Komatsu HM400-5E0 Dump Truck Shop Manual SEN06747-14 – PDF DOWNLOAD 

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Komatsu HM400-5E0 Dump Truck Shop Manual SEN06747-14 – PDF DOWNLOAD

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Komatsu HM400-5E0 Dump Truck Shop Manual SEN06747-14 – PDF DOWNLOAD 

Language : English
Pages : 3596
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HM400-5E0 Dump Truck Shop Manual SEN06747-14 – 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: HM400-5E0 105
Specifications 107
Specifications: HM400-5E0 107
Weight Table 113
Weight Table: HM400-5E0 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 130
Function of Urea SCR System 131
Function of DEF System 131
Inducement Strategy 133
Component Parts of Urea SCR System 147
DEF Mixing Tube 147
SCR Assembly 147
DEF Tank 150
DEF Pump 152
DEF Injector 153
DEF Hose 154
DEF Tank Heating Valve 155
Boot-up System 156
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 156
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 158
System Operating Lamp System 160
System Diagram of System Operating Lamp System (Machine with KOMTRAX Terminal) 160
Function of System Operating Lamp System (Machine with KOMTRAX Terminal) 160
System Diagram of System Operating Lamp System (Machine with Gateway Function Controller) 161
Function of System Operating Lamp System (Machine with Gateway Function Controller) 161
Battery Disconnect Switch 163
Layout Drawing of Battery Disconnect Switch 163
Function of Battery Disconnect Switch (Machine with KOMTRAX Terminal) 163
Function of Battery Disconnect Switch (Machine with Gateway Function Controller) 164
Engine System 165
Layout Drawing of Engine System 165
Function of Engine System 167
Automatic Idle Stop System 168
Function of Automatic Idle Stop System 168
Component Parts of Engine System 170
Damper 170
VGT 171
EGR System 174
EGR Valve 176
EGR Cooler 178
KCCV System 179
KCCV Ventilator 181
KDPF 183
Cooling System 188
Layout Drawing of Cooling System 188
Specifications of Cooling System 189
Radiator Fan Control System 190
Radiator Fan Control System Diagram 190
Function of Radiator Fan Control System 190
Aftercooler Fan Control System 192
Aftercooler Fan Control System Diagram 192
Function of Aftercooler Fan Control System 192
Component Parts of Cooling System 194
Radiator Fan Pump 194
Radiator Fan Motor 200
Aftercooler Fan Motor 205
Center Brake Cooling Remote Motor 216
Center Brake Cooling Remote Pump 219
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) 222
Retarder and Hoist Control System 223
System Diagram of Retarder and Hoist Control System (Machine with KOMTRAX Terminal) 223
System Diagram of Retarder and Hoist Control System (Machine with Gateway Function Controller) 224
Machine Monitor System 225
System Diagram of Machine Monitor System (Machine with KOMTRAX Terminal) 225
System Diagram of Machine Monitor System (Machine with Gateway Function Controller) 226
Function of Machine Monitor System 227
Rearview Monitor System 228
System Diagram of Rearview Monitor System 228
Function of Rearview Monitor System 228
KOMTRAX System 229
KOMTRAX System Diagram (Machine with KOMTRAX Terminal) 229
Function of KOMTRAX System (Machine with KOMTRAX Terminal) 229
System Diagram of KOMTRAX System (Machine with Gateway Function Controller) 230
Function of KOMTRAX System (Machine with Gateway Function Controller) 230
Payload Meter System 231
Layout Drawing of Payload Meter System 231
System Diagram of Payload Meter (Machine with KOMTRAX Terminal) 232
System Diagram of Payload Meter (Machine with Gateway Function Controller) 233
Function of Payload Meter System 233
Measurement Principle of Loading Mass 234
Component Parts of Control System 245
Machine Monitor 245
Switch Panel 266
Rearview Monitor 267
Rearview Camera 269
KOMTRAX Terminal 270
Gateway Function Controller 272
Communication Terminal 275
Transmission Controller 277
Retarder and Hoist Controller 281
Monitor Controller 286
Engine Controller 290
Payload Meter Controller 297
Accelerator Pedal 306
Shift Lever 307
Retarder Control Lever 308
Fuel Feed Pump 309
Fuel Feed Pump Switch 310
Hydraulic System 311
Layout Drawing of Hydraulic System 311
Component Parts of Hydraulic System 312
Hydraulic Tank 312
Steering and Hoist Pump 313
LS Valve 320
PC Valve 321
Power Train and Front Brake Cooling Duplex Pump, Aftercooler Fan Pump, and Center Brake Cooling Remote Motor Drive Pump 325
Hoist Valve 327
Power Train System 332
Layout Drawing of Power Train System 332
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 378
Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 380
Differential Lock Clutch ECMV 385
Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 388
Axle 392
Differential 395
Final Drive 399
Work Equipment System 403
Work Equipment Control 403
Layout Drawing of Work Equipment Control 403
Function of Work Equipment Control 403
Hoist Control 404
Hoist Control System Diagram 404
Function of Hoist Control 404
Component Parts of Work Equipment System 406
Dump Lever 406
Dump EPC Valve 411
Steering System 413
Layout Drawing of Steering System 413
Function of Steering System 414
Steering Column 415
Structure of Steering Column 415
Component Parts of Steering System 416
Flow Amplifier Valve 416
Steering Valve 420
Steering Pump Selector Solenoid Valve 425
Secondary Steering Pump 426
Secondary Steering Motor 427
Brake System 428
Layout Drawing of Brake System 428
Retarder Control 430
Retarder Control System Diagram 430
Function of Retarder Control 431
Parking Brake Interlock Function 433
Function of Parking Brake Interlock Function 433
Operation of Parking Brake Interlock Function 433
ARAC System 434
ARAC System Diagram 434
Function of ARAC System 434
Component Parts of Brake System 435
Brake Charge Pump 435
Parking Brake Solenoid Valve and Accumulator Charge Valve 436
Parking Brake Solenoid Valve 437
Accumulator Charge Valve 437
Brake Circuit Accumulator 442
Shut Off Solenoid Valve 444
Brake Valve 445
Proportional Pressure Reducing Valve 448
Slack Adjuster 449
Brake 452
Front Brake Cooling Relief Valve 454
Center Brake Cooling Relief Valve 455
Brake System Tank 456
Parking Brake 457
Spring Cylinder 458
Parking Brake Caliper 460
Undercarriage and Frame 462
Front Suspension 462
Structure of Front Suspension 462
Function of Front Suspension 462
Center and Rear Suspensions 464
Structure of Center and Rear Suspensions 464
Function of Center Suspension 464
Function of Rear Suspension 465
Suspension Cylinder 466
Structure of Suspension Cylinder 466
Function of Suspension Cylinder 466
Operation of Suspension Cylinder 468
Oscillation Hitch 469
Structure of Oscillation Hitch 469
Function of Oscillation Hitch 470
Work Equipment 471
Structure of Work Equipment 471
Function of Work Equipment 472
CAB Related Parts 473
ROPS CAB 473
Structure of ROPS CAB 473
Function of ROPS CAB 474
CAB Tilt 475
Structure of CAB Tilt 475
20 Standard Value Table 477
Table of Contents 478
Abbreviation List 479
Standard Value Table for Engine 485
Standard Value Table for Engine: HM400-5E0 485
Standard Value Table for Machine 489
Standard Value Table for Machine: HM400-5E0 489
Machine Posture and Procedures to Measure Performance 503
Standard Value Table for Electricity 504
Standard Value Table for Electricity 504
30 Testing and Adjusting 521
Table of Contents 522
Abbreviation List 525
Related Information on Testing and Adjusting 531
Tools for Testing and Adjusting 531
Sketch of Tools for Testing and Adjusting 539
Engine and Cooling System 541
Examine Engine Speed 541
How to Examine Engine Speed 541
Examine Boost Pressure 544
How to Examine Boost Pressure 544
Examine Exhaust Gas Temperature 546
How to Examine Exhaust Gas Temperature 546
Examine Exhaust Gas Color 549
How to Examine Exhaust Gas Color with the Handy Smoke Checker 549
How to Examine Exhaust Gas Color with Smoke Meter 550
Examine Mass Air Flow and Temperature Sensor 552
How to Examine Mass Air Flow and Temperature Sensor 552
Examine and Adjust Valve Clearance 555
How to Examine Valve Clearance 555
How to Adjust Valve Clearance 556
Examine Compression Pressure 557
How to Examine Compression Pressure 557
Examine Blowby Pressure 560
How to Examine Blowby Pressure 560
Examine Engine Oil Pressure 562
How to Examine Engine Oil Pressure on Machine Monitor 562
How to Examine Engine Oil Pressure by Testing Tool 562
Examine EGR Valve and VGT Oil Pressure 564
How to Examine EGR Valve and VGT Oil Pressure 564
Examine Fuel Pressure 566
How to Examine Fuel Pressure 566
Examine Fuel Return Rate and Leakage 568
How to Examine Fuel Return Rate and Leakage 569
Bleed Air from Fuel System 574
How to Bleed Air from Fuel System 574
Examine Fuel Circuit for Leakage 576
How to Examine Fuel System for Leakage 576
Handle Cylinder Cut-out Mode Operation 578
Handle No-Injection Cranking Operation 579
Clean Fuel Doser 580
How to Clean Fuel Doser 580
Write Injector Compensation Value to Engine Controller 583
How to Write Injector Compensation Value 583
Write Correction for Ash in Soot Accumulation to Engine Controller 590
How to Write Correction for Ash in Soot Accumulation to Engine Controller 590
Examine SCR Related Functions 591
Examine DEF Pump Raised Pressure 595
Examine Injection Volume from DEF Injector 598
Examine DEF Line Heater Relay 1 603
Examine DEF Line Heater Relay 2 607
Examine DEF Pump Heater Relay 611
Examine DEF Tank Heater Valve 615
Examine SCR Denitration Efficiency 619
Clean DEF Tank 623
How to Clean DEF Tank 623
Clean DEF Pump 628
How to Clean DEF Pump 628
Examine Torque Converter Stall Speed 635
How to Examine Torque Converter Stall Speed 635
Examine Radiator Fan and Aftercooler Fan Speed 640
How to Examine Radiator Fan and Aftercooler Fan Speed 640
Power Train 642
Examine Power Train Oil Pressure 642
How to Examine Power Train Oil Pressure 645
Adjust Transmission Speed Sensor 660
How to Adjust Transmission Speed Sensor 661
Adjust Transmission Controller 663
How to Adjust Transmission Controller 663
Move Machine Which Has a Trouble in Electrical System 664
How to Move Machine Which Has a Trouble in Engine Control System 664
How to Move Machine Which Has a Trouble in Transmission Control System 664
Move Machine Which Has a Trouble in Traction Control System (KTCS) 671
How to Move Machine with Secondary KTCS Operation Connector 673
Steering System 674
Examine and Adjust Steering Circuit Oil Pressure 674
How to Examine Steering Circuit Oil Pressure 674
How to Adjust Steering Circuit Oil Pressure 675
Bleed Air from Steering Cylinder Circuit 676
How to Bleed Air from Steering Cylinder Circuit 676
Brake System 678
Examine and Adjust Brake Oil Pressure 678
How to Examine Brake Oil Pressure 678
How to Adjust Brake Oil Pressure 682
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 684
How to Examine Accumulator Nitrogen Gas Pressure 684
How to Charge Accumulator Nitrogen Gas for Brake 688
Release Remained Pressure in Brake Accumulator Circuit 693
How to Release Remained Pressure in Brake Accumulator Circuit 693
Bleed Air from Brake Circuit 694
How to Bleed Air from Brake Circuit 694
Examine Brake Performance 696
How to Examine Brake Performance 696
Examine Wear of Wheel Brake Disc 700
How to Examine Wear of Wheel Brake Disc 700
Release Parking Brake Manually 702
How to Release Parking Brake Manually 702
Examine and Adjust Wear of Parking Brake Pad 703
How to Examine Wear of Parking Brake Pad 703
How to Adjust Clearance of Parking Brake Pad 704
Hydraulic System 706
Examine and Adjust Suspension Cylinder 706
How to Examine Suspension Cylinder 707
How to Adjust Suspension Cylinder 707
Examine and Adjust Dump Circuit Oil Pressure 711
How to Examine Dump Circuit Oil Pressure 711
How to Adjust Dump Circuit Oil Pressure 712
Work Equipment 714
Examine and Adjust Dump Body Positioner Sensor 714
How to Examine Dump Body Positioner Sensor 714
How to Adjust Dump Body Positioner Sensor 714
Examine and Adjust Dump Body Mount 717
How to Examine Dump Body Mount 717
How to Adjust Dump Body Mount 718
CAB Related Parts 719
CAB Tilt Up 719
How to Tilt Up Cab 720
Adjust Tilt Lock Lever of Steering Wheel 726
How to Adjust Tilt Lock Lever of Steering Wheel 726
Adjust Play of Operator Seat 728
How to Adjust Play of Operator Seat 728
Electrical System 729
Set and Adjust Each Equipment 729
Prepare for Transmission ECMV Current Adjustment 731
How to Adjust Transmission ECMV Current 732
How to Set and Reset Transmission Initial Learning 735
How to Set Property Value of ARAC (Automatic Retarder Accelerator Control) 740
How to Do System Check of KTCS (Komatsu Traction Control System) 743
Set and Operate Machine Monitor 745
Operator Mode 749
Function to Show Technician Identification Status Screen 749
Function to Show Operator Identification Input Screen 749
Examine Function by LCD (Liquid Crystal Display) 750
Examine Function of Service Meter and Odometer 751
How to Set Usage Limitation and Change Maintenance Password 751
Service Mode 755
How to Operate Service Mode 755
How to See Pre-defined Monitoring Information 758
How to Examine Self-Define Monitor Information 766
Abnormality Record Menu 782
How to See Maintenance Record 787
Maintenance Mode Setting 789
How to Set Phone Number Entry 793
Default Menu 795
Diagnostic Tests Menu 810
Adjustment Menu 821
No-Injection Cranking Operation 827
Payload Meter Setting 829
KOMTRAX Settings Menu 852
How to Show Service Message 856
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 858
How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal) 862
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 864
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller) 869
Adjust Optical Axis of Head Lamp 871
How to Adjust Optical Axis of Head Lamp 871
Set Region of Bluetooth(R) Compatible Radio 875
How to Set Region of Bluetooth(R) Compatible Radio 875
Handle Voltage Circuit of Engine Controller 877
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 878
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 879
Examine Diodes 880
How to Examine Diodes by Digital Tester 880
How to Examine Diodes by Analog Tester 880
Pm Clinic 881
Pm Clinic Service 881
Pm Clinic Check Sheet: HM400-5E0 884
40 Troubleshooting 893
Table of Contents 894
Abbreviation List 907
Related Information to Troubleshooting 913
General Troubleshooting Points 913
Troubleshooting Points for Urea SCR System 914
Sequence of Events in Troubleshooting 928
Checks Before Troubleshooting 930
Inspection Procedure Before Troubleshooting 932
Walk-Around Check 932
Test in Accordance with Testing Procedure 934
Examine Fuel Level and Type 934
Examine for Impure Ingredient in Fuel 934
Examine DEF Level and Type 935
Examine Fuel Prefilter 935
Examine Fuel Main Filter 937
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type 938
Examine Coolant Level (Reservoir Tank) 939
Examine Air Cleaner Clogging 940
Clean Outer Element 941
Replace Element 943
Examine Hydraulic Oil Level 945
Examine Hydraulic Oil Strainer 945
Examine Hydraulic Oil Filter 946
Examine Oil Level in Transmission Case 947
Examine Oil Level in Differential Case 947
Examine Oil Level in Final Drive Case 948
Bleed Air from Fuel System 948
Bleed Air from Hydraulic System 948
How to Examine Electric Equipment 948
Preparation for Troubleshooting of Electrical System 957
Procedure for Troubleshooting 966
Symptom and Troubleshooting Numbers 968
Information Shown in Troubleshooting Table 971
Connector List and Layout 973
Connector Contact Connection Table 1000
T-Branch Box and T-Branch Adapter Table 1040
Fuse Location Table (Machine with KOMTRAX Terminal) 1046
Fuse Location Table (Machine with Gateway Function Controller) 1050
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1054
Prepare Troubleshoot Machine Monitor 1058
Procedure to Make Harness Checker on Machine Monitor LCD Unit 1060
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1066
Failure Code Table 1068
Troubleshooting by Failure Code (Display of Code) 1094
Failure Code [1500L0] 1094
Failure Code [15B0NX] 1095
Failure Code [15F0KM] 1097
Failure Code [15F0MB] 1098
Failure Code [15F7KM] 1099
Failure Code [15G0MW] 1100
Failure Code [15G7KM] 1103
Failure Code [15H0MW] 1104
Failure Code [15J0MW] 1107
Failure Code [15K0MW] 1110
Failure Code [15L0MW] 1113
Failure Code [15M0MW] 1116
Failure Code [15SBL1] 1119
Failure Code [15SBMA] 1122
Failure Code [15SCL1] 1123
Failure Code [15SCMA] 1127
Failure Code [15SDL1] 1128
Failure Code [15SDMA] 1131
Failure Code [15SEL1] 1132
Failure Code [15SEMA] 1135
Failure Code [15SFL1] 1136
Failure Code [15SFMA] 1139
Failure Code [15SGL1] 1140
Failure Code [15SGMA] 1143
Failure Code [15SJMA] 1144
Failure Code [15SKMA] 1146
Failure Code [2F00KM] 1148
Failure Code [2G42ZG] 1150
Failure Code [2G43ZG] 1151
Failure Code [879AKA] 1152
Failure Code [879AKB] 1153
Failure Code [879BKA] 1154
Failure Code [879BKB] 1156
Failure Code [879CKA] 1158
Failure Code [879CKB] 1159
Failure Code [879EMC] 1160
Failure Code [879FMC] 1161
Failure Code [879GKX] 1162
Failure Code [989D00] 1164
Failure Code [989L00] 1165
Failure Code [989M00] 1166
Failure Code [989N00] 1167
Failure Code [A1U0N3] 1168
Failure Code [A1U0N4] 1170
Failure Code [AA10NX] 1172
Failure Code [AB00KE] 1174
Failure Code [AB00KY] 1176
Failure Code [AQ10N3] 1178
Failure Code [AS00N3] 1180
Failure Code [AS00R2] 1182
Failure Code [AS00R3] 1183
Failure Code [AS00R4] 1184
Failure Code [AS00R5] 1185
Failure Code [AS00R6] 1186
Failure Code [AS00ZK] 1187
Failure Code [AS10KM] 1188
Failure Code [AS10NR] 1189
Failure Code [AS10NT] 1190
Failure Code [B@BAZG] 1191
Failure Code [B@BAZK] 1192
Failure Code [B@BCNS] 1193
Failure Code [B@BCQA] 1194
Failure Code [B@BCZK] 1196
Failure Code [B@C6NS] 1198
Failure Code [B@C8NS] 1199
Failure Code [B@CENS] 1200
Failure Code [B@JANS] 1201
Failure Code [CA115] 1202
Failure Code [CA122] 1203
Failure Code [CA123] 1205
Failure Code [CA131] 1207
Failure Code [CA132] 1209
Failure Code [CA135] 1212
Failure Code [CA141] 1214
Failure Code [CA144] 1216
Failure Code [CA145] 1218
Failure Code [CA153] 1220
Failure Code [CA154] 1223
Failure Code [CA187] 1226
Failure Code [CA221] 1228
Failure Code [CA222] 1230
Failure Code [CA227] 1232
Failure Code [CA234] 1233
Failure Code [CA238] 1234
Failure Code [CA239] 1236
Failure Code [CA249] 1238
Failure Code [CA256] 1240
Failure Code [CA271] 1242
Failure Code [CA272] 1244
Failure Code [CA273] 1245
Failure Code [CA274] 1247
Failure Code [CA322] 1248
Failure Code [CA323] 1250
Failure Code [CA324] 1252
Failure Code [CA325] 1254
Failure Code [CA331] 1256
Failure Code [CA332] 1258
Failure Code [CA343] 1260
Failure Code [CA351] 1261
Failure Code [CA352] 1262
Failure Code [CA356] 1265
Failure Code [CA357] 1267
Failure Code [CA386] 1269
Failure Code [CA431] 1270
Failure Code [CA432] 1273
Failure Code [CA441] 1276
Failure Code [CA442] 1279
Failure Code [CA449] 1280
Failure Code [CA451] 1281
Failure Code [CA452] 1283
Failure Code [CA515] 1285
Failure Code [CA516] 1287
Failure Code [CA553] 1289
Failure Code [CA555] 1290
Failure Code [CA556] 1291
Failure Code [CA559] 1292
Failure Code [CA595] 1297
Failure Code [CA687] 1298
Failure Code [CA689] 1300
Failure Code [CA691] 1302
Failure Code [CA692] 1304
Failure Code [CA697] 1306
Failure Code [CA698] 1307
Failure Code [CA731] 1308
Failure Code [CA778] 1309
Failure Code [CA1117] 1312
Failure Code [CA1664] 1313
Failure Code [CA1669] 1316
Failure Code [CA1673] 1317
Failure Code [CA1677] 1318
Failure Code [CA1678] 1319
Failure Code [CA1682] 1320
Failure Code [CA1683] 1324
Failure Code [CA1684] 1326
Failure Code [CA1686] 1328
Failure Code [CA1691] 1329
Failure Code [CA1694] 1332
Failure Code [CA1695] 1334
Failure Code [CA1696] 1335
Failure Code [CA1712] 1337
Failure Code [CA1713] 1340
Failure Code [CA1714] 1342
Failure Code [CA1715] 1343
Failure Code [CA1776] 1344
Failure Code [CA1777] 1347
Failure Code [CA1843] 1350
Failure Code [CA1844] 1352
Failure Code [CA1879] 1355
Failure Code [CA1881] 1358
Failure Code [CA1883] 1360
Failure Code [CA1885] 1364
Failure Code [CA1887] 1366
Failure Code [CA1921] 1368
Failure Code [CA1922] 1371
Failure Code [CA1923] 1376
Failure Code [CA1924] 1378
Failure Code [CA1925] 1380
Failure Code [CA1927] 1382
Failure Code [CA1928] 1384
Failure Code [CA1942] 1386
Failure Code [CA1963] 1387
Failure Code [CA1977] 1391
Failure Code [CA1993] 1394
Failure Code [CA2185] 1397
Failure Code [CA2186] 1399
Failure Code [CA2249] 1401
Failure Code [CA2265] 1402
Failure Code [CA2266] 1404
Failure Code [CA2271] 1407
Failure Code [CA2272] 1409
Failure Code [CA2349] 1412
Failure Code [CA2353] 1414
Failure Code [CA2357] 1416
Failure Code [CA2381] 1417
Failure Code [CA2382] 1419
Failure Code [CA2383] 1421
Failure Code [CA2386] 1423
Failure Code [CA2387] 1425
Troubleshooting Flowchart 1429
Failure Code [CA2555] 1430
Failure Code [CA2556] 1432
Failure Code [CA2637] 1434
Failure Code [CA2639] 1436
Failure Code [CA2732] 1439
Failure Code [CA2733] 1441
Failure Code [CA2741] 1443
Failure Code [CA2765] 1444
Failure Code [CA2771] 1445
Failure Code [CA2777] 1451
Failure Code [CA2878] 1454
Failure Code [CA2881] 1457
Failure Code [CA2976] 1460
Failure Code [CA3133] 1462
Failure Code [CA3134] 1464
Failure Code [CA3135] 1466
Failure Code [CA3142] 1470
Failure Code [CA3143] 1471
Failure Code [CA3144] 1472
Failure Code [CA3146] 1474
Failure Code [CA3147] 1475
Failure Code [CA3148] 1476
Failure Code [CA3151] 1478
Failure Code [CA3165] 1484
Failure Code [CA3167] 1486
Failure Code [CA3229] 1489
Failure Code [CA3231] 1491
Failure Code [CA3232] 1493
Failure Code [CA3235] 1497
Failure Code [CA3239] 1499
Failure Code [CA3241] 1502
Failure Code [CA3242] 1505
Failure Code [CA3251] 1508
Failure Code [CA3253] 1510
Failure Code [CA3254] 1514
Failure Code [CA3255] 1517
Failure Code [CA3256] 1521
Failure Code [CA3311] 1523
Failure Code [CA3312] 1525
Failure Code [CA3313] 1528
Failure Code [CA3314] 1529
Failure Code [CA3315] 1530
Failure Code [CA3316] 1533
Failure Code [CA3317] 1535
Failure Code [CA3318] 1536
Failure Code [CA3319] 1539
Failure Code [CA3321] 1540
Failure Code [CA3322] 1542
Failure Code [CA3419] 1545
Failure Code [CA3421] 1547
Failure Code [CA3497] 1549
Failure Code [CA3498] 1550
Failure Code [CA3543] 1551
Failure Code [CA3545] 1558
Failure Code [CA3547] 1560
Failure Code [CA3558] 1561
Failure Code [CA3559] 1563
Failure Code [CA3562] 1565
Failure Code [CA3563] 1567
Failure Code [CA3567] 1570
Failure Code [CA3568] 1573
Failure Code [CA3571] 1579
Failure Code [CA3572] 1581
Failure Code [CA3574] 1583
Failure Code [CA3575] 1586
Failure Code [CA3577] 1588
Failure Code [CA3578] 1590
Failure Code [CA3582] 1592
Failure Code [CA3583] 1599
Failure Code [CA3596] 1601
Failure Code [CA3649] 1606
Failure Code [CA3681] 1608
Failure Code [CA3682] 1613
Failure Code [CA3713] 1619
Failure Code [CA3717] 1622
Failure Code [CA3718] 1623
Failure Code [CA3725] 1624
Failure Code [CA3748] 1627
Failure Code [CA3751] 1630
Failure Code [CA3755] 1632
Failure Code [CA3866] 1634
Failure Code [CA3867] 1638
Failure Code [CA3868] 1641
Failure Code [CA3899] 1645
Failure Code [CA3911] 1647
Failure Code [CA3912] 1651
Failure Code [CA3932] 1653
Failure Code [CA3933] 1655
Failure Code [CA3934] 1657
Failure Code [CA3935] 1660
Failure Code [CA3936] 1662
Failure Code [CA4151] 1664
Failure Code [CA4152] 1668
Failure Code [CA4155] 1672
Failure Code [CA4156] 1675
Failure Code [CA4157] 1678
Failure Code [CA4158] 1680
Failure Code [CA4159] 1681
Failure Code [CA4161] 1682
Failure Code [CA4162] 1685
Failure Code [CA4163] 1688
Failure Code [CA4164] 1690
Failure Code [CA4165] 1692
Failure Code [CA4166] 1694
Failure Code [CA4168] 1696
Failure Code [CA4169] 1699
Failure Code [CA4171] 1703
Failure Code [CA4249] 1707
Failure Code [CA4251] 1711
Failure Code [CA4259] 1715
Failure Code [CA4261] 1718
Failure Code [CA4277] 1720
Failure Code [CA4281] 1724
Failure Code [CA4459] 1727
Failure Code [CA4461] 1730
Failure Code [CA4658] 1733
Failure Code [CA4731] 1737
Failure Code [CA4732] 1738
Failure Code [CA4739] 1739
Failure Code [CA4768] 1740
Failure Code [CA4769] 1742
Failure Code [CA4842] 1745
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 1749
Failure Code [CA4952] (Machine with Gateway Function Controller) 1751
Failure Code [CA5115] 1753
Failure Code [CA5179] 1756
Failure Code [CA5181] 1758
Failure Code [CA5383] 1760
Failure Code [D150KB] 1762
Failure Code [D150KZ] 1763
Failure Code [D151KB] 1764
Failure Code [D151KZ] 1765
Failure Code [D164KY] 1766
Failure Code [D19HKZ] 1768
Failure Code [D19JKZ] 1770
Failure Code [D1EHKA] 1772
Failure Code [D1EHKB] 1773
Failure Code [D1EHKY] 1774
Failure Code [D1EMKA] 1775
Failure Code [D1EMKB] 1776
Failure Code [D1EMKY] 1777
Failure Code [D1FBKB] 1778
Failure Code [D5ZHL6] 1780
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 1782
Failure Code [D811MC] (Machine with Gateway Function Controller) 1783
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 1784
Failure Code [D862KA] (Machine with Gateway Function Controller) 1785
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 1786
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 1788
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 1790
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 1792
Failure Code [D8AQK4] (Machine with KOMTRAX Terminal) 1794
Failure Code [D8AQK4] (Machine with Gateway Function Controller) 1795
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 1796
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 1798
Failure Code [D8G1KT] 1800
Failure Code [D8G6KT] 1801
Failure Code [DAF0KT] 1802
Failure Code [DAF0MB] 1803
Failure Code [DAF0MC] 1804
Failure Code [DAF3KK] 1805
Failure Code [DAF8KB] 1807
Failure Code [DAFDKB] 1809
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 1811
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 1812
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 1813
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 1815
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 1817
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 1819
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 1821
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 1822
Failure Code [DAQ0KK] 1823
Failure Code [DAQ0KT] 1825
Failure Code [DAQ0MC] 1826
Failure Code [DAQ1KA] 1827
Failure Code [DAQ2KK] 1830
Failure Code [DAQ9KQ] 1832
Failure Code [DAQLKA] (Machine with KOMTRAX Terminal) 1833
Failure Code [DAQLKA] (Machine with Gateway Function Controller) 1835
Failure Code [DAQLKB] (Machine with KOMTRAX Terminal) 1837
Failure Code [DAQLKB] (Machine with Gateway Function Controller) 1839
Failure Code [DAQQKR] 1841
Failure Code [DAQRKR] 1842
Failure Code [DAQRMA] 1843
Failure Code [DAQV00] 1844
Failure Code [DAQW00] 1845
Failure Code [DAZ9KQ] 1846
Failure Code [DAZQKR] 1847
Failure Code [DB10KT] 1848
Failure Code [DB10MC] 1849
Failure Code [DB11KA] 1850
Failure Code [DB11KA] (Machine with Emergency Engine Stop Switch) 1852
Failure Code [DB12KK] 1855
Failure Code [DB13KK] 1857
Failure Code [DB19KQ] 1859
Failure Code [DB1LKA] (Machine with KOMTRAX Terminal) 1860
Failure Code [DB1LKA] (Machine with Gateway Function Controller) 1862
Failure Code [DB1LKB] (Machine with KOMTRAX Terminal) 1864
Failure Code [DB1LKB] (Machine with Gateway Function Controller) 1866
Failure Code [DB1QKR] 1868
Failure Code [DB1QMA] 1869
Failure Code [DB1RKR] 1870
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 1871
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1877
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 1883
Failure Code [DB2QKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1889
Failure Code [DB2RKR] 1895
Failure Code [DBS0KK] 1901
Failure Code [DBS0KK] (Machine with Payload Meter Controller: CR720) 1904
Failure Code [DBS6KP] 1907
Failure Code [DBS6KP] (Machine with Payload Meter Controller: CR720) 1910
Failure Code [DBSQKQ] 1913
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) 1914
Failure Code [DBSQKR] (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) 1919
Failure Code [DBSQKR] (Machine with Gateway Function Controller) 1924
Failure Code [DBSQKR] (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) 1929
Failure Code [DD1ML4] 1934
Failure Code [DDAAL6] 1937
Failure Code [DDAAL6] (Machine with Emergency Engine Stop Switch) 1939
Failure Code [DDTHKA] 1942
Failure Code [DDTJKA] 1944
Failure Code [DDTKKA] 1946
Failure Code [DDTLKA] 1948
Failure Code [DDTMKA] 1950
Failure Code [DDTNKA] 1952
Failure Code [DF10KA] 1954
Failure Code [DF10KB] 1958
Failure Code [DGF1KX] 1963
Failure Code [DGR3KB] 1965
Failure Code [DGR3L8] 1966
Failure Code [DGR4KB] 1968
Failure Code [DGR4L8] 1969
Failure Code [DGR6KB] 1971
Failure Code [DGR6L8] 1972
Failure Code [DGR7KX] 1974
Failure Code [DGT1KX] 1976
Failure Code [DHAAMA] 1978
Failure Code [DHACMA] 1980
Failure Code [DHP4KY] 1982
Failure Code [DHP4KY] (Machine with Payload Meter Controller: CR720) 1984
Failure Code [DHP4KZ] 1986
Failure Code [DHP4KZ] (Machine with Payload Meter Controller: CR720) 1988
Failure Code [DHP5KY] 1990
Failure Code [DHP5KY] (Machine with Payload Meter Controller: CR720) 1992
Failure Code [DHP5KZ] 1994
Failure Code [DHP5KZ] (Machine with Payload Meter Controller: CR720) 1996
Failure Code [DHP6KY] 1998
Failure Code [DHP6KY] (Machine with Payload Meter Controller: CR720) 2000
Failure Code [DHP6KZ] 2002
Failure Code [DHP6KZ] (Machine with Payload Meter Controller: CR720) 2004
Failure Code [DHP7KY] 2006
Failure Code [DHP7KY] (Machine with Payload Meter Controller: CR720) 2008
Failure Code [DHP7KZ] 2010
Failure Code [DHP7KZ] (Machine with Payload Meter Controller: CR720) 2012
Failure Code [DHQ2KX] 2014
Failure Code [DHT5KX] 2016
Failure Code [DHT5L6] 2018
Failure Code [DHT8KX] 2020
Failure Code [DHT8ZG] 2022
Failure Code [DHU2KX] 2024
Failure Code [DHU3KX] 2026
Failure Code [DHUAKX] 2028
Failure Code [DHUBKX] 2030
Failure Code [DHUCKX] 2032
Failure Code [DHUDKX] 2034
Failure Code [DHUEKX] 2036
Failure Code [DHUQKX] 2038
Failure Code [DHURKX] 2040
Failure Code [DJF1KA] 2042
Failure Code [DK30KX] 2044
Failure Code [DK51L5] 2046
Failure Code [DK52KX] 2049
Failure Code [DK53L8] 2051
Failure Code [DK54KX] 2053
Failure Code [DK60KX] 2055
Failure Code [DKH0KX] 2057
Failure Code [DKH1KX] 2059
Failure Code [DKH1KX] (Machine with Payload Meter Controller: CR720) 2061
Failure Code [DLF1KA] 2063
Failure Code [DLF1LC] 2065
Failure Code [DLF2KA] 2067
Failure Code [DLF2LC] 2069
Failure Code [DLF400] 2071
Failure Code [DLF4KA] 2072
Failure Code [DLF4LC] 2074
Failure Code [DLF6LC] 2076
Failure Code [DLF7LC] 2078
Failure Code [DLFDLC] 2080
Failure Code [DLFELC] 2082
Failure Code [DLFFLC] 2084
Failure Code [DLFGLC] 2085
Failure Code [DLM3KA] 2086
Failure Code [DLM3LC] 2088
Failure Code [DLM3MB] 2090
Failure Code [DLM4KA] 2091
Failure Code [DLM4LC] 2093
Failure Code [DLM4MB] 2095
Failure Code [DLT3KA] 2097
Failure Code [DLT3LC] 2099
Failure Code [DPQ1KR] 2101
Failure Code [DPQ2KR] 2104
Failure Code [DPQ3KR] 2107
Failure Code [DSJ0KR] 2111
Failure Code [DV00KB] 2112
Failure Code [DW2BKA] 2114
Failure Code [DW2BKB] 2115
Failure Code [DW2BKY] 2116
Failure Code [DW2BL1] 2117
Failure Code [DW2BLH] 2118
Failure Code [DW4BK4] 2119
Failure Code [DW4BMA] 2122
Failure Code [DW72KZ] 2125
Failure Code [DW73KA] 2127
Failure Code [DW73KB] 2129
Failure Code [DW73KY] 2131
Failure Code [DW7BKB] 2133
Failure Code [DW7BKY] 2135
Failure Code [DW7BKZ] 2136
Failure Code [DW7LKB] 2138
Failure Code [DW7LKY] 2139
Failure Code [DW7LKZ] 2140
Failure Code [DW7NKZ] 2141
Failure Code [DWNJKZ] 2143
Failure Code [DWNKKZ] 2145
Failure Code [DX13KA] 2147
Failure Code [DX13KB] 2149
Failure Code [DX13KY] 2151
Failure Code [DX16KA] 2152
Failure Code [DX16KB] 2153
Failure Code [DX16KY] 2155
Failure Code [DX29KA] 2156
Failure Code [DX29KB] 2158
Failure Code [DX29KY] 2160
Failure Code [DX30K4] 2161
Failure Code [DX30KA] 2163
Failure Code [DX30KB] 2165
Failure Code [DX30KY] 2167
Failure Code [DX30MA] 2169
Failure Code [DX31K4] 2171
Failure Code [DX31KA] 2173
Failure Code [DX31KB] 2175
Failure Code [DX31KY] 2177
Failure Code [DX31MA] 2179
Failure Code [DX32K4] 2181
Failure Code [DX32KA] 2183
Failure Code [DX32KB] 2185
Failure Code [DX32KY] 2187
Failure Code [DX32MA] 2189
Failure Code [DX33K4] 2191
Failure Code [DX33KA] 2193
Failure Code [DX33KB] 2195
Failure Code [DX33KY] 2197
Failure Code [DX33MA] 2199
Failure Code [DX34KA] 2201
Failure Code [DX34KB] 2202
Failure Code [DX34KY] 2204
Failure Code [DXH0KA] 2205
Failure Code [DXH0KB] 2207
Failure Code [DXH0KY] 2209
Failure Code [DXH1KA] 2211
Failure Code [DXH1KB] 2213
Failure Code [DXH1KY] 2215
Failure Code [DXH2KA] 2217
Failure Code [DXH2KB] 2220
Failure Code [DXH2KY] 2223
Failure Code [DXH3KA] 2226
Failure Code [DXH3KB] 2229
Failure Code [DXH3KY] 2232
Failure Code [DXH4KA] 2235
Failure Code [DXH4KB] 2237
Failure Code [DXH4KY] 2239
Failure Code [DXH5KA] 2242
Failure Code [DXH5KB] 2244
Failure Code [DXH5KY] 2246
Failure Code [DXH6KA] 2249
Failure Code [DXH6KB] 2251
Failure Code [DXH6KY] 2253
Failure Code [DXH7KA] 2256
Failure Code [DXH7KB] 2258
Failure Code [DXH7KY] 2260
Failure Code [DY30MA] 2263
Failure Code [DY30MC] 2266
Failure Code [DY30ME] 2269
Failure Code [DY32MC] 2271
Failure Code [F313KA] 2274
Failure Code [F313KB] 2276
Failure Code [F318KB] 2277
Failure Code [F318KY] 2279
Troubleshooting of Electrical System (E-Mode) 2280
Engine Does Not Start (Engine Does Not Crank) 2280
Manual Preheating System Does Not Operate 2286
Automatic Preheating System Does Not Operate 2289
While Preheating is in Operation, Preheating Monitor Does Not Come On 2291
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing 2293
All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Show Nothing (For Machines to Which Emergency Engine Stop Switch is Installed) 2296
LCD Unit on Machine Monitor Shows Nothing 2299
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers) 2302
LCD Screen on Machine Monitor Does Not Show Correctly 2305
Meter Unit Display on Machine Monitor is Abnormal 2308
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal 2311
LED Unit Lamp on Machine Monitor is Abnormal 2315
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly 2317
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate 2320
Switch Panel Buzzer of Machine Monitor is Abnormal 2323
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally 2326
DEF Level is Not Shown Correctly 2327
Rearview Monitor Does Not Come On or Backlight Flickers 2330
Rearview Monitor Images are Not Shown Clearly 2333
Rearview Monitor Brightness Cannot be Adjusted 2337
Night Mode Lamp of Rearview Monitor is Abnormal 2340
Rearview Monitor Does Not Display Images While REVERSE Linked Display Function is Enabled 2342
Guide Line on Rearview Monitor is Not Shown While Guide Line is Set 2345
Fuel Gauge Does Not Show Normally 2347
Seatbelt Caution Lamp Does Not Show Normally 2349
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position 2350
Alarm Buzzer Does Not Operate 2351
Alarm Buzzer Does Not Stop 2352
Engine Mode Selector Function Does Not Operate Correctly 2354
AISS Function Does Not Operate Correctly 2356
Hoist Lever Does Not Operate Correctly 2358
Fuel Feed Pump Does Not Operate or Stop Automatically 2360
Turn Signal Lamp and Winker Lamp (Hazard Lamp) Do Not Operate Correctly 2363
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On 2367
Clearance Lamp Does Not Come On 2369
Tail Lamp Does Not Come On 2371
Headlamp (Low Beam) Does Not Come On 2373
Headlamp (High Beam) Does Not Come On 2375
Head Lamps (Low Beam) and (High Beam) Do Not Come on 2377
Passing Lamp Does Not Come On 2379
KOMTRAX System Does Not Operate Correctly (Machine with KOMTRAX Terminal) 2381
KOMTRAX System Does Not Operate Correctly (Machine with Gateway Function Controller) 2383
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2385
Information Shown in Troubleshooting Table (H-Mode) 2385
System Chart of Hydraulic and Mechanical Systems 2386
Failure Mode and Cause Table 2388
Machine Does Not Start 2398
Machine Does Not Travel Smoothly (Machine Hunts) 2401
Lockup is Not Released 2402
Strong Shock is Made When You Start Machine or Shift Gears 2403
Shiftup Does Not Operate 2405
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function 2408
Travel Speed is Low or Power is Low During Travel with Torque Converter 2410
Travel Speed is Low or Power is Low in Specified Gear Speed 2411
Time Lag is Large When You Start Machine or Shift Gears 2413
Torque Converter Oil Temperature is High 2416
Torque Converter Oil Pressure is Low 2418
Steering Wheel is Heavy to Operate 2420
Steering Wheel is Disabled 2421
Steering Wheel Waggles 2422
Front Brake Does Not Operate Sufficiently 2423
Center Brake Does Not Work Sufficiently 2424
Speed is Low When Dump Body is Raised 2425
Hydraulic Drift of Dump Body is Large 2427
Dump Body is Disabled 2428
Radiator Fan Speed is Unusual (Too High or Low, or Fan Stops) 2430
Aftercooler Fan Speed is Unusual (Too Much High or Low, or Fan Stops) 2431
Unusual Noise is Heard from Around Radiator Fan 2432
Unusual Noise is Heard from Around Aftercooler Fan 2433
Troubleshooting of Engine (S-Mode) 2434
Information Shown in Troubleshooting Table (S-Mode) 2434
Engine Does Not Crank When Starting Switch is Turned to Start Position 2435
Engine Cranks but No Exhaust Smoke Comes Out 2436
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2437
Engine Startability is Unsatisfactory 2438
Engine Does Not Pick Up Smoothly 2440
Engine Stops During Operation 2442
Engine Does Not Rotate Smoothly 2444
Engine Lacks Output (or Lacks Power) 2445
KDPF Becomes Clogged in a Short Time 2447
Engine Oil Consumption is Excessive 2449
Engine Oil Becomes Dirty Quickly 2450
Fuel Consumption is Excessive 2451
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 2452
Engine Oil Pressure Drops 2453
Fuel Mixes Into Engine Oil 2455
Water Mixes Into Engine Oil (Milky) 2456
Coolant Temperature Increases Too High (Overheat) 2457
Unusual Noise is Heard 2458
Vibration is Excessive 2459
Air Cannot be Bled from Fuel Circuit 2460
Active Regeneration is Done Frequently 2461
Active Regeneration Continues Long 2463
White Smoke is Exhausted During Active Regeneration 2464
DEF Consumption is Excessive 2465
There is an Unusual Smell (Irritating Odor) 2467
Foreign Materials Enter DEF (DEF Increases) 2468
50 Disassembly and Assembly 2469
Table of Contents 2470
Abbreviation List 2475
Related Information on Disassembly and Assembly 2481
How to Read This Manual 2481
Coating Materials List 2482
Special Tool List 2487
Sketches of Special Tools 2505
Engine and Cooling System 2524
Remove and Install Supply Pump Assembly 2524
How to Remove Supply Pump Assembly 2524
How to Install Supply Pump Assembly 2525
Remove and Install Injector Assembly 2529
How to Remove Injector Assembly 2529
How to Install Injector Assembly 2542
Remove and Install Fuel Doser Assembly 2560
How to Remove Fuel Doser Assembly 2560
How to Install Fuel Doser Assembly 2561
Remove and Install Cylinder Head Assembly 2564
How to Remove Cylinder Head Assembly 2565
How to Install Cylinder Head Assembly 2579
Remove and Install EGR Valve Assembly 2603
How to Remove EGR Valve Assembly 2603
How to Install EGR Valve Assembly 2605
Remove and Install EGR Cooler Assembly 2607
How to Remove EGR Cooler Assembly 2607
How to Install EGR Cooler Assembly 2611
Remove and Install Starter Assembly 2615
How to Remove Starting Motor Assembly 2615
How to Install Starting Motor Assembly 2618
Remove and Install Alternator Belt 2621
How to Remove Alternator Belt 2621
How to Install Alternator Belt 2622
Remove and Install Radiator Assembly 2624
How to Remove Radiator Assembly 2624
How to Install Radiator Assembly 2629
Remove and Install Cooling Fan and Fan Motor Assembly 2636
How to Remove Cooling Fan and Fan Motor Assembly 2636
How to Install Cooling Fan and Fan Motor Assembly 2642
Remove and Install Aftercooler Assembly 2649
How to Remove Aftercooler Assembly 2649
How to Install Aftercooler Assembly 2651
Remove and Install Aftercooler Fan and Fan Motor Assembly 2655
How to Remove Aftercooler Fan and Fan Motor Assembly 2655
How to Install Aftercooler Fan and Fan Motor Assembly 2656
Remove and Install Engine Assembly 2659
How to Remove Engine Assembly 2660
How to Install Engine Assembly 2669
Remove and Install Engine Front Oil Seal 2680
How to Remove Engine Front Oil Seal 2680
How to Install Engine Front Oil Seal 2681
Remove and Install Engine Rear Oil Seal 2684
How to Remove Engine Rear Oil Seal 2684
How to Install Engine Rear Oil Seal 2685
Remove and Install Output Shaft 2692
How to Remove Output Shaft 2693
How to Install Output Shaft 2696
Disassemble and Assemble Output Shaft 2700
How to Disassemble Output Shaft 2700
How to Assemble Output Shaft 2701
Remove and Install DEF Tank Assembly 2703
How to Remove DEF Tank Assembly 2703
How to Install DEF Tank Assembly 2708
Remove and Install DEF Tank Sensor Flange Assembly 2712
How to Remove DEF Tank Sensor Flange Assembly 2712
How to Install DEF Tank Sensor Flange Assembly 2717
Remove and Install DEF Tank Sensor 2722
How to Remove DEF Tank Sensor 2722
How to Install DEF Tank Sensor 2723
Remove and Install DEF Tank Strainer 2725
How to Remove DEF Tank Strainer 2725
How to Install DEF Tank Strainer 2725
Remove and Install KDPF Assembly 2726
How to Remove KDPF Assembly 2727
How to Install KDPF Assembly 2730
Disassemble and Assemble KDPF Assembly 2734
How to Disassemble KDPF Assembly 2734
How to Assemble KDPF Assembly 2738
Remove and Install SCR Assembly 2743
How to Remove SCR Assembly 2743
How to Install SCR Assembly 2747
Remove and Install KCCV Assembly 2752
How to Remove KCCV Assembly 2752
How to Install KCCV Assembly 2754
Remove and Install DEF Mixing Tube 2757
How to Remove DEF Mixing Tube 2757
How to Install DEF Mixing Tube 2764
Remove and Install DEF Injector 2772
How to Remove DEF Injector 2772
How to Install DEF Injector 2775
Remove and Install DEF Pump 2778
How to Remove DEF Pump 2778
How to Install DEF Pump 2782
Remove and Install DEF Hose 2786
How to Remove DEF Hose 2786
How to Install DEF Hose 2790
Remove and Install Air Cleaner Assembly 2795
How to Remove Air Cleaner Assembly 2795
How to Install Air Cleaner Assembly 2798
Remove and Install Air Conditioner Compressor Assembly 2801
How to Remove Air Conditioner Compressor Assembly 2802
How to Install Air Conditioner Compressor Assembly 2803
Power Train 2806
Remove and Install Transmission and Front Differential Assembly 2806
How to Remove Transmission and Front Differential Assembly 2806
How to Install Transmission and Front Differential Assembly 2820
Disconnect and Connect Transmission and Front Differential Assembly 2835
How to Disconnect Transmission and Front Differential Assembly 2835
How to Connect Transmission and Front Differential Assembly 2836
Disassemble and Assemble Front Differential Assembly 2839
How to Disassemble Front Differential Assembly 2840
How to Assemble Front Differential Assembly 2847
Disassemble and Assemble Torque Converter Assembly 2859
How to Disassemble Torque Converter Assembly 2860
How to Assemble Torque Converter Assembly 2864
Disassemble and Assemble Transmission Assembly 2870
How to Disassemble Transmission Assembly 2871
How to Assemble Transmission Assembly 2901
Remove and Install Center Differential Assembly 2936
How to Remove Center Differential Assembly 2936
How to Install Center Differential Assembly 2939
Disassemble and Assemble Center Differential Assembly 2943
How to Disassemble Center Differential Assembly 2944
How to Assemble Center Differential Assembly 2951
Remove and Install Rear Differential Assembly 2964
How to Remove Rear Differential Assembly 2964
How to Install Rear Differential Assembly 2966
Disassemble and Assemble Rear Differential Assembly 2968
How to Disassemble Rear Differential Assembly 2969
How to Assemble Rear Differential Assembly 2973
Remove and Install Front Final Drive and Brake Assembly 2982
How to Remove Front Final Drive and Brake Assembly 2982
How to Install Front Final Drive and Brake Assembly 2983
Disassemble and Assemble Front Final Drive and Brake Assembly 2985
How to Disassemble Front Final Drive and Brake Assembly 2986
How to Assemble Front Final Drive and Brake Assembly 2994
Remove and Install Center Final Drive and Brake Assembly 3005
How to Remove Center Final Drive and Brake Assembly 3005
How to Install Center Final Drive and Brake Assembly 3007
Disassemble and Assemble Center Final Drive and Brake Assembly 3009
How to Disassemble Center Final Drive and Brake Assembly 3009
How to Assemble Center Final Drive and Brake Assembly 3016
Remove and Install Rear Final Drive Assembly 3025
How to Remove Rear Final Drive Assembly 3025
How to Install Rear Final Drive Assembly 3026
Disassemble and Assemble Rear Final Drive Assembly 3028
How to Disassemble Rear Final Drive Assembly 3028
How to Assemble Rear Final Drive Assembly 3031
Remove and Install Center Axle Assembly 3036
How to Remove Center Axle Assembly 3036
How to Install Center Axle Assembly 3039
Remove and Install Rear Axle Assembly 3043
How to Remove Rear Axle Assembly 3043
How to Install Rear Axle Assembly 3046
Remove and Install Brake Accumulator 3049
How to Remove Brake Accumulator 3049
How to Install Brake Accumulator 3061
Steering System 3074
Disassemble and Assemble Steering Valve 3074
How to Disassemble Steering Valve 3074
How to Assemble Steering Valve 3077
Disassemble and Assemble Steering Cylinder Assembly 3084
How to Disassemble Steering Cylinder Assembly 3084
How to Assemble Steering Cylinder Assembly 3088
Undercarriage and Frame 3093
Remove and Install Front Suspension Cylinder Assembly 3093
How to Remove Front Suspension Cylinder Assembly 3093
How to Install Front Suspension Cylinder Assembly 3094
Remove and Install Rear Suspension Cylinder Assembly 3096
How to Remove Rear Suspension Cylinder Assembly 3096
How to Install Rear Suspension Cylinder Assembly 3097
Disassemble and Assemble Suspension Cylinder Assembly 3099
How to Disassemble Suspension Cylinder Assembly 3099
How to Assemble Suspension Cylinder Assembly 3100
Remove and Install Equalizer Bar Assembly 3102
How to Remove Equalizer Bar Assembly 3102
How to Install Equalizer Bar Assembly 3104
Remove and Install Front Wheel Assembly 3107
How to Remove Front Wheel Assembly 3108
How to Install Front Wheel Assembly 3113
Remove and Install Rear (Front Side) Wheel Assembly 3118
How to Remove Rear (Front Side) Wheel Assembly 3118
How to Install Rear (Front Side) Wheel Assembly 3118
Remove and Install Rear (Back Side) Wheel Assembly 3119
How to Remove Rear (Back Side) Wheel Assembly 3119
How to Install Rear (Back Side) Wheel Assembly 3119
Remove and Install Hitch Frame Assembly 3120
How to Remove Hitch Frame Assembly 3121
How to Install Hitch Frame Assembly 3129
Disassemble and Assemble Hitch Frame Assembly 3138
How to Disassemble Hitch Frame Assembly 3138
How to Assemble Hitch Frame Assembly 3140
Hydraulic System 3145
Remove and Install Hydraulic Tank Assembly 3145
How to Remove Hydraulic Tank Assembly 3145
How to Install Hydraulic Tank Assembly 3150
Remove and Install Flow Amplifier Valve Assembly 3154
How to Remove Flow Amplifier Valve Assembly 3154
How to Install Flow Amplifier Valve Assembly 3157
Remove and Install Hoist Valve Assembly 3160
How to Remove Hoist Valve Assembly 3160
How to Install Hoist Valve Assembly 3165
Disassemble and Assemble Hoist Valve Assembly 3169
How to Disassemble Hoist Valve Assembly 3169
How to Assemble Hoist Valve Assembly 3170
Disassemble and Assemble Hoist Cylinder Assembly 3173
How to Disassemble Hoist Cylinder Assembly 3173
How to Assemble Hoist Cylinder Assembly 3176
Work Equipment 3182
Remove and Install Dump Body Assembly 3182
How to Remove Body Assembly 3182
How to Install Body Assembly 3184
CAB Related Parts 3187
Remove and Install Operator Cab Assembly 3187
How to Remove Operator Cab Assembly 3188
How to Install Operator Cab Assembly 3191
Remove and Install Operator Cab Glass (Adhered Glass) 3195
How to Remove Operator Cab Glass (Adhered Glass) 3196
How to Install Operator Cab Glass (Adhered Glass) 3196
Remove and Install Air Conditioner Unit Assembly 3201
How to Remove Air Conditioner Unit Assembly 3202
How to Install Air Conditioner Unit Assembly 3208
Remove and Install Operator Seat Assembly (Made by GRAMMER) 3214
How to Remove Operator Seat Assembly 3214
How to Install Operator Seat Assembly 3215
Remove and Install Operator Seat Assembly (Made by SEARS) 3217
How to Remove Operator Seat Assembly 3217
How to Install Operator Seat Assembly 3219
How to Remove and Install Seat Belt 3222
How to Remove Seat Belt 3222
How to Install Seatbelt 3223
Electrical System 3224
Remove and Install Engine Controller Assembly 3224
How to Remove Engine Controller Assembly 3224
How to Install Engine Controller Assembly 3227
Remove and Install Retarder and Hoist Controller Assembly 3230
How to Remove Retarder and Hoist Controller Assembly 3230
How to Install Retarder and Hoist Controller Assembly 3231
Remove and Install Transmission Controller Assembly 3232
How to Remove Transmission Controller Assembly 3232
How to Install Transmission Controller Assembly 3233
Remove and Install Machine Monitor Assembly 3234
How to Remove Machine Monitor Assembly 3234
How to Install Machine Monitor Assembly 3236
Remove and Install Mass Air Flow and Temperature Sensor 3239
How to Remove Mass Air Flow and Temperature Sensor 3239
How to Install Mass Air Flow and Temperature Sensor 3241
Remove and Install SCR Temperature Sensor 3243
How to Remove SCR Temperature Sensor 3243
How to Install SCR Temperature Sensor 3245
Remove and Install KOMTRAX Terminal Assembly 3247
How to Remove KOMTRAX Terminal Assembly 3247
How to Install KOMTRAX Terminal Assembly 3248
Remove and Install Gateway Function Controller Assembly 3249
How to Remove Gateway Function Controller Assembly 3249
How to Install Gateway Function Controller Assembly 3251
Remove and Install Communication Terminal Wiring Harness 3255
How to Remove Communication Terminal Wiring Harness 3255
How to Install Communication Terminal Wiring Harness 3262
Remove and Install Communication Terminal 3268
How to Remove Communication Terminal 3268
How to Install Communication Terminal 3274
60 Maintenance Standard 3281
Table of Contents 3282
Abbreviation List 3284
Engine and Cooling System 3290
Maintenance Standard for Engine Mount 3290
Maintenance Standard for Damper 3291
Maintenance Standard for Radiator Fan Pump 3292
Maintenance Standard for Servo Valve of Radiator Fan Pump 3293
Maintenance Standard for Radiator Fan Motor 3294
Maintenance Standard for Aftercooler Fan Motor 3295
Power Train 3298
Maintenance Standard for Drive Shaft 3298
Maintenance Standard for Torque Converter and Transmission Mount 3300
Maintenance Standard for Torque Converter and PTO 3301
Maintenance Standard for Lockup Clutch ECMV 3304
Maintenance Standard for Transmission 3305
Maintenance Standard for FL, R Clutch 3310
Maintenance Standard for FH, 1st Clutch 3311
Maintenance Standard for 2nd, 3rd Clutch 3312
Maintenance Standard for Differential Lock Clutch 3313
Maintenance Standard for Transmission Control Valve 3315
Maintenance Standard for Forward and Reverse Clutch ECMV and Gear Speed Clutch ECMV 3316
Maintenance Standard for Differential Lock Clutch ECMV 3317
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 3318
Maintenance Standard for Front Axle 3320
Maintenance Standard for Center Axle 3321
Maintenance Standard for Rear Axle 3322
Maintenance Standard for Front Differential 3323
Maintenance Standard for Center Differential 3324
Maintenance Standard for Rear Differential 3325
Maintenance Standard for Front Final Drive 3326
Maintenance Standard for Center Final Drive 3328
Maintenance Standard for Rear Final Drive 3329
Steering System 3331
Maintenance Standard for Steering Column 3331
Maintenance Standard for Steering Cylinder 3332
Brake System 3333
Maintenance Standard for Front Slack Adjuster 3333
Maintenance Standard for Center Slack Adjuster 3334
Maintenance Standard for Front Brake 3335
Maintenance Standard for Center Brake 3337
Maintenance Standard for Parking Brake 3338
Undercarriage and Frame 3340
Maintenance Standard for Front Suspension 3340
Maintenance Standard for Center and Rear Suspensions 3342
Maintenance Standard for Front Suspension Cylinder 3345
Maintenance Standard for Rear Suspension Cylinder 3346
Maintenance Standard for Oscillation Hitch 3347
Hydraulic System 3349
Maintenance Standard for Steering and Hoist Pump 3349
Maintenance Standard for Servo Valve for Steering and Hoist Pump 3350
Maintenance Standard for Power Train and Front Brake Cooling Duplex Pump, Aftercooler Fan Pump, and Center Brake Cooling Remote Motor Drive Pump 3352
Maintenance Standard for Center Brake Cooling Pump 3354
Maintenance Standard for Center Brake Cooling Remote Pump 3355
Maintenance Standard for Center Brake Cooling Remote Motor 3356
Maintenance Standard for Brake Charge Pump 3359
Maintenance Standard for Hoist Valve 3360
Work Equipment 3362
Maintenance Standard for Hoist Cylinder 3362
80 Appendix 3365
Table of Contents 3366
Abbreviation List 3368
Air Conditioner System 3374
Precautions for Refrigerant 3374
Air Conditioner Component 3375
Specifications of Air Conditioner 3377
Structure and Function of Refrigeration Cycle 3378
Outline of Refrigeration Cycle 3379
Component Parts of Air Conditioner System 3381
Air Conditioner Unit 3381
Configuration Diagram of Air Conditioner Unit 3381
Function of Air Conditioner Unit 3383
Component Parts of Air Conditioner Unit 3385
Function of Evaporator as Air Conditioner Unit Component 3386
Function of Heater Core as Air Conditioner Unit Component 3386
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3386
Function of Servo Motor as Air Conditioner Unit Component 3386
Structure of Expansion Valve as Air Conditioner Unit Component 3387
Function of Expansion Valve as Air Conditioner Unit Component 3387
Operate Expansion Valve as Air Conditioner Unit Component 3387
Function of Dual Pressure Switch 3388
Air Conditioner Controller 3389
Structure of Air Conditioner Controller 3389
Compressor 3390
Structure of Compressor 3390
Specifications of Compressor 3390
Function of Compressor 3390
Condenser 3391
Structure of Condenser 3391
Specifications of Condenser 3391
Function of Condenser 3391
Receiver Drier 3392
Structure of Receiver Dryer 3392
Specifications of Receiver Dryer 3392
Function of Receiver Dryer 3392
Air Conditioner Related Sensors 3393
Structure of Outside Temperature Sensor 3393
Function of Outside Air Temperature Sensor 3393
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3394
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3396
System Diagram of Air Conditioner 3398
Input and Output Signals of Air Conditioner Controller 3399
Function of Air Conditioner Controller 3400
Locations of Air Conditioner Parts and Layout of Connectors 3401
Examine Air Leakage (Duct) 3404
How to Examine Air Leakage (Duct) 3404
Examine Air Conditioner with Self-Diagnosis Function 3408
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3409
Examine Vent (Mode) Changeover 3411
How to Examine Vent (Mode) Changeover 3411
Examine Fresh/Recirc Air Changeover 3412
How to Examine Fresh/Recirc Air Changeover 3412
Examine Refrigerant (Dual) Pressure Switch 3413
How to Examine Refrigerant (Dual) Pressure Switch 3413
Examine Relay 3414
How to Examine Relay 3414
Air Conditioner Troubleshooting Chart 1 3416
Air Conditioner Troubleshooting Chart 2 3417
Information Shown in Troubleshooting Table 3420
Failure Code [879AKA] 3421
Failure Code [879AKB] 3422
Failure Code [879BKA] 3423
Failure Code [879BKB] 3425
Failure Code [879CKA] 3427
Failure Code [879CKB] 3428
Failure Code [879EMC] 3429
Failure Code [879FMC] 3430
Failure Code [879GKX] 3431
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3433
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3435
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3438
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3440
Troubleshooting by Gauge Pressure 3442
Connect Service Tool 3445
How to Connect Service Tool 3445
Precautions for Disconnection and Connection of Air Conditioner Piping 3447
Handle Compressor Oil 3449
90 Circuit Diagrams 3451
Table of Contents 3452
Abbreviation List 3454
Hydraulic Circuit Diagram 3460
Symbols Used in Hydraulic Circuit Diagram 3460
Hydraulic Circuit Diagram 3465
Power Train Hydraulic Circuit Diagram 3467
Electrical Circuit Diagram 3469
Symbols Used in Electric Circuit Diagram 3469
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (1/8) 3473
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (2/8) 3475
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (3/8) 3477
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (4/8) 3479
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (5/8) 3481
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (6/8) 3483
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (7/8) 3485
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (8/8) 3487
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (1/8) 3489
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (2/8) 3491
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (3/8) 3493
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (4/8) 3495
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (5/8) 3497
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (6/8) 3499
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (7/8) 3501
Electrical Circuit Diagram of Inside of CAB (Machine with KOMTRAX Terminal) (Machine with Payload Meter Controller: CR720) (8/8) 3503
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (1/9) 3505
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (2/9) 3507
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (3/9) 3509
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (4/9) 3511
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (5/9) 3513
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (6/9) 3515
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (7/9) 3517
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (8/9) 3519
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (9/9) 3521
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (1/9) 3523
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (2/9) 3525
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (3/9) 3527
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (4/9) 3529
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (5/9) 3531
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (6/9) 3533
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (7/9) 3535
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (8/9) 3537
Electrical Circuit Diagram of Inside of CAB (Machine with Gateway Function Controller) (Machine with Payload Meter Controller: CR720) (9/9) 3539
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (1/8) 3541
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (2/8) 3543
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (3/8) 3545
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (4/8) 3547
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (5/8) 3549
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (6/8) 3551
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (7/8) 3553
Electrical Circuit Diagram of Outside of CAB (Machine with KOMTRAX Terminal) (8/8) 3555
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (1/8) 3557
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (2/8) 3559
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (3/8) 3561
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (4/8) 3563
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (5/8) 3565
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (6/8) 3567
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (7/8) 3569
Electrical Circuit Diagram of Outside of CAB (Machine with Gateway Function Controller) (8/8) 3571
Index 3573

DESCRIPTION:

Komatsu HM400-5E0 Dump Truck Shop Manual SEN06747-14 – 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 30/12/24