor Assembly 2643
How to Remove Aftercooler Fan and Fan Motor Assembly 2643
How to Install Aftercooler Fan and Fan Motor Assembly 2644
Remove and Install Engine Assembly 2648
How to Remove Engine Assembly 2650
How to Install Engine Assembly 2656
Remove and Install Engine Front Oil Seal 2664
How to Remove Engine Front Oil Seal 2664
How to Install Engine Front Oil Seal 2668
Remove and Install Engine Rear Oil Seal 2674
How to Remove Engine Rear Oil Seal 2674
How to Install Engine Rear Oil Seal 2676
Remove and Install Output Shaft 2682
How to Remove Output Shaft 2683
How to Install Output Shaft 2686
Disassemble and Assemble Output Shaft 2692
How to Disassemble Output Shaft 2692
How to Assemble Output Shaft 2694
Remove and Install DEF Tank Assembly 2697
How to Remove DEF Tank Assembly 2697
How to Install DEF Tank Assembly 2703
Remove and Install DEF Tank Sensor Flange Assembly 2707
How to Remove DEF Tank Sensor Flange Assembly 2707
How to Install DEF Tank Sensor Flange Assembly 2712
Remove and Install DEF Tank Sensor 2717
How to Remove DEF Tank Sensor 2717
How to Install DEF Tank Sensor 2718
Remove and Install DEF Tank Strainer 2720
How to Remove DEF Tank Strainer 2720
How to Install DEF Tank Strainer 2720
Remove and Install KDPF Assembly 2721
How to Remove KDPF Assembly 2722
How to Install KDPF Assembly 2725
Disassemble and Assemble KDPF Assembly 2729
How to Disassemble KDPF Assembly 2729
How to Assemble KDPF Assembly 2733
Remove and Install SCR Assembly 2738
How to Remove SCR Assembly 2738
How to Install SCR Assembly 2742
Remove and Install KCCV Assembly 2747
How to Remove KCCV Assembly 2747
How to Install KCCV Assembly 2748
Remove and Install DEF Mixing Tube 2749
How to Remove DEF Mixing Tube 2749
How to Install DEF Mixing Tube 2755
Remove and Install DEF Injector 2762
How to Remove DEF Injector 2762
How to Install DEF Injector 2765
Remove and Install DEF Pump 2768
How to Remove DEF Pump 2768
How to Install DEF Pump 2772
Remove and Install DEF Hose 2776
How to Remove DEF Hose 2776
How to Install DEF Hose 2780
Remove and Install Air Cleaner Assembly 2784
How to Remove Air Cleaner Assembly 2784
How to Install Air Cleaner Assembly 2787
Remove and Install Air Conditioner Compressor Assembly 2790
How to Remove Air Conditioner Compressor Assembly 2790
How to Install Air Conditioner Compressor Assembly 2792
Remove and Install Air Conditioner Condenser Assembly 2794
How to Remove Air Conditioner Condenser Assembly 2794
How to Install Air Conditioner Condenser Assembly 2795
Power Train 2796
Remove and Install Transmission and Front Differential Assembly 2796
How to Remove Transmission and Front Differential Assembly 2797
How to Install Transmission and Front Differential Assembly 2809
Disconnect and Connect Transmission and Front Differential Assembly 2823
How to Disconnect Transmission and Front Differential Assembly 2823
How to Connect Transmission and Front Differential Assembly 2824
Disassemble and Assemble Front Differential Assembly 2826
How to Disassemble Front Differential Assembly 2826
How to Assemble Front Differential Assembly 2831
Disassemble and Assemble Torque Converter Assembly 2842
How to Disassemble Torque Converter Assembly 2843
How to Assemble Torque Converter Assembly 2847
Disassemble and Assemble Transmission Assembly 2852
How to Disassemble Transmission Assembly 2853
How to Assemble Transmission Assembly 2878
Remove and Install Center Differential Assembly 2905
How to Remove Center Differential Assembly 2905
How to Install Center Differential Assembly 2908
Disassemble and Assemble Center Differential Assembly 2912
How to Disassemble Center Differential Assembly 2913
How to Assemble Center Differential Assembly 2918
Remove and Install Rear Differential Assembly 2929
How to Remove Rear Differential Assembly 2929
How to Install Rear Differential Assembly 2931
Disassemble and Assemble Rear Differential Assembly 2933
How to Disassemble Rear Differential Assembly 2933
How to Assemble Rear Differential Assembly 2937
Remove and Install Front Final Drive and Brake Assembly 2946
How to Remove Front Final Drive and Brake Assembly 2946
How to Install Front Final Drive and Brake Assembly 2951
Disassemble and Assemble Front Final Drive and Brake Assembly 2956
How to Disassemble Front Final Drive and Brake Assembly 2957
How to Assemble Front Final Drive and Brake Assembly 2963
Remove and Install Center Final Drive and Brake Assembly 2972
How to Remove Center Final Drive and Brake Assembly 2972
How to Install Center Final Drive and Brake Assembly 2974
Disassemble and Assemble Center Final Drive and Brake Assembly 2976
How to Disassemble Center Final Drive and Brake Assembly 2977
How to Assemble Center Final Drive and Brake Assembly 2980
Disassemble and Assemble Rear Final Drive Assembly 2987
How to Disassemble Rear Final Drive Assembly 2987
How to Assemble Rear Final Drive Assembly 2991
Remove and Install Center Axle Assembly 2996
How to Remove Center Axle Assembly 2996
How to Install Center Axle Assembly 2999
Remove and Install Rear Axle Assembly 3002
How to Remove Rear Axle Assembly 3002
How to Install Rear Axle Assembly 3004
Steering System 3007
Disassemble and Assemble Steering Cylinder Assembly 3007
How to Disassemble Steering Cylinder Assembly 3008
How to Assemble Steering Cylinder Assembly 3011
Undercarriage and Frame 3016
Remove and Install Front Suspension Cylinder Assembly 3016
How to Remove Front Suspension Cylinder Assembly 3017
How to Install Front Suspension Cylinder Assembly 3020
Remove and Install Rear Suspension Cylinder Assembly 3025
How to Remove Rear Suspension Cylinder Assembly 3025
How to Install Rear Suspension Cylinder Assembly 3026
Disassemble and Assemble Suspension Cylinder Assembly 3028
How to Disassemble Suspension Cylinder Assembly 3028
How to Assemble Suspension Cylinder Assembly 3028
Remove and Install Equalizer Bar Assembly 3030
How to Remove Equalizer Bar Assembly 3030
How to Install Equalizer Bar Assembly 3032
Remove and Install Hitch Frame Assembly 3034
How to Remove Hitch Frame Assembly 3035
How to Install Hitch Frame Assembly 3044
Disassemble and Assemble Hitch Frame Assembly 3055
How to Disassemble Hitch Frame Assembly 3055
How to Assemble Hitch Frame Assembly 3057
Hydraulic System 3062
Remove and Install Hydraulic Tank Assembly 3062
How to Remove Hydraulic Tank Assembly 3062
How to Install Hydraulic Tank Assembly 3067
Remove and Install Flow Amplifier Valve Assembly 3071
How to Remove Flow Amplifier Valve Assembly 3071
How to Install Flow Amplifier Valve Assembly 3073
Remove and Install Hoist Valve Assembly 3076
How to Remove Hoist Valve Assembly 3076
How to Install Hoist Valve Assembly 3079
Disassemble and Assemble Hoist Cylinder Assembly 3081
How to Disassemble Hoist Cylinder Assembly 3081
How to Assemble Hoist Cylinder Assembly 3084
Work Equipment 3090
Remove and Install Dump Body Assembly 3090
How to Remove Body Assembly 3090
How to Install Body Assembly 3092
CAB Related Parts 3094
Remove and Install Operator Cab Assembly 3094
How to Remove Operator Cab Assembly 3095
How to Install Operator Cab Assembly 3097
Remove and Install Operator Cab Glass (Adhered Glass) 3101
How to Remove Operator Cab Glass (Adhered Glass) 3102
How to Install Operator Cab Glass (Adhered Glass) 3102
Remove and Install Air Conditioner Unit Assembly 3107
How to Remove Air Conditioner Unit Assembly 3108
How to Install Air Conditioner Unit Assembly 3114
Remove and Install Operator Seat Assembly (Made by GRAMMER) 3121
How to Remove Operator Seat Assembly 3121
How to Install Operator Seat Assembly 3122
Remove and Install Operator Seat Assembly (Made by SEARS) 3124
How to Remove Operator Seat Assembly 3124
How to Install Operator Seat Assembly 3126
How to Remove and Install Seat Belt 3129
How to Remove Seat Belt 3129
How to Install Seatbelt 3130
Electrical System 3131
Remove and Install Engine Controller Assembly 3131
How to Remove Engine Controller Assembly 3131
How to Install Engine Controller Assembly 3133
Remove and Install Retarder and Hoist Controller Assembly 3136
How to Remove Retarder and Hoist Controller Assembly 3136
How to Install Retarder and Hoist Controller Assembly 3137
Remove and Install Transmission Controller Assembly 3138
How to Remove Transmission Controller Assembly 3138
How to Install Transmission Controller Assembly 3139
Remove and Install Machine Monitor Assembly 3140
How to Remove Machine Monitor Assembly 3140
How to Install Machine Monitor Assembly 3142
Remove and Install Mass Air Flow and Temperature Sensor 3145
How to Remove Mass Air Flow and Temperature Sensor 3145
How to Install Mass Air Flow and Temperature Sensor 3147
Remove and Install SCR Temperature Sensor 3149
How to Remove SCR Temperature Sensor 3149
How to Install SCR Temperature Sensor 3151
Remove and Install KOMTRAX Terminal Assembly 3153
How to Remove KOMTRAX Terminal Assembly 3153
How to Install KOMTRAX Terminal Assembly 3154
Remove and Install Gateway Function Controller Assembly 3155
How to Remove Gateway Function Controller Assembly 3155
How to Install Gateway Function Controller Assembly 3157
Remove and Install Communication Terminal Wiring Harness 3161
How to Remove Communication Terminal Wiring Harness 3161
How to Install Communication Terminal Wiring Harness 3168
Remove and Install Communication Terminal 3174
How to Remove Communication Terminal 3174
How to Install Communication Terminal 3180
60 Maintenance Standard 3187
Table of Contents 3188
Abbreviation List 3189
Engine and Cooling System 3195
Maintenance Standard for Engine Mount 3195
Maintenance Standard for Damper 3196
Maintenance Standard for Radiator Fan Pump 3197
Maintenance Standard for Servo Valve of Radiator Fan Pump 3198
Maintenance Standard for Radiator Fan Motor 3199
Maintenance Standard for Aftercooler Fan Motor 3201
Power Train 3204
Maintenance Standard for Drive Shaft 3204
Maintenance Standard for Torque Converter and Transmission Mount 3205
Maintenance Standard for Torque Converter and PTO 3206
Maintenance Standard for Lockup Clutch ECMV 3209
Maintenance Standard for Transmission 3210
Maintenance Standard for FL, R Clutch 3214
Maintenance Standard for FH, 1st Clutch 3215
Maintenance Standard for 2nd, 3rd Clutch 3216
Maintenance Standard for Differential Lock Clutch 3218
Maintenance Standard for Transmission Control Valve 3220
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 3221
Maintenance Standard for Differential Lock Clutch ECMV 3222
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 3223
Maintenance Standard for Front Axle 3225
Maintenance Standard for Center Axle 3226
Maintenance Standard for Rear Axle 3227
Maintenance Standard for Front Differential 3228
Maintenance Standard for Center Differential 3229
Maintenance Standard for Rear Differential 3230
Maintenance Standard for Front Final Drive 3231
Maintenance Standard for Center Final Drive 3233
Maintenance Standard for Rear Final Drive 3234
Steering System 3235
Maintenance Standard for Steering Column 3235
Maintenance Standard for Steering Cylinder 3236
Brake System 3237
Maintenance Standard for Front Slack Adjuster 3237
Maintenance Standard for Center Slack Adjuster 3238
Maintenance Standard for Front Brake 3239
Maintenance Standard for Center Brake 3241
Maintenance Standard for Parking Brake 3243
Undercarriage and Frame 3245
Maintenance Standard for Front Suspension 3245
Maintenance Standard for Center and Rear Suspensions 3247
Maintenance Standard for Suspension Cylinder 3250
Maintenance Standard for Oscillation Hitch 3252
Hydraulic System 3254
Maintenance Standard for Steering and Hoist Pump 3254
Maintenance Standard for Servo Valve for Steering and Hoist Pump 3255
Maintenance Standard for Power Train and Front Brake Cooling Duplex Pump and Aftercooler Fan Pump 3257
Maintenance Standard for Center Brake Cooling Pump 3259
Maintenance Standard for Brake Charge Pump 3260
Maintenance Standard for Hoist Valve 3261
Work Equipment 3263
Maintenance Standard for Hoist Cylinder 3263
80 Appendix 3265
Table of Contents 3266
Precautions Before Work 3268
Abbreviation List 3269
Air Conditioner System 3275
Precautions for Refrigerant 3275
Air Conditioner Component 3276
Specifications of Air Conditioner 3278
Structure and Function of Refrigeration Cycle 3279
Outline of Refrigeration Cycle 3280
Component Parts of Air Conditioner System 3282
Air Conditioner Unit 3282
Configuration Diagram of Air Conditioner Unit 3282
Function of Air Conditioner Unit 3284
Component Parts of Air Conditioner Unit 3286
Function of Evaporator as Air Conditioner Unit Component 3287
Function of Heater Core as Air Conditioner Unit Component 3287
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3287
Function of Servo Motor as Air Conditioner Unit Component 3287
Structure of Expansion Valve as Air Conditioner Unit Component 3288
Function of Expansion Valve as Air Conditioner Unit Component 3288
Operate Expansion Valve as Air Conditioner Unit Component 3288
Function of Dual Pressure Switch 3289
Air Conditioner Controller 3290
Structure of Air Conditioner Controller 3290
Compressor 3291
Structure of Compressor 3291
Specifications of Compressor 3291
Function of Compressor 3291
Condenser 3292
Structure of Condenser 3292
Specifications of Condenser 3292
Function of Condenser 3292
Receiver Drier 3293
Structure of Receiver Dryer 3293
Specifications of Receiver Dryer 3293
Function of Receiver Dryer 3293
Air Conditioner Related Sensors 3294
Structure of Outside Temperature Sensor 3294
Function of Outside Air Temperature Sensor 3294
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3295
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3297
System Diagram of Air Conditioner 3299
Input and Output Signals of Air Conditioner Controller 3300
Function of Air Conditioner Controller 3301
Locations of Air Conditioner Parts and Layout of Connectors 3302
Examine Air Leakage (Duct) 3305
How to Examine Air Leakage (Duct) 3305
Examine Air Conditioner with Self-Diagnosis Function 3309
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3310
Examine Vent (Mode) Changeover 3312
How to Examine Vent (Mode) Changeover 3312
Examine Fresh/Recirc Air Changeover 3313
How to Examine Fresh/Recirc Air Changeover 3313
Examine Refrigerant (Dual) Pressure Switch 3314
How to Examine Refrigerant (Dual) Pressure Switch 3314
Examine Relay 3315
How to Examine Relay 3315
Air Conditioner Troubleshooting Chart 1 3317
Air Conditioner Troubleshooting Chart 2 3318
Information Shown in Troubleshooting Table 3321
Failure Code [879AKA] 3322
Failure Code [879AKB] 3323
Failure Code [879BKA] 3324
Failure Code [879BKB] 3326
Failure Code [879CKA] 3328
Failure Code [879CKB] 3329
Failure Code [879EMC] 3330
Failure Code [879FMC] 3331
Failure Code [879GKX] 3332
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3334
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3336
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3339
Troubleshooting for Fresh/Recirc Air Changeover 3341
Troubleshooting by Gauge Pressure 3343
Connect Service Tool 3346
How to Connect Service Tool 3346
Precautions for Disconnection and Connection of Air Conditioner Piping 3348
Handle Compressor Oil 3350
90 Circuit Diagrams 3353
Table of Contents 3354
Abbreviation List 3356
Hydraulic Circuit Diagram 3362
Symbols Used in Hydraulic Circuit Diagram 3362
Hydraulic Circuit Diagram 3367
Power Train Hydraulic Circuit Diagram 3369
Hydraulic Circuit Diagram of Steering, Hoist (at Reverse 1st, Right Turn, Brake Operation) 3371
Hydraulic Circuit Diagram of Brake (at Reverse 1st + Right Turn + Brake Operation) 3372
Hydraulic Circuit Diagram of Power Train (at Reverse 1st + Right Turn + Brake Operation) 3373
Hydraulic Circuit Diagram of Steering, Hoist (at Dump Body RAISE, Forward 2nd Operation) 3375
Hydraulic Circuit Diagram of Power Train (at Dump Body RAISE, Forward 2nd Operation) 3377
Electrical Circuit Diagram 3379
Symbols Used in Electric Circuit Diagram 3379
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (1/8) 3383
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (2/8) 3385
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (3/8) 3387
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (4/8) 3389
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (5/8) 3391
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (6/8) 3393
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (7/8) 3395
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (8/8) 3397
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (1/8) 3399
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (2/8) 3401
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (3/8) 3403
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (4/8) 3405
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (5/8) 3407
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (6/8) 3409
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (7/8) 3411
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (8/8) 3413
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (1/9) 3415
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (2/9) 3417
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (3/9) 3419
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (4/9) 3421
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (5/9) 3423
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (6/9) 3425
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (7/9) 3427
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (8/9) 3429
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (9/9) 3431
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (1/9) 3433
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (2/9) 3435
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (3/9) 3437
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (4/9) 3439
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (5/9) 3441
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (6/9) 3443
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (7/9) 3445
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (8/9) 3447
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (9/9) 3449
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (1/8) 3451
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (2/8) 3453
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (3/8) 3455
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (4/8) 3457
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (5/8) 3459
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (6/8) 3461
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (7/8) 3463
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (8/8) 3465
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (1/8) 3467
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (2/8) 3469
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (3/8) 3471
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (4/8) 3473
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (5/8) 3475
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (6/8) 3477
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (7/8) 3479
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (8/8) 3481
Index 3483

DESCRIPTION:

Komatsu HM300-5E0 Dump Truck Shop Manual SEN06746-14 – PDF DOWNLOAD 

SERIAL NUMBERS 20001 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 29/12/24