Complete service repair manual with Electrical Wiring Diagrams for Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Articulated Dump Truck HM300-1, HM300-2, HM300-3, HM300-5 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 27,061 pages
File Format: PDF
Language: English

SEBM024805 - Dump Truck HM300-1 Shop Manual.pdf
SEBM024815 - Articulated Dump Truck HM300-1 Shop Manual.pdf
SEN00237-04 - Dump Truck GALEO HM300-2 Shop Manual.pdf
SEN00237-13 - Articulated Dump Truck HM300-2 Shop Manual.pdf
SEN00237-14 - Articulated Dump Truck HM300-2 Shop Manual.pdf
SEN05629-04 - Articulated Dump Truck HM300-3 Shop Manual.pdf
SEN05629-05 - Articulated Dump Truck HM300-3 Shop Manual.pdf
SEN06511-05 - Articulated Dump Truck HM300-5 Shop Manual.pdf
CEAM017504 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
CEBM007700 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM022402 - Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
EEAM024700 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM027303 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EEAM030700 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
EENAM03082 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
EENAM03312 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
EENAM03372 - Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
EENAM03491 - Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
EPAM022402 - Camião Basculante Articulado HM300-1 Manual de Operação e Manutenção.pdf
EPAM024700 - Camião Basculante Articulado HM300-2 Manual de Operação e Manutenção.pdf
EPAM027303 - Camião Basculante Articulado HM300-2 Manual de Operação e Manutenção.pdf
EPTAM03490 - Camião Basculante Articulado HM300-5 Manual de Operação e Manutenção.pdf
GEN00017-00 - Articulated Dump Truck HM300-1 Field Assembly Instruction.pdf
GEN00037-03 - Articulated Dump Truck HM300-2 Field Assembly Manual.pdf
GEN00111-03 - Articulated Dump Truck HM300-3 Field Assembly Instruction.pdf
GEN00131-00 - Articulated Dump Truck HM300-5 Field Assembly Instruction.pdf
PEN00044-11 - Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
PEN00101-04 - Articulated Dump Truck GALEO HM300-2 Operation & Maintenance Manual.pdf
PEN00231-06 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00239-00 - Articulated Dump Truck GALEO HM300-1 Operation & Maintenance Manual.pdf
PEN00372-01 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00474-11 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
PEN00554-03 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
PEN00661-04 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
PEN00833-01 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00044-10 - Articulated Dump Truck HM300-1 Operation & Maintenance Manual.pdf
TEN00112-04 - Articulated Dump Truck GALEO HM300-2 Operation & Maintenance Manual.pdf
TEN00228-06 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00238-00 - Articulated Dump Truck GALEO HM300-1 Operation & Maintenance Manual.pdf
TEN00344-01 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00442-07 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00442-11 - Articulated Dump Truck HM300-2 Operation & Maintenance Manual.pdf
TEN00517-03 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00631-01 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf
TEN00662-01 - Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
TEN00745-02 - Articulated Dump Truck HM300-5 Operation & Maintenance Manual.pdf
TEN00747-01 - Articulated Dump Truck HM300-3 Operation & Maintenance Manual.pdf

TABLE OF CONTENTS
SEBM024805 - Dump Truck HM300-1 Shop Manual...2
  SAFETY ...8
    SAFETY NOTICE ...8
  FOREWORD ...10
    GENERAL ...10
    STANDARD TIGHTENING TORQUE ...17
    CONVERSION TABLE ...21
  01 GENERAL ...28
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...36
    RADIATOR, OIL COOLER, AFTERCOOLER ...37
  POWER TRAIN SKELETON OUTPUT SHAFT ...41
  TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING TORQUE CONVERTER ...45
  TRANSMISSION ...51
  TRANSMISSION VALVE ...71
  ECMV ( Electronic Control Modulation Valve) ...72
  MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE ...79
  DRIVE SHAFT ...81
  AXLE ...82
  DIFFERENTIAL ...85
  LIMITED SLIP DIFFERENTIAL ...91
  FINAL DRIVE ...97
  STEERING COLUMN ...102
  BRAKE PIPING BRAKE VALVE ...105
  ACCUMULATOR CHARGE VALVE ...108
  ACCUMULATOR ...112
  SLACK ADJUSTER ...113
  BRAKE ...115
  PROPORTIONAL REDUCING VALVE ...120
  BRAKE SYSTEM TANK ...121
  PARKING BRAKE ...123
  PARKING BRAKE CALIPER ...125
  PARKING BRAKE SOLENOID VALVE ...127
  SPRING CYLINDER ...126
  SUSPENSION ...129
  SUSPENSION CYLINDER ...135
  OSCILLATION HITCH ...137
  STEERING, HOIST OIL PRESSURE PIPING DIAGRAM ...141
  DUMP BODY CONTROL ...142
  HYDRAULIC TANK AND FILTER ...143
  FLOW AMP VALVE ...144
  STEERING CYLINDER ...151
  EPC VALVE ...159
  HOIST CYLINDER ...162
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP ...163
  HYDRAULIC PUMP ...163
    STEERING · HOIST+ PILOT PUMP SAR( 3) 63+ 63+( 1) 6 ...163
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP ...164
    TORQUE CONVERTER, TRANSMISSION AND FRONT BRAKE COOLING PUMP SAR( 3) 90 ...164
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CAB TILT ...167
  CAB TILT ...167
  AIR CONDITIONER ...168
    FUNCTION ...168
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...169
    AIR CONDITIONER UNIT ...169
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...170
    RECEIVER DRYER ...170
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...171
    CONDENSER ...171
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER ...172
    COMPRESSOR ...172
    STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR SYSTEM ...173
  MACHINE MONITOR SYSTEM ...173
    Network data ...173
  AUTOMATIC SHIFT CONTROL SYSTEM ...186
  TRANSMISSION CONTROLLER ...188
  AUTO EMERGENCY STEERING SYSTEM ...194
  SENSORS, SWITCHES ...195
  20 TESTING AND ADJUSTING ...228
    STANDARD VALUE TABLE FOR ENGINE ...229
    STANDARD VALUE TABLE FOR CHASSIS ...230
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS ...234
    TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ...247
    MEASURING ENGINE SPEED ...249
    MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) ...250
    MEASURING EXHAUST TEMPERATURE ...251
    MEASURING EXHAUST COLOR ...253
    MEASURING COMPRESSION PRESSURE ...254
    ADJUSTING VALVE CLEARANCE ...255
    MEASURING BLOW- BY PRESSURE ...256
    MEASURING ENGINE OIL PRESSURE ...257
    HANDLING EQUIPMENT IN FUEL CIRCUIT ...258
    RELEASING REMAINING PRESSURE IN FUEL SYSTEM ...258
    MEASURING FUEL PRESSURE ...259
    BLEEDING AIR FROM FUEL CIRCUIT ...260
    REDUCED CYLINDER MODE OPERATION FOR ENGINE ...262
    CHECKING FOR LEAKAGE IN FUEL CIRCUIT ...263
    ADJUSTING ENGINE SPEED SENSOR ...264
    TESTING AND ADJUSTING ALTERNATOR BELT TENSION ...265
    TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION ...265
    TESTING TORQUE CONVERTER STALL SPEED ...266
    MEASURING POWER TRAIN OIL PRESSURE ...267
    ADJUSTING TRANSMISSION SPEED SENSOR ...274
    TESTING AND ADJUSTING BRAKE OIL PRESSURE ...275
    TESTING BRAKE PERFORMANCE ...279
    BLEEDING AIR FROM BRAKE CIRCUIT ...282
    TESTING WEAR OF WHEEL BRAKE DISC ...285
    TESTING WEAR OF PARKING BRAKE PAD ...286
    METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE ...287
    TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE ...288
    TESTING AND ADJUSTING SUSPENSION CYLINDER ...290
    METHOD OF TILTING CAB UP ...294
    TESTING DUMP CIRCUIT PRESSURE ...295
    ADJUSTING BODY POSITIONER SENSOR ...298
    HANDLING ENGINE CONTROLLER HIGH- VOLTAGE CIRCUIT ...299
    ADJUSTING TRANSMISSION CONTROLLER ...300
    METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM ...301
    ADJUSTING MACHINE MONITOR ...305
    SPECIAL FUNCTIONS OF MACHINE MONITOR ...309
    CHECKS BEFORE TROUBLESHOOTING ...359
    CONNECTOR TYPES AND MOUNTING LOCATIONS ...360
    CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ...375
    CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS ...397
    ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...439
    CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...443
    TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...515
    CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...521
    BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...659
    CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...665
    MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM ...721
    CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...725
  TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM ( ENG MODE) ...436
    ENG- 1 FAILURE CODE [ A000N1] ( ENGINE: OVERRUN N1)) ...455
    ENG- 2 FAILURE CODE [ A570NX] ( ENGINE OIL FILTER: CLOGGED ( NX)) ...456
    ENG- 3 FAILURE CODE [ AD00L2] ( COMMON RAIL: * SEE CONTENTS ( L2)) ...457
    ENG- 4 FAILURE CODE [ AD00MA] ( COMMON RAIL: FUNCTION IMPOSSIBLE ( MA)) ...457
    ENG- 5 FAILURE CODE [ AD10L3] ( FUEL SUPPLY PUMP: * SEE CONTENTS ( L3)) ...458
    ENG- 6 FAILURE CODE [ AD10MA] ( FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE ( MA)) ...460
    ENG- 7 FAILURE CODE [ AD10MB] ( FUEL SUPPLY PUMP: DROP IN FUNCTION ( MB)) ...460
    ENG- 8 FAILURE CODE [ AD11KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION ( KA)) ...461
    ENG- 9 FAILURE CODE [ AD11KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT ( KB)) ...462
    ENG- 10 FAILURE CODE [ AD51KA] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION ( KA)) ...463
    ENG- 11 FAILURE CODE [ AD51KB] ( FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT ( KB)) ...464
    ENG- 12 FAILURE CODE [ ADA1KA] ( NO. 1 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...465
    ENG- 13 FAILURE CODE [ ADAZKB] ( NO. 1, 2, 3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) ...466
    ENG- 14 FAILURE CODE [ ADB1KA] ( NO. 2 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...470
    ENG- 15 FAILURE CODE [ ADC1KA] ( NO. 3 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...471
    ENG- 16 FAILURE CODE [ ADD1KA] ( NO. 4 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...472
    ENG- 17 FAILURE CODE [ ADDZKB] ( NO. 4, 5, 6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT ( KB)) ...473
    ENG- 18 FAILURE CODE [ ADE1KA] ( NO. 5 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...477
    ENG- 19 FAILURE CODE [ ADF1KA] ( NO. 6 INJECTOR SOLENOID VALVE: DISCONNECTION ( KA)) ...478
    ENG- 20 FAILURE CODE [ B@ BAZG] ( ENGINE OIL: DROP IN OIL PRESSURE ( ZG)) ...479
    ENG- 21 FAILURE CODE [ B@ BAZK] ( ENGINE OIL: DROP IN LEVEL ( ZK)) ...480
    ENG- 22 FAILURE CODE [ B@ BCNS] ( RADIATOR WATER: OVERHEAT ( NS)) ...481
    ENG- 23 FAILURE CODE [ D181KZ] ( PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...482
    ENG- 24 FAILURE CODE [ D182KZ] ( PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...484
    ENG- 25 FAILURE CODE [ D1D0KB] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT ( KB)) ...485
    ENG- 26 FAILURE CODE [ D5ZAKX] ( ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...487
    ENG- 27 FAILURE CODE [ DB20KT] ( ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER ( KT)) ...488
    ENG- 28 FAILURE CODE [ DB22KK] ( ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...490
    ENG- 29 FAILURE CODE [ DB29KQ] ( ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH ( KQ)) ...492
    ENG- 30 FAILURE CODE [ DB2AMA] ( ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE ( MA)) ...493
    ENG- 31 FAILURE CODE [ DD11KB] ( STARTING SWITCH: SHORT CIRCUIT ( KB)) ...494
    ENG- 32 FAILURE CODE [ DDA1L5] ( ACCELERATION SWITCH: * SEE CONTENTS ( L5)) ...495
    ENG- 33 FAILURE CODE [ DDE2L6] ( ENGINE OIL PRESSURE SWITCH: * SEE CONTENTS ( L6)) ...497
    ENG- 34 FAILURE CODE [ DGE2KX] ( ENGINE WATER TEMPERATURE SENSOR ( FOR HIGH- TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...499
    ENG- 35 FAILURE CODE [ DGE3L6] ( ENGINE WATER TEMPERATURE SENSOR ( FOR LOW- TEMPERATURE): * SEE CONTENTS ( L6)) ...500
    ENG- 36 FAILURE CODE [ DH30KX] ( BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...501
    ENG- 37 FAILURE CODE [ DH40KX] ( COMMON RAIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...503
    ENG- 38 FAILURE CODE [ DK10KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...505
    ENG- 39 FAILURE CODE [ DLE3LC] ( ENGINE NE SPEED SENSOR: * SEE CONTENTS ( LC)) ...507
    ENG- 40 FAILURE CODE [ DLH1LC] ( ENGINE G SPEED SENSOR: * SEE CONTENTS ( LC)) ...508
    ENG- 41 ENGINE DOES NOT START ( STARTING MOTOR DOES NOT TURN) ...509
  TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM ( TM MODE) ...512
    TM- 1 FAILURE CODE [ 1380MW] ( LOCK- UP CLUTCH: SLIPPING ( MW)) ...547
    TM- 2 FAILURE CODE [ 1500LO] ( TRANSMISSION CLUTCH: * SEE THE TABLE IN CONTENTS. ( LO)) ...548
    TM- 3 FAILURE CODE [ 15BONX] ( TRANSMISSION OIL FILTER: CLOGGED ( NX)) ...549
    TM- 4 FAILURE CODE [ 15GOMW] ( R CLUTCH: SLIPPING ( MW)) ...550
    TM- 5 FAILURE CODE [ 15HOMW] ( HI CLUTCH: SLIPPING ( MW)) ...551
    TM- 6 FAILURE CODE [ 15JOMW] ( LO CLUTCH: SLIPPING ( MW)) ...552
    TM- 7 ...553
    TM- 8 FAILURE CODE [ 15LOMW] ( 2ND CLUTCH: SLIPPING ( MW)) ...554
    TM- 9 FAILURE CODE [ 15MOMW] ( 3RD CLUTCH: SLIPPING ( MW)) ...555
    TM- 10 FAILURE CODE [ 15SBL1] ( ECMV FOR R CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...556
    TM- 11 FAILURE CODE [ 15SBMA] ( ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...557
    TM- 12 FAILURE CODE [ 15SCL1] ( ECMV FOR HI CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...558
    TM- 13 FAILURE CODE [ 15SCMA] ( ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...559
    TM- 14 FAILURE CODE [ 15SDL1] ( ECMV FOR LO CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...560
    TM- 15 FAILURE CODE [ 15SDMA] ( ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...561
    TM- 16 FAILURE CODE [ 15SEL1] ( ECMV FOR 1ST CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...562
    TM- 17 FAILURE CODE [ 15SEMA] ( ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...563
    TM- 18 FAILURE CODE [ 15SFL1] ( ECMV FOR 2ND CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...564
    TM- 19 FAILURE CODE [ 15SFMA] ( ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...565
    TM- 20 FAILURE CODE [ 15SGL1] ( ECMV FOR 3RD CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...566
    TM- 21 FAILURE CODE [ 15SGMA] ( ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...567
    TM- 22 FAILURE CODE [ 15SJL1] ( ECMV FOR LOCK- UP CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...568
    TM- 23 FAILURE CODE [ 15SJMA] ( ECMV FOR LOCK- UP CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...569
    TM- 24 FAILURE CODE [ 15SKL1] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: * SEE THE TABLE IN CONTENTS. ( L1)) ...570
    TM- 25 FAILURE CODE [ 15SKMA] ( ECMV FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE ( MA)) ...571
    TM- 26 FAILURE CODE [ 2B61MW] ( INTER- AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING ( MW)) ...572
    TM- 27 FAILURE CODE [ 2F00KM] ( PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...573
    TM- 28 FAILURE CODE [ 989A00] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED ( 00)) ...575
    TM- 29 FAILURE CODE [ 989AKZ] ( ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...576
    TM- 30 FAILURE CODE [ 989D00] ( REAR OVERTURN SIGNAL: ACTUATED ( 00)) ...577
    TM- 31 FAILURE CODE [ AA10NX] ( AIR CLEANER ELEMENT: CLOGGED ( NX)) ...579
    TM- 32 FAILURE CODE [ AB00MA] ( ALTERNATOR: FUNCTION IMPOSSIBLE ( MA)) ...581
    TM- 33 FAILURE CODE [ B@ BCZK] ( RADIATOR COOLING WATER: DROP IN LEVEL ( ZK)) ...582
    TM- 34 FAILURE CODE [ B@ HAZK] ( HYDRAULIC TANK OIL: DROP IN LEVEL ( ZK)) ...583
    TM- 35 FAILURE CODE [ B@ JANS] ( STEERING OIL: OVERHEAT ( NS)) ...584
    TM- 36 FAILURE CODE [ D1B0KZ] ( TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...585
    TM- 37 FAILURE CODE [ D5ZBKX] ( INTER- AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...587
    TM- 38 FAILURE CODE [ D5ZCKZ] ( EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...589
    TM- 39 FAILURE CODE [ D5ZDL4] ( FORCED NEUTRAL DEMAND SIGNAL: * SEE THE TABLE IN CONTENTS. ( L4)) ...590
    TM- 40 FAILURE CODE [ D5ZEKX] ( ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...592
    TM- 41 FAILURE CODE [ DAQ0KK] ( TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...593
    TM- 42 FAILURE CODE [ DAQ1KK] ( TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...595
    TM- 43 FAILURE CODE [ DAQ2KK] ( TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...596
    TM- 44 FAILURE CODE [ DAQ3KK] ( TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT ( KK)) ...597
    TM- 45 FAILURE CODE [ DAQ5KP] ( TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE ( KP)) ...598
    TM- 46 FAILURE CODE [ DAQ9KM] ( TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...599
    TM- 47 FAILURE CODE [ DAQ9KQ] ( TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...600
    TM- 48 FAILURE CODE [ DAQAKQ] ( TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...601
    TM- 49 FAILURE CODE [ DAQSMA] ( TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE ( MA) ...601
    TM- 50 FAILURE CODE [ DDTFKA] ( FILL SWITCH FOR INTER- AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION ( KA)) ...602
    TM- 51 FAILURE CODE [ DDTGKA] ( FILL SWITCH FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) ...603
    TM- 52 FAILURE CODE [ DDTHKA] ( FILL SWITCH FOR HI CLUTCH: DISCONNECTION ( KA)) ...604
    TM- 53 FAILURE CODE [ DDTJKA] ( FILL SWITCH FOR LO CLUTCH: DISCONNECTION ( KA)) ...605
    TM- 54 FAILURE CODE [ DDTKKA] ( FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION ( KA)) ...606
    TM- 55 FAILURE CODE [ DDTLKA] ( FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION ( KA)) ...607
    TM- 56 FAILURE CODE [ DDTMKA] ( FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION ( KA)) ...608
    TM- 57 FAILURE CODE [ DDTNKA] ( FILL SWITCH FOR R CLUTCH: DISCONNECTION ( KA)) ...609
    TM- 58 FAILURE CODE [ DF10KA] ( GEARSHIFT LEVER: DISCONNECTION ( KA)) ...610
    TM- 59 FAILURE CODE [ DF10KB] ( GEARSHIFT LEVER: SHORT CIRCUIT ( KB)) ...612
    TM- 60 FAILURE CODE [ DGF1KX] ( TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...614
    TM- 61 FAILURE CODE [ DGR3L8] ( BRAKE OIL TEMPERATURE SENSOR ( CENTER): * SEE THE TABLE IN CONTENTS. ( L8)) ...616
    TM- 62 FAILURE CODE [ DGR4L8] ( BRAKE OIL TEMPERATURE SENSOR ( FRONT): * SEE THE TABLE IN CONTENTS. ( L8)) ...618
    TM- 63 FAILURE CODE [ DGT1LX] ( TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...620
    TM- 64 FAILURE CODE [ DHT5KX] ( TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...622
    TM- 65 FAILURE CODE [ DHT5L6] ( TORQUE CONVERTER OIL PRESSURE SENSOR: * SEE THE TABLE IN CONTENTS. ( L6)) ...624
    TM- 66 FAILURE CODE [ DJF1KA] ( FUEL LEVEL SENSOR: DISCONNECTION ( KA)) ...625
    TM- 67 FAILURE CODE [ DK11KX] ( THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...626
    TM- 68 FAILURE CODE [ DLE2KA] ( ENGINE SPEED SENSOR: DISCONNECTION ( KA)) ...628
    TM- 69 FAILURE CODE [ DLE2LC] ( ENGINE SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...629
    TM- 70 FAILURE CODE [ DLF1KA] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION ( KA)) ...630
    TM- 71 FAILURE CODE [ DLF1LC] ( TRANSMISSION INPUT SHAFT SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...631
    TM- 72 FAILURE CODE [ DLF2KA] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...632
    TM- 73 FAILURE CODE [ DLF2LC] ( TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...633
    TM- 74 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...634
    TM- 75 FAILURE CODE [ DLT3LC] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: * SEE THE TABLE IN CONTENTS. ( LC)) ...635
    TM- 76 FAILURE CODE [ DXH0KA] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: DISCONNECTION ( KA)) ...637
    TM- 77 FAILURE CODE [ DXH0KB] ( SOLENOID FOR INTER- AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT ( KB)) ...638
    TM- 78 FAILURE CODE [ DXH1KA] ( SOLENOID FOR LOCK- UP CLUTCH: DISCONNECTION ( KA)) ...639
    TM- 79 FAILURE CODE [ DXH1KB] ( SOLENOID FOR LOCK- UP CLUTCH: SHORT CIRCUIT ( KB)) ...640
    TM- 80 FAILURE CODE [ DXH2KA] ( SOLENOID FOR HI CLUTCH: DISCONNECTION ( KA)) ...641
    TM- 81 FAILURE CODE [ DXH2KB] ( SOLENOID FOR HI CLUTCH: SHORT CIRCUIT ( KB)) ...642
    TM- 82 FAILURE CODE [ DXH3KA] ( SOLENOID FOR LO CLUTCH: DISCONNECTION ( KA)) ...643
    TM- 83 FAILURE CODE [ DXH3KB] ( SOLENOID FOR LO CLUTCH: SHORT CIRCUIT ( KB)) ...644
    TM- 84 FAILURE CODE [ DXH4KA] ( SOLENOID FOR 1ST CLUTCH: DISCONNECTION ( KA)) ...645
    TM- 85 FAILURE CODE [ DXH4KB] ( SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT ( KB)) ...646
    TM- 86 FAILURE CODE [ DXH5KA] ( SOLENOID FOR 2ND CLUTCH: DISCONNECTION ( KA)) ...647
    TM- 87 FAILURE CODE [ DXH5KB] ( SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT ( KB)) ...648
    TM- 88 FAILURE CODE [ DXH6KA] ( SOLENOID FOR 3RD CLUTCH: DISCONNECTION ( KA)) ...649
    TM- 89 FAILURE CODE [ DXH6KB] ( SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT ( KB)) ...650
    TM- 90 FAILURE CODE [ DXH7KA] ( SOLENOID FOR R CLUTCH: DISCONNECTION ( KA)) ...651
    TM- 91 FAILURE CODE [ DXH7KB] ( SOLENOID FOR R CLUTCH: SHORT CIRCUIT ( KB)) ...652
    TM- 92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY ...653
  TROUBLESHOOTING OF RETARDER CONTROLLER SYSTEM ( BK MODE) ...656
    BK- 1 FAILURE CODE [ 2G42ZG] ( ACCUMULATOR ( FRONT): DROP IN OIL PRESSURE ( ZG)) ...677
    BK- 2 FAILURE CODE [ 2G43ZG] ( ACCUMULATOR ( REAR): DROP IN OIL PRESSURE ( ZG)) ...677
    BK- 3 FAILURE CODE [ D1C0KZ] ( BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...678
    BK- 4 FAILURE CODE [ D5ZFKZ] ( NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...680
    BK- 5 FAILURE CODE [ D5ZGKZ] ( NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...681
    BK- 6 FAILURE CODE [ DB10KK] ( RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...682
    BK- 7 FAILURE CODE [ DB11KK] ( RETARDER CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...684
    BK- 8 FAILURE CODE [ DB12KK] ( RETARDER CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...685
    BK- 9 FAILURE CODE [ DB13KK] ( RETARDER CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT ( KK)) ...686
    BK- 10 FAILURE CODE [ DB19KM] ( RETARDER CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...687
    BK- 11 FAILURE CODE [ DB1SKQ] ( RETARDER CONTROLLER S- NET LINE: MODEL SELECTION SIGNAL MISMATCH ( KQ)) ...688
    BK- 12 FAILURE CODE [ DHU2KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( FRONT): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...689
    BK- 13 FAILURE CODE [ DHU3KX] ( ACCUMULATOR OIL PRESSURE SENSOR ( REAR): INPUT SIGNAL OUTSIDE RANGE ( KX)) ...691
    BK- 14 FAILURE CODE [ DK51L5] ( RETARDER LEVER POTENTIOMETER: * SEE SEPARATE TABLE ( L5)) ...693
    BK- 15 FAILURE CODE [ DK52KX] ( DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...696
    BK- 16 FAILURE CODE [ DK53L8] ( DUMP LEVER POTENTIOMETER 2: * SEE THE TABLE IN CONTENTS. ( L8)) ...698
    BK- 17 FAILURE CODE [ DK54KX] ( BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE ( KX)) ...699
    BK- 18 FAILURE CODE [ DLF4KA] ( TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION ( KA)) ...701
    BK- 19 FAILURE CODE [ DLT3KA] ( TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION ( KA)) ...702
    BK- 20 FAILURE CODE [ DW71KZ] ( EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...703
    BK- 21 FAILURE CODE [ DW72KZ] ( DUMP LEVER KICK- OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...704
    BK- 22 FAILURE CODE [ DW73KZ] ( DUMP SELECTOR VALVE SOLENOID: DISCONNECTION OR SHORT CIRCUIT ( KZ)) ...706
    BK- 23 FAILURE CODE [ DX11KA] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) ...708
    BK- 24 FAILURE CODE [ DX11KB] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...709
    BK- 25 FAILURE CODE [ DX11KY] ( REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...710
    BK- 26 FAILURE CODE [ DX12KA] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION ( KA)) ...711
    BK- 27 FAILURE CODE [ DX12KB] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...712
    BK- 28 FAILURE CODE [ DX12KY] ( FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...713
    BK- 29 FAILURE CODE [ DX13KA] ( DUMP EPC VALVE SOLENOID: DISCONNECTION ( KA)) ...714
    BK- 30 FAILURE CODE [ DX13KB] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT ( KB)) ...715
    BK- 31 FAILURE CODE [ DX13KY] ( DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE ( KY)) ...716
    BK- 32 PARKING BRAKE DOES NOT WORK PROPERLY ...717
  TROUBLESHOOTING OF MACHINE MONITOR SYSTEM ( MON MODE) ...720
    MON- 1 FAILURE CODE [ B@ C6NS] ( FRONT BRAKE OIL: OVERHEAT ( NS)) ...729
    MON- 2 FAILURE CODE [ B@ C8NS] ( CENTER BRAKE OIL: OVERHEAT ( NS)) ...729
    MON- 3 FAILURE CODE [ B@ CENS] ( TORQUE CONVERTER: OVERHEAT ( NS)) ...729
    MON- 4 FAILURE CODE [ DAF0KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...730
    MON- 5 FAILURE CODE [ DAF9KM] ( MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING ( KM)) ...731
    MON- 6 FAILURE CODE [ DAFSKQ] ( MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL ( KQ)) ...732
    MON- 7 FAILURE CODE [ DAQSKR] ( TRANSMISSION CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...733
    MON- 8 FAILURE CODE [ DB1SKR] ( RETARDER CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...735
    MON- 9 FAILURE CODE [ DB2SKR] ( ENGINE CONTROLLER S- NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM ( KR)) ...737
    MON- 10 FAILURE CODE [ DV00KB] ( ALARM BUZZER: SHORT CIRCUIT ( KB)) ...739
    MON- 11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY ...740
    MON- 12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED ...741
    MON- 13 ALARM BUZZER DOES NOT SOUND ...742
    MON- 14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY ...743
    MON- 15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY ...744
    MON- 16 ...745
    MON- 17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY ...748
    MON- 18 AISS FUNCTION DOES NOT WORK PROPERLY ...749
    MON- 19 EXHAUST BRAKE DOES NOT WORK PROPERLY ( MACHINES EQUIPPED WITH EXHAUST BRAKE) ...750
    MON- 20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY ...752
    MON- 21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY ...754
    MON- 22 NIGHT LIGHTING IS NOT NORMAL ...759
  TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ( H MODE) ...766
    H- 1 MACHINE DOES NOT START ...767
    H- 2 MACHINE DOES NOT TRAVEL SMOOTHLY ( MACHINE JERKS) H- 3 LOCK- UP CLUTCH CANNOT BE DISENGAGED ( ENGINE STALLS) ...768
    H- 4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING ...769
    H- 5 ...770
    H- 6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING ...771
    H- 7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR ...774
    H- 8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ...775
    H- 9 TORQUE CONVERTER OIL PRESSURE IS LOW ...776
    H- 10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE ...777
    H- 11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE ...778
    H- 12 STEERING WHEEL IS HEAVY ...779
    H- 13 STEERING WHEEL DOES NOT WORK ...780
    H- 14 STEERING WHEEL VIBRATES ...781
    H- 15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER ...782
    H- 16 DUMP DOES NOT WORK ...783
    H- 17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY ...784
  30 DISASSEMBLY AND ASSEMBLY ...810
    HOW TO READ THIS MANUAL ...812
      REMOVAL AND INSTALLATION OF ASSEMBLIES ...812
      DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES ...813
      2. Precautions when carrying out installation work ...815
      3. Precautions when completing the operation ...815
  REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY ...820
  REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY ...823
  REMOVAL AND INSTALLATION OF NOZZLE TIP ...827
  REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY ...830
  REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY ...838
  REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY ...843
  REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY ...846
  ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY ...849
  REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY ...852
  CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY ...859
  DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY ...861
  DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY ...870
  DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY ...916
  REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY ...931
  DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY ...935
  REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY ...955
  DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY ...957
  REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ...972
  DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY ...974
  REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY ...988
  DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY ...990
  DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY ...1001
  REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY ...1009
  REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY ...1011
  REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY ...1014
  INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY ...1016
  REMOVAL AND INSTALLATION OF EQUALIZER BAR ...1017
  REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY ...1019
  DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY ...1029
  DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY ...1036
  REMOVAL AND INSTALLATION OF FLOW AMP VALVE ...1046
  REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY ...1047
  DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY ...1049
  DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY ...1052
  REMOVAL AND INSTALLATION OF BODY ASSEMBLY ...1056
  90 OTHERS ...1070
SEBM024815 - Articulated Dump Truck HM300-1 Shop Manual...1090
  COVER...1090
  CONTENTS...1091
  01 GENERAL...1116
    SPECIFICATION DRAWINGS...1117
    SPECIFICATIONS...1118
    WEIGHT TABLE...1121
    FUEL, COOLANT AND LUBRICANTS...1122
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...1125
    RADIATOR, OIL COOLER, AFTERCOOLER...1126
    POWER TRAIN SKELETON...1127
    OUTPUT SHAFT...1129
    TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING...1131
    TORQUE CONVERTER...1133
    TRANSMISSION...1139
    TRANSMISSION VALVE...1158
    ECMV (ELECTRONIC CONTROL MODULATION VALVE)...1159
    MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...1166
    DRIVE SHAFT...1168
    AXLE...1169
    DIFFERENTIAL...1172
    LIMITED SLIP DIFFERENTIAL...1178
    FINAL DRIVE...1182
    STEERING COLUMN...1187
    BRAKE PIPING...1188
    BRAKE VALVE...1190
    ACCUMULATOR CHARGE VALVE...1193
    ACCUMULATOR...1197
    SLACK ADJUSTER...1198
    BRAKE...1200
    PROPORTIONAL REDUCING VALVE...1205
    BRAKE SYSTEM TANK...1206
    PARKING BRAKE...1207
    PARKING BRAKE CALIPER...1209
    SPRING CYLINDER...1210
    PARKING BRAKE SOLENOID...1211
    SUSPENSION...1212
    SUSPENSION CYLINDER...1217
    OSCILLATION HITCH...1219
    STEERING, HOIST OIL PRESSURE PIPING DIAGRAM...1222
    DUMP BODY CONTROL...1223
    HYDRAULIC TANK AND FILTER...1224
    FLOW AMP VALVE...1225
    STEERING VALVE...1228
    STEERING CYLINDER...1232
    HOIST VALVE...1233
    EPC VALVE...1239
    PILOT CHECK VALVE...1240
    HOIST CYLINDER...1241
    HYDRAULIC PUMP...1242
    CAB TILT...1246
    AIR CONDITIONER...1247
    HEARTER...1252
    MACHINE MONITOR SYSTEM...1255
    AUTOMATIC SHIFT CONTROL SYSTEM...1268
    TRANSMISSION CONTROLLER...1270
    AUTO EMERGENCY STEERING SYSTEM...1276
    SENSORS, SWITCHES...1277
    RETARDER CONTROL SYSTEM...1285
    BRAKE CONTROL SYSTEM (E-SPEC)...1295
    DUMP CONTROL LEVER...1304
  20 TESTING AND ADJUSTING...1309
    STANDARD VALUE TABLE FOR ENGINE...1310
    STANDARD VALUE TABLE FOR CHASSIS...1311
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS...1315
    TESTING AND ADJUSTING...1327
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...1328
      MEASURING ENGINE SPEED...1330
      MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...1331
      MEASURING EXHAUST TEMPERATURE...1332
      MEASURING EXHAUST COLOR...1334
      MEASURING COMPRESSION PRESSURE...1335
      ADJUSTING VALVE CLEARANCE...1336
      MEASURING BLOW-BY PRESSURE...1337
      MEASURING ENGINE OIL PRESSURE...1338
      HANDING EQUIPMENT IN FUEL CIRCUIT...1339
      RELEASING REMAINING PRESSURE IN FUEL SYSTEM...1339
      MEASURING FUEL PRESSURE...1340
      BLEEDING AIR FROM FUEL CIRCUIT...1341
      REDUCED CYLINDER MODE OPERATION FOR ENGINE...1343
      CHECKING FOR LEAKAGE IN FUEL CIRCUIT...1344
      ADJUSTING ENGINE SPEED SENSOR...1345
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION...1346
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...1346
      ADJUSTING THE BODY MOUNT...1347
      TESTING TORQUE CONVERTER STALL SPEED...1349
      MEASURING POWER TRAIN OIL PRESSURE...1350
      ADJUSTING TRANSMISSION SPEED SENSOR...1357
      TESTING AND ADJUSTING BRAKE OIL PRESSURE...1359
      TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS...1363
      TESTING BRAKE PERFORMANCE...1367
      BLEEDING AIR FROM BRAKE CIRCUIT...1369
      TESTING WEAR OF WHEEL BRAKE DISC...1371
      TESTING WEAR OF PARKING BRAKE PAD...1372
      METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE...1373
      TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE...1374
      TESTING AND ADJUSTING SUSPENSION CYLINDER...1376
      METHOD OF TILTING CAB UP...1380
      TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE...1383
      ADJUSTING BODY POSITIONER SENSOR...1386
      PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT...1387
      HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT...1387
      ADJUSTING TRANSMISSION CONTROLLER...1388
      METHOD FOR EMERGENCY ESCAPE WHEN THERE IS FAILURE IN ELECTRICAL SYSTEM...1389
      ADJUSTING MACHINE MONITOR...1393
      SPECIAL FUNCTIONS OF MACHINE MONITOR...1397
      PM-CLINIC INSPECTION SHEET...1431
    TROUBLESHOOTING...1434
      POINTS TO REMEMBER WHEN TROUBLESHOOTING...1435
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...1436
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...1437
      CHECKS BEFORE TROUBLESHOOTING...1445
      CONNECTOR TYPES AND MOUNTING LOCATIONS...1446
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1461
      T-ADAPTER TABLE...1484
      CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS...1487
      TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (ENG MODE)...1491
        ENG MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...1493
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE...1496
        ENG-1 FAILURE CODE [A000N1] (ENGINE: OVERRUN N1))...1508
        ENG-2 FAILURE CODE [A570NX] (ENGINE OIL FILTER: CLOGGED (NX))...1509
        ENG-3 FAILURE CODE [AD00L2] (COMMON RAIL: *SEE CONTENTS (L2))...1510
        ENG-4 FAILURE CODE [AD00MA] (COMMON RAIL: FUNCTION IMPOSSIBLE (MA))...1510
        ENG-5 FAILURE CODE [AD10L3] (FUEL SUPPLY PUMP: *SEE CONTENTS (L3))...1511
        ENG-6 FAILURE CODE [AD10MA] (FUEL SUPPLY PUMP: FUNCTION IMPOSSIBLE (MA))...1513
        ENG-7 FAILURE CODE [AD10MB] (FUEL SUPPLY PUMP: DROP IN FUNCTION (MB))...1513
        ENG-8 FAILURE CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID VALVE 1: DISCONNECTION (KA))...1514
        ENG-9 FAILURE CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID VALVE 1: SHORT CIRCUIT (KB))...1515
        ENG-10 FAILURE CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID VALVE 2: DISCONNECTION (KA))...1516
        ENG-11 FAILURE CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID VALVE 2: SHORT CIRCUIT (KB))...1517
        ENG-12 FAILURE CODE [ADA1KA] (NO.1 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1518
        ENG-13 FAILURE CODE [ADAZKB] (NO.1,2,3 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))...1519
        ENG-14 FAILURE CODE [ADB1KA] (NO.2 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1523
        ENG-15 FAILURE CODE [ADC1KA] (NO.3 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1524
        ENG-16 FAILURE CODE [ADD1KA] (NO.4 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1525
        ENG-17 FAILURE CODE [ADDZKB] (NO.4,5,6 INJECTOR SOLENOID VALVE: SHORT CIRCUIT (KB))...1526
        ENG-18 FAILURE CODE [ADE1KA] (NO.5 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1530
        ENG-19 FAILURE CODE [ADF1KA] (NO.6 INJECTOR SOLENOID VALVE: DISCONNECTION (KA))...1531
        ENG-20 FAILURE CODE [B@BAZG] (ENGINE OIL: DROP IN OIL PRESSURE (ZG))...1532
        ENG-21 FAILURE CODE [B@BAZK] (ENGINE OIL: DROP IN LEVEL (ZK))...1533
        ENG-22 FAILURE CODE [B@BCNS] (RADIATOR WATER: OVERHEAT (NS))...1534
        ENG-23 FAILURE CODE [D181KZ] (PREHEATING RELAY CONTACT: DISCONNECTION OR SHORT CIRCUIT (KZ))...1535
        ENG-24 FAILURE CODE [D182KZ] (PREHEATING RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))...1537
        ENG-25 FAILURE CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: SHORT CIRCUIT (KB))...1538
        ENG-26 FAILURE CODE [D5ZAKX] (ENGINE THROTTLE MODIFY 1 SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))...1540
        ENG-27 FAILURE CODE [DB20KT] (ENGINE CONTROLLER: ABNORMALITY INSIDE CONTROLLER (KT))...1541
        ENG-28 FAILURE CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SOURCE RELAY: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK))...1543
        ENG-29 FAILURE CODE [DB29KQ] (ENGINE CONTROLLER CONNECTION WIRING HARNESS: MODEL SELECTION SIGNAL MISMATCH (KQ))...1545
        ENG-30 FAILURE CODE [DB2AMA] (ENGINE CONTROLLER FUEL INJECTION QUANTITY CONTROL SWITCH: FUNCTION IMPOSSIBLE (MA))...1546
        ENG-31 FAILURE CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB))...1547
        ENG-32 FAILURE CODE [DDA1L5] (ACCELERATION SWITCH: *SEE CONTENTS (L5))...1548
        ENG-33 FAILURE CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: *SEE CONTENTS (L6))...1550
        ENG-34 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH-TEMPERATURE): INPUT SIGNAL OUTSIDE RANGE (KX))...1552
        ENG-35 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW-TEMPERATURE): *SEE CONTENTS (L6))...1553
        ENG-36 FAILURE CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1554
        ENG-37 FAILURE CODE [DH40KX] (COMMON PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1556
        ENG-38 FAILURE CODE [DH10KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1558
        ENG-39 FAILURE CODE [DLE3LC] (ENGINE NE SPEED SENSOR: *SEE CONTENTS (LC))...1560
        ENG-40 FAILURE CODE [DLH1LC] (ENGINE G SPEED SENSOR: *SEE CONTENTS (LC))...1561
        ENG-41 ENGINE DOES NOT STARTS (STARTING MOTOR DOES NOT TURN)...1562
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (TM MODE)...1565
        TM MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...1568
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE...1574
        TM-1 FAILURE CODE [1380MW] (LOCK-UP CLUTCH: SLIPPING (MW))...1600
        TM-2 FAILURE CODE [1500LO] (TRANSMISSION CLUTCH: *SEE THE TABLE IN CONTENTS (LO))...1601
        TM-3 FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED (NX))...1602
        TM-4 FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING (MW))...1603
        TM-5 FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING (MW))...1604
        TM-6 FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING (MW))...1605
        TM-7 FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING (MW))...1606
        TM-8 FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING (MW))...1607
        TM-9 FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING (MW))...1608
        TM-10 FAILURE CODE [15SBL1] (ECMV FOR R CLUTCH: *SEE THE TABLE CONTENTS (L1)) ...1609
        TM-11 FAILURE CODE [15SBMA] (ECMV FOR R CLUTCH: FUNCTION IMPOSSIBLE (MA))...1610
        TM-12 FAILURE CODE [15SCL1] (ECMV FOR HI CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1611
        TM-13 FAILURE CODE [15SCMA] (ECMV FOR HI CLUTCH: FUNCTION IMPOSSIBLE (MA))...1612
        TM-14 FAILURE CODE [15SDL1] (ECMV FOR LO CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1613
        TM-15 FAILURE CODE [15SDMA] (ECMV FOR LO CLUTCH: FUNCTION IMPOSSIBLE (MA))...1614
        TM-16 FAILURE CODE [15SEL1] (ECMV FOR 1ST CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1615
        TM-17 FAILURE CODE [15SEMA] (ECMV FOR 1ST CLUTCH: FUNCTION IMPOSSIBLE (MA))...1616
        TM-18 FAILURE CODE [15SFL1] (ECMV FOR 2ND CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1617
        TM-19 FAILURE CODE [15SFMA] (ECMV FOR 2ND CLUTCH: FUNCTION IMPOSSIBLE (MA))...1618
        TM-20 FAILURE CODE [15SGL1] (ECMV FOR 3RD CLUTCH: *SEE HTE TABLE IN CONTENTS (L1))...1619
        TM-21 FAILURE CODE [15SGMA] (ECMV FOR 3RD CLUTCH: FUNCTION IMPOSSIBLE (MA))...1620
        TM-22 FAILURE CODE [15SJL1] (ECMV FOR LOCK-UP CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1621
        TM-23 FAILURE CODE [15SJMA] (ECMV FOR LOCK-UP CLUTCH: FUNCTION IMPOSSIBLE (MA))...1622
        TM-24 FAILURE CODE [15SKL1] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: *SEE THE TABLE IN CONTENTS (L1))...1623
        TM-25 FAILURE CODE [15SKMA] (ECMV FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: FUNCTION IMPOSSIBLE (MA))...1624
        TM-26 FAILURE CODE [2B61MW] (INTER-AXLE DIFFERENTIAL LOCK CLUTCH: SLIPPING (MW))...1625
        TM-27 FAILURE CODE [2F00KM] (PARKING BRAKE: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))  ...1626
        TM-28 FAILURE CODE [989A00] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: ACTUATED (00))...1628
        TM-29 FAILURE CODE [989AKZ] (ENGINE OVERRUN PREVENTION COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))...1629
        TM-30 FAILURE CODE [989D00] (REAR OVERTURN SIGNAL: ACTUATED (00))...1630
        TM-31 FAILURE CODE [AA10NX] (AIR CLANER ELEMENT: CLOGGED (NX))...1632
        TM-32 FAILURE CODE [AB00MA] (ALTERNATOR: FUNCTION IMPOSSIBLE (MA))...1634
        TM-33 FAILURE CODE [B@BCZK] (RADIATOR COOLING WATER: DROP IN LEVEL (ZK))...1635
        TM-34 FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: DROP IN LEVEL (ZK))...1636
        TM-35 FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT (NS))...1637
        TM-36 FAILURE CODE [D1B0KZ] (TRANSMISSION CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))...1638
        TM-37 FAILURE CODE [D5ZBKX] (INTER-AXLE DIFFERENTIAL LOCK COMMAND SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))...1640
        TM-38 FAILURE CODE [D5ZCKZ] (EXHAUST BRAKE COMMAND SIGNAL: DISCONNECTION OR SHORT CIRCUIT (KZ))...1642
        TM-39 FAILURE CODE [D5ZDL4] (FORCED NEUTRAL DEMAND SIGNAL: *SEE THE TABLE IN CONTENTS (L4))...1643
        TM-40 FAILURE CODE [D5ZEKX] (ENGINE LOAD SIGNAL: INPUT SIGNAL OUTSIDE RANGE (KX))...1645
        TM-41 FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...1646
        TM-42 FAILURE CODE [DAQ1KK] (TRANSMISSION CONTROLLER MAIN POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...1648
        TM-43 FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER LOAD POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...1649
        TM-44 FAILURE CODE [DAQ3KK] (TRANSMISSION CONTROLLER BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SOURCE VOLTAGE, INPUT (KK))...1650
        TM-45 FAILURE CODE [DAQ5KP] (TRANSMISSION CONTROLLER POWER SUPPLY OUTPUT 1: DROP IN OUTPUT VOLTAGE (KP))...1651
        TM-46 FAILURE CODE [DAQ9KM] (TRANSMISSION CONTROLLER WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))...1652
        TM-47 FAILURE CODE [DAQ9KQ] (TRANSMISSION CONTROLLER WIRING HARNESS: NON MATCH IN MODEL SELECTION SIGNAL (KQ))...1653
        TM-48 FAILURE CODE [DAQAKQ] (TRANSMISSION CONTROLLER ROTARY SWITCH: NON MATCH IN MODEL SELECTION SIGNAL (KQ))...1654
        TM-49 FAILURE CODE [DAQSMA] (TRANSMISSION CONTROLLER: FUNCTION IMPOSSIBLE (MA))...1654
        TM-50 FAILURE CODE [DDTFKA] (FILL SWITCH FOR INTER-AXLE DIFFERENTIAL LOCK CLUTCH: DISCONNECTION (KA))...1655
        TM-51 FAILURE CODE [DDTGKA] (FILL SWITCH FOR LOCK-UP CLUTCH: DISCONNECTION (KA))...1656
        TM-52 FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION (KA))...1657
        TM-53 FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION (KA))...1658
        TM-54 FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION (KA))...1659
        TM-55 FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION (KA))...1660
        TM-56 FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION (KA))...1661
        TM-57 FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION (KA))...1662
        TM-58 FAILURE CODE [DF10KA] (GEARSHIFT LEVER: DISCONNECTION (KA))...1663
        TM-59 FAILURE CODE [DF10KB] (GEARSHIFT LEVER: SHORT CIRCUIT (KB))...1665
        TM-60 FAILURE CODE [DGF1KX] (TRANSMISSION VALVE OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1667
        TM-61 FAILURE CODE [DGR3L8] (BRAKE OIL TEMPERATURE SENSOR (CENTER): *SEE THE TABLE IN CONTENTS (L8))...1669
        TM-62 FAILURE CODE [DGR4L8] (BRAKE OIL TEMPERATURE SENSOR (FRONT): *SEE THE TABLE IN CONTENTS (L8))...1671
        TM-63 FAILURE CODE [DGT1LX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1673
        TM-64 FAILURE CODE [DHT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1675
        TM-65 FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: *SEE THE TABLE IN CONTENTS (L6))...1677
        TM-66 FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION (KA))...1678
        TM-67 FAILURE CODE [DK11KX] (THROTTLE ANGLE SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1679
        TM-68 FAILURE CODE [DLE2KA] (ENGINE SPEED SENSOR: DISCONNECTION (KA))...1681
        TM-69 FAILURE CODE [DLE2LC] (ENGINE SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))...1682
        TM-70 FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION (KA))...1683
        TM-71 FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))...1684
        TM-72 FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: DISCONNECTION (KA))...1685
        TM-73 FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT R SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))...1686
        TM-74 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))...1687
        TM-75 FAILURE CODE [DLT3LC] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: *SEE THE TABLE IN CONTENTS (LC))...1688
        TM-76 FAILURE CODE [DXH0KA] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: DISCONNECTION (KA))...1690
        TM-77 FAILURE CODE [DXH0KB] (SOLENOID FOR INTER-AXLE DIFFERENTIAL LOCK: SHORT CIRCUIT (KB))...1691
        TM-78 FAILURE CODE [DXH1KA] (SOLENOID FOR LOCK-UP CLUTCH: DISCONNECTION (KA))...1692
        TM-79 FAILURE CODE [DXH1KB] (SOLENOID FOR LOCK-UP CLUTCH: SHORT CIRCUIT (KB))...1693
        TM-80 FAILURE CODE [DXH2KA] (SOLENOID FOR HI CLUTCH: DISCONNECTION (KA))...1694
        TM-81 FAILURE CODE [DXH2KB] (SOLENOID FOR HI CLUTCH: SHORT CIRCUIT (KB))...1695
        TM-82 FAILURE CODE [DXH3KA] (SOLENOID FOR LO CLUTCH: DISCONNECTION (KA))...1696
        TM-83 FAILURE CODE [DXH3KB] (SOLENOID FOR LO CLUTCH: SHORT CIRCUIT (KB))...1697
        TM-84 FAILURE CODE [DXH4KA] (SOLENOID FOR 1ST CLUTCH: DISCONNECTION (KA))...1698
        TM-85 FAILURE CODE [DXH4KB] (SOLENOID FOR 1ST CLUTCH: SHORT CIRCUIT (KB))...1699
        TM-86 FAILURE CODE [DXH5KA] (SOLENOID FOR 2ND CLUTCH: DISCONNECTION (KA))...1700
        TM-87 FAILURE CODE [DXH5KB] (SOLENOID FOR 2ND CLUTCH: SHORT CIRCUIT (KB))...1701
        TM-88 FAILURE CODE [DXH6KA] (SOLENOID FOR 3RD CLUTCH: DISCONNECTION (KA))...1702
        TM-89 FAILURE CODE [DXH6KB] (SOLENOID FOR 3RD CLUTCH: SHORT CIRCUIT (KB))...1703
        TM-90 FAILURE CODE [DXH7KA] (SOLENOID FOR R CLUTCH: DISCONNECTION (KA))...1704
        TM-91 FAILURE CODE [DXH7KB] (SOLENOID FOR R CLUTCH: SHORT CIRCUIT (KB))...1705
        TM-92 BACKUP LAMP, BACKUP BUZZER DO NOT WORK PROPERLY...1706
        TM-93 EMERGENCY STEERING DOES NOT OPERATE...1709
      TROUBLESHOOTING OF RETARDER CONTROLLER (*1) SYSTEM (BK MODE)...1713
        BK MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...1715
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE...1720
        BK-1 FAILURE CODE [2G42ZG] (ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG))...1732
        BK-2 FAILURE CODE [2G43ZG] (ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG))...1732
        BK-3 FAILURE CODE [D1C0KZ] (BRAKE CUT RELAY: DISCONNECTION OR SHORT CIRCUIT (KZ))...1733
        BK-4 FAILURE CODE [D5ZFKZ] (NEUTRAL SIGNAL 1: DISCONNECTION OR SHORT CIRCUIT (KZ))...1735
        BK-5 FAILURE CODE [D5ZGKZ] (NEUTRAL SIGNAL 2: DISCONNECTION OR SHORT CIRCUIT (KZ))...1736
        BK-6 FAILURE CODE [DB10KK] (RETARDER CONTROLLER: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)...1737
        BK-7 FAILURE CODE [DB11KK] (RETARDER CONTROLLER (*1) MAIN POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)...1739
        BK-8 FAILURE CODE [DB12KK] (RETARDER CONTROLLER (*1) LOAD POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)...1740
        BK-9 FAILURE CODE [DB13KK] (RETARDER CONTROLLER (*1) BATTERY DIRECT POWER SUPPLY LINE: DROP IN POWER SUPPLY VOLTAGE, INPUT (KK)...1741
        BK-10 FAILURE CODE [DB19KM] (RETARDER CONTROLLER (*1) WIRING HARNESS: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))...1742
        BK-11 FAILURE CODE [DB1SKQ] (RETARDER CONTROLLER (*1) S-NET LINE: MODEL SELECTION SIGNAL MISMATCH (KQ))...1743
        BK-12 FAILURE CODE [DHU2KX] (ACCUMULATOR OIL PRESSURE SENSOR (FRONT): INPUT SIGNAL OUTSIDE RANGE (KX))...1744
        BK-13 FAILURE CODE [DHU3KX] (ACCUMULATOR OIL PRESSURE SENSOR (REAR): INPUT SIGNAL OUTSIDE RANGE (KX))...1746
        BK-14 FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: *SEE SEPARATE TABLE (L5))...1748
        BK-15 FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER 1: INPUT SIGNAL OUTSIDE RANGE (KX))...1751
        BK-16 FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER 2: *SEE THE TABLE IN CONTENTS (L8))...1753
        BK-17 FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUTSIDE RANGE (KX))...1754
        BK-18 FAILURE CODE [DLF4KA] (TRANSMISSION OUTPUT SHAFT F SPEED SENSOR: DISCONNECTION (KA))...1756
        BK-19 FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT R SPEED SENSOR: DISCONNECTION (KA))...1757
        BK-20 FAILURE CODE [DW71KZ] (EXHAUST BRAKE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ)) (MACHINE WITH EXHAUST BRAKE)...1758
        BK-21 FAILURE CODE [DW72KZ] (DUMP LEVER KICK-OUT SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...1759
        BK-22 FAILURE CODE [DW73KZ] (DUMP SELECTOR VAVLE SOLENOID: DISCONNECTION OR SHORT CIRCUIT (KZ))...1761
        BK-23 FAILURE CODE [DX11KA] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))...1763
        BK-24 FAILURE CODE [DX11KB] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))...1764
        BK-25 FAILURE CODE [DX11KY] (REAR BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))...1765
        BK-26 FAILURE CODE [DX12KA] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: DISCONNECTION (KA))...1766
        BK-27 FAILURE CODE [DX12KB] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT (KB))...1767
        BK-28 FAILURE CODE [DX12KY] (FRONT BRAKE PRESSURE REDUCING VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))...1768
        BK-29 FAILURE CODE [DX13KA] (DUMP EPC VALVE SOLENOID: DISCONNECTION (KA))...1769
        BK-30 FAILURE CODE [DX13KB] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT (KB))...1770
        BK-31 FAILURE CODE [DX13KY] (DUMP EPC VALVE SOLENOID: SHORT CIRCUIT IN POWER SUPPLY LINE (KY))...1771
        BK-32 PARKING BRAKE DOES NOT WORK PROPERLY...1772
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (MON MODE)...1775
        MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM...1776
        CONTENT OF DISPLAY AND PROBLEM THAT APPEARS ON MACHINE FOR EACH FAILURE CODE ...1780
        MON-1 FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT (NS))...1784
        MON-2 FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT (NS))...1784
        MON-3 FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT (NS))...1784
        MON-4 FAILURE CODE [DAF0KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))...1785
        MON-5 FAILURE CODE [DAF9KM] (MONITOR PANEL: MISTAKEN OPERATION OR MISTAKEN SETTING (KM))...1786
        MON-6 FAILURE CODE [DAFSKQ] (MONITOR PANEL: NON MATCH IN MODEL SELECTION SIGNAL (KQ))...1787
        MON-7 FAILURE CODE [DAQSKR] (TRANSMISSION CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))...1788
        MON-8 FAILURE CODE [DB1SKR] (RETARDER CONTROLLER (*1) S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))...1790
        MON-9 FAILURE CODE [DB2SKR] (ENGINE CONTROLLER S-NET: DEFECTIVE COMMUNICATION, ABNORMALITY IN CORRESPONDING COMPONENT SYSTEM (KR))...1792
        MON-10 FAILURE CODE [DV00KB] (ALARM BUZZER: SHORT CIRCUIT (KB))...1794
        MON-11 WHEN STARTING SWITCH IS TURNED ON, MACHINE MONITOR GIVES NO DISPLAY...1795
        MON-12 WHEN STARTING SWITCH IS OFF, MACHINE MONITOR CANNOT BE OPERATED...1796
        MON-13 ALARM BUZZER DOES NOT SOUND...1797
        MON-14 GAUGES, CAUTION LAMPS, CHARACTER DISPLAY ON MACHINE MONITOR DO NOT GIVE CORRECT DISPLAY...1798
        MON-15 ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED PROPERLY...1799
        MON-16 CHARACTER DISPLAY CANNOT BE SWITCHED PROPERLY...1800
        MON-17 POWER MODE SELECTOR FUNCTION DOES NOT WORK PROPERLY...1803
        MON-18 AISS FUNCTION DOES NOT WORK PROPERLY...1804
        MON-19 EXHAUST BRAKE DOES NOT WORK PROPERLY (MACHINES EQUIPPED WITH EXHAUST BRAKE)...1805
        MON-20 SEAT BELT CAUTION LAMP DISPLAY IS NOT SHOWN PROPERLY...1807
        MON-21 TURN SIGNAL LAMP, HAZARD LAMP DO NOT WORK PROPERLY...1809
        MON-22 NIGHT LIGHTING IS NOT NORMAL...1814
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...1821
        H-1 MACHINE DOES NOT START...1822
        H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)...1823
        H-3 LOCK-UP CLUTCH CANNOT BE DISENGAGED (ENGINE STALLS)...1823
        H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING...1824
        H-5 TRANSMISSION DOES NOT SHIFT UP...1825
        H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING...1826
        H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR...1829
        H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...1830
        H-9 TORQUE CONVERTER OIL PRESSURE IS LOW...1831
        H-10 FRONT BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE...1832
        H-11 CENTER BRAKE IS INEFFECTIVE, OR EFFECTIVE ONLY ON ONE SIDE...1833
        H-12 STEERING WHEEL IS HEAVY...1834
        H-13 STEERING WHEEL DOES NOT WORK...1835
        H-14 STEERING WHEEL VIBRATES...1836
        H-15 DUMP BODY LIFTING SPEED IS SLOW, OR LACKS POWER...1837
        H-16 DUMP DOES NOT WORK...1838
        H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY...1839
      TROUBLESHOOTING OF THE ENGINE BODY (S MODE)...1840
        POINTS TO REMEMBER WHEN TROUBLESHOOTING...1841
        METHOD OF USING TROUBLESHOOTING CHARTS...1842
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...1845
        S-2 ENGINE DOES NOT START...1846
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...1849
        S-4 ENGINE STOPS DURING OPERATIONS...1850
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...1851
        S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...1852
        S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...1853
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...1854
        S-9 OIL BECOMES CONTAMINATED QUICKLY...1855
        S-10 FUEL CONSUMPTION IS EXCESSIVE...1856
        S-11 OIL IS IN COOLING (OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN)...1857
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...1858
        S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...1859
        S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...1860
        S-15 ABNORMAL NOISE IS MADE...1861
        S-16 VIBRATION IS EXCESSIVE...1862
  30 DISASSEMBLY AND ASSEMBLY...1863
    HOW TO READ THIS MANUAL...1865
      REMOVAL AND INSTALLATION OF ASSEMBLIES...1865
      DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...1866
    PRECAUTIONS WHEN CARRYING OUT OPERATION...1867
    SPECIAL TOOL LIST...1869
    REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...1873
      SPECIAL TOOL...1873
      REMOVAL...1873
      INSTALLATION...1876
    REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY...1878
      REMOVAL...1878
      INSTALLATION...1879
    REMOVAL AND INSTALLATION OF NOZZLE TIP...1882
      SPECIAL TOOL...1882
      REMOVAL...1882
      INSTALLATION...1883
      SKETCHES OF SPECIAL TOOLS...1884
    REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...1885
      SPECIAL TOOL...1885
      REMOVAL...1885
      INSTALLATION...1889
    REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...1893
      SPECIAL TOOL...1893
      REMOVAL...1893
      INSTALLATION...1897
    REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...1898
      REMOVAL...1898
      INSTALLATION...1900
    REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY...1901
      SPECIAL TOOL...1901
      REMOVAL...1901
      INSTALLATION...1903
    ASSEMBLY AND DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY...1906
      DISASSEMBLY...1906
      ASSEMBLY...1907
    REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...1909
      SPECIAL TOOL...1909
      REMOVAL...1909
      INSTALLATION...1914
    CONNECTION AND DISCONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY...1916
      DISCONNECTION...1916
      CONNECTION...1917
    DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...1918
      SPECIAL TOOL...1918
      DISASSEMBLY...1918
      ASSEMBLY...1921
      SKETCHES OF SPECIAL TOOLS...1926
    DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY...1927
      SPECIAL TOOL...1927
      DISASSEMBLY...1927
      ASSEMBLY...1944
      SKETCHES OF SPECIAL TOOLS...1970
    DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY...1973
      SPECIAL TOOL...1973
      DISASSEMBLY...1973
      ASSEMBLY...1977
      SKETCHES OF SPECIAL TOOLS...1987
    REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY...1988
      SPECIAL TOOL...1988
      REMOVAL...1988
      INSTALLATION...1990
    DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY...1992
      SPECIAL TOOL...1992
      DISASSEMBLY...1992
      ASSEMBLY...1997
      SKETCHES OF SPECIAL TOOLS...2009
    REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY...2012
      REMOVAL...2012
      INSTALLATION...2013
    DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY ...2014
      SPECIAL TOOL...2014
      DISASSEMBLY...2014
      ASSEMBLY...2018
      SKETCHES OF SPECIAL TOOLS...2028
    REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY...2029
      REMOVAL...2029
      INSTALLATION...2030
    DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY...2031
      SPECIAL TOOL...2031
      DISASSEMBLY...2031
      ASSEMBLY...2035
      SKETCHES OF SPECIAL TOOLS...2042
    REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY...2045
      REMOVAL...2045
      INSTALLATION...2046
    DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY...2047
      SPECIAL TOOL...2047
      DISASSEMBLY...2047
      ASSEMBLY...2049
      SKETCHES OF SPECIAL TOOLS...2055
    DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY...2058
      SPECIAL TOOL...2058
      DISASSEMBLY...2058
      ASSEMBLY...2060
      SKETCHES OF SPECIAL TOOLS...2065
    REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY...2066
      REMOVAL...2066
      INSTALLATION...2067
    REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...2068
      REMOVAL...2068
      INSTALLATION...2070
    REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY...2071
      REMOVAL...2071
      INSTALLATION...2072
    INSTALLATION AND REMOVAL OF REAR SUSPENSION CYLINDER ASSEMBLY...2073
      REMOVAL...2073
      INSTALLATION...2073
    REMOVAL AND INSTALLATION OF EQUALIZER BAR...2076
      REMOVAL...2076
      INSTALLATION...2077
    REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY...2078
      SPECIAL TOOL...2078
      REMOVAL...2078
      INSTALLATION...2083
      SKETCHES OF SPECIAL TOOLS...2087
    DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY...2088
      SPECIAL TOOL...2088
      DISASSEMBLY...2088
      ASSEMBLY...2089
      SKETCHES OF SPECIAL TOOLS...2094
    DISASSEMBLY AND ASSEMBLY OF STEERING VALVE ASSEMBLY...2095
      DISASSEMBLY...2097
      ASSEMBLY...2100
    REMOVAL AND INSTALLATION OF FLOW AMP VALVE...2105
      SPECIAL TOOL...2105
      REMOVAL...2105
      INSTALLATION...2106
    REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY...2107
      SPECIAL TOOL...2107
      REMOVAL...2107
      INSTALLATION...2108
    DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY...2110
      SPECIAL TOOL...2110
      DISASSEMBLY...2110
      ASSEMBLY...2111
    DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY...2113
      SPECIAL TOOL...2113
      DISASSEMBLY...2113
      ASSEMBLY...2115
    REMOVAL AND INSTALLATION OF BODY ASSEMBLY...2117
      REMOVAL...2117
      INSTALLATION...2118
    DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY...2120
      DISASSEMBLY...2120
      ASSEMBLY...2125
  90 OTHERS...2130
    POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...2131
    STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM...2132
    BRAKE HYDRAULIC CIRCUIT DIAGRAM...2133
    BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM...2134
    BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM (-30°C SPECIFICATION)...2135
    DIAGRAM FOR ELECTRICAL CIRCUIT AIR CONDITIONER...2136
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (1/4)...2137
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (2/4)...2138
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (3/4)...2139
    DIAGRAM FOR ELECTRICAL CIRCUIT INSIDE CAB (4/4)...2140
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (1/3)...2141
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (2/3)...2142
    DIAGRAM FOR ELECTRICAL CIRCUIT OUTSIDE CAB (3/3)...2143
    DIAGRAM FOR ELECTRICAL CIRCUIT EXTERNAL POWER SUPPLY HEATER...2144
    DIAGRAM FOR ELECTRICAL CIRCUIT HEATER MIRROR...2145
SEN00237-04 - Dump Truck GALEO HM300-2 Shop Manual...2146
  COVER...2146
  00 INDEX AND FOREWORD...0
    INDEX...2147
      COMPOSITION OF SHOP MANUAL...2148
      TABLE OF CONTENTS...2150
    FOREWORD AND GENERAL INFORMATION...2161
      SAFETY NOTICE...2162
      HOW TO READ THE SHOP MANUAL ...2167
      EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...2169
      HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT...2171
      HOW TO READ ELECTRIC WIRE CODE...2183
      PRECAUTIONS WEHN CARRYING OUT OPERATION...2186
      MENTHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER...2189
      STANDARD TIGHTENING TORQUE TABLE...2192
      CONVERSION TABLE...2196
  01 SPECIFICATION...0
    SPECIFICATION AND TECHNICAL DATA...2203
      SPECIFICATION DRAWINGS...2204
      SPECIFICATIONS...2205
      WEIGHT TABLE...2208
      FUEL, COOLANT AND LUBRICANTS...2209
  10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...0
    ENGINE AND COOLING SYSTEM...2213
      RADIATOR, OIL COOLER, AFTERCOOLER...2214
      OUTPUT SHAFT...2215
    POWER TRAIN, PART 1...2219
      POWER TRAIN SKELETON...2220
      TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING...2222
      BRAKE COOLING OIL CONTROL VALVE (BCV)...2224
      POWER TRAIN PUMP...2225
      TORQUE CONVERTER...2228
      TRANSMISSION...2234
      TRANSMISSION CONTROL VALVE...2262
      ECMV...2263
      MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE...2270
    POWER TRAIN, PART 2...2273
      DRIVE SHAFT...2274
      AXLE...2275
      DIFFERENTIAL...2278
      LIMITED SLIP DIFFERENTIAL...2284
      FINAL DRIVE...2288
    STEERING SYSTEM...2295
      STEERING COLUMN...2296
    BRAKE SYSTEM...2299
      BRAKE PIPING...2300
      BRAKE VALVE...2302
      ACCUMULATOR CHARGE VALVE...2305
      ACCUMULATOR...2309
      SLACK ADJUSTER...2310
      BRAKE...2312
      PROPORTIONAL REDUCING VALVE...2317
      BRAKE SYSTEM TANK...2318
      PARKING BRAKE ...2320
      PARKING BRAKE SOLENOID...2324
    UNDERCARRIAGE AND FRAME...2327
      SUSPENSION...2328
      SUSPENSION CYLINDER...2334
      OSCILLATION HITCH...2336
    HYDRAULIC SYSTEM...2341
      STEERING, HOIST OIL PRESSURE PIPING DIAGRAM...2342
      DUMP BODY CONTROL...2343
      HYDRAULIC TANK AND FILTER...2344
      FLOW AMP VALVE...2345
      STEERING VALVE...2348
      STEERING CYLINDER...2352
      HOIST VALVE...2354
      EPC VALVE...2360
      HOIST CYLINDER...2361
      HYDRAULIC PUMP...2362
    CAB AND ITS ATTACHMENTS...2365
      ROPS CAB...2366
      CAB TILT...2367
      AIR CONDITIONER...2368
      REAR VIEW MONITOR...2376
      CONTROLLER RELATED...2379
    ELECTRICAL SYSTEM, PART 1...2381
      MACHINE MONITOR SYSTEM...2382
    ELECTRICAL SYSTEM, PART 2...2403
      AUTOMATIC SHIFT CONTROL SYSTEM...2404
      RETARDER CONTROL SYSTEM...2436
      AUTO EMERGENCY STEERING SYSTEM...2448
      DUMP CONTROL LEVER...2449
    ELECTRICAL SYSTEM, PART 3...2455
      SENSORS, SWITCHES...2456
      KOMTRAX TERMINAL SYSTEM (IF EQUIPPED)...2464
  20 STANDARD VALUE TABLE...0
    STANDARD SERVICE VALUE TABLE...2467
      STANDARD VALUE TABLE FOR ENGINE...2468
      STANDARD VALUE TABLE FOR CHASSIS...2469
  30 TESTING AND ADJUSTING ...0
    TESTING AND ADJUSTING, PART 1...2475
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ...2477
      MEASURING ENGINE SPEED...2481
      MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)...2482
      MEASURING EXHAUST TEMPERATURE...2483
      MEASURING EXHAUST GAS COLOR...2485
      ADJUSTING VALVE CLEARANCE...2486
      MEASURING COMPRESSION PRESSURE...2488
      MEASURING BLOW-BY PRESSURE...2490
      MEASURING ENGINE OIL PRESSURE...2491
      MEASURING EGR VALVE AND BYPASS VALVE DRIVE PRESSURE...2492
      HANDLING OF FUEL SYSTEM DEVICES...2493
      RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM...2493
      TESTING FUEL PRESSURE...2494
      TESTING FUEL RETURN AND LEAK AMOUNT...2495
      BLEEDING AIR FROM FUEL CIRCUIT...2498
      TESTING THE FUEL CIRCUIT FOR LEAKAGE...2499
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION...2500
      TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...2500
    TESTING AND ADJUSTING, PART 2...2503
      MEASURING TORQUE CONVERTER STALL SPEED...2505
      MEASURING POWER TRAIN OIL PRESSURE...2506
      ADJUSTING TRANSMISSION SPEED SENSOR...2514
      TESTING AND ADJUSTING BRAKE OIL PRESSURE...2516
      TESTING OF ACCUMULATOR NITROGEN GAS PRESSURE AND PROCEDURE FOR CHARGING ACCUMULATOR WITH NITROGEN GAS...2520
      TESTING BRAKE PERFORMANCE...2523
      BLEEDING AIR FROM BRAKE CIRCUIT...2524
      MEASURING WEAR OF WHEEL BRAKE DISC...2525
      MEASURING WEAR OF PARKING BRAKE PAD...2526
      METHOD FOR EMERGENCY RELEASE OF PARKING BRAKE...2528
      TESTING AND ADJUSTING STEERING CIRCUIT OIL PRESSURE...2529
      TESTING AND ADJUSTING SUSPENSION CYLINDER...2531
      METHOD OF TILTING CAB UP...2535
      TESTING AND ADJUSTING DUMP CIRCUIT OIL PRESSURE...2537
      ADJUSTING BODY POSITIONER SENSOR...2540
      PROCEDURE FOR ADJUSTING LENGTH OF SPRING IN BODY HEATING SPHERICAL JOINT...2541
      HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT...2541
      ADJUSTING TRANSMISSION CONTROLLER...2542
      METHOD FOR EMERGENCY ESCAPE AT ELECTRICAL SYSTEM FAILURE...2543
    TESTING AND ADJUSTING, PART 3...2549
      SETTING AND ADJUSTING VARIOUS EQUIPMENTS...2550
      SPECIAL FUNCTION OF MACHINE MONITOR (EMMS)...2561
      HOW TO START OPERATION OF KOMTRAX TERMINAL...2595
      LAMP DISPLAY OF KOMTRAX TERMINAL...2598
  40 TROUBLESHOOTING...0
    FAILURE CODE TABLE AND FUSE LOCATIONS...2603
      FAILURE CODE TABLE...2604
      BEFORE TROUBLESHOOTING BY FAILURE CODES...2612
    GENERAL INFORMATION ON TROUBLESHOOTING...2617
      POINTS TO REMEMBER WHEN TROUBLESHOOTING ...2618
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...2619
      CHECKS BEFORE TROUBLESHOOTING...2620
      CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING...2621
      INFORMATION IN TROUBLESHOOTING TABLE...2622
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2624
      T-ADAPTER BOX AND T-BRANCH ADAPTER TABLE...2658
    TROUBLESHOOTING BY FAILURE CODE, PART 1...2663
      FAILURE CODE [1500L0] (DUAL ENGAGEMENT)...2665
      FAILURE CODE [15BONX] (TRANSMISSION OIL FILTER: CLOGGED)...2666
      FAILURE CODE [15FOKM] (R→F SHIFTING ABUSE 1: OPERATIONAL ERROR OR INCORRECT SETTING)...2668
      FAILURE CODE [15FOMB] (R→F SHIFTING ABUSE 2: FUNCTIONAL DETERIORATION)...2668
      FAILURE CODE [15F7KM] (FORWARD CLUTCH DISK ABUSE)...2669
      FAILURE CODE [15GOMW] (R CLUTCH: SLIPPING)...2670
      FAILURE CODE [15G7KM] (REVERSE CLUTCH DISK ABUSE)...2672
      FAILURE CODE [15HOMW] (HI CLUTCH: SLIPPING)...2673
      FAILURE CODE [15JOMW] (LO CLUTCH: SLIPPING)...2676
      FAILURE CODE [15KOMW] (1ST CLUTCH: SLIPPING)...2678
      FAILURE CODE [15LOMW] (2ND CLUTCH: SLIPPING)...2680
      FAILURE CODE [15MOMW] (3RD CLUTCH: SLIPPING)...2682
      FAILURE CODE [15SBL1] (R CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)...2684
      FAILURE CODE [15SBMA] (R CLUTCH SOLENOID: MALFUNCTION)...2688
      FAILURE CODE [15SCL1] (HI CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)...2690
      FAILURE CODE [15SCMA] (HI CLUTCH SOLENOID: MALFUNCTION)...2694
      FAILURE CODE [15SDL1] (LO CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)...2696
      FAILURE CODE [15SDMA] (LO CLUTCH SOLENOID: MALFUNCTION)...2698
      FAILURE CODE [15SEL1] (1ST CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF)...2702
      FAILURE CODE [15SEMA] (1ST CLUTCH SOLENOID: MALFUNCTION)...2706
      FAILURE CODE [15SFL1] (2ND CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)...2708
      FAILURE CODE [15SFMA] (2ND CLUTCH SOLENOID: MALFUNCTION)...2712
      FAILURE CODE [15SGL1] (3RD CLUTCH SOLENOID: FILL SIGNAL IS ON WHEN COMMAND CURRENT IS OFF.)...2714
      FAILURE CODE [15SGMA] (3RD CLUTCH SOLENOID: MALFUNCTION)...2718
      FAILURE CODE [15SJMA] (LOCKUP CLUTCH SOLENOID: MALFUNCTION)...2720
      FAILURE CODE [15SKMA] (INTER-AXLE DIFFERENTIAL LOCKUP PRESSURE CONTROL VALVE: MALFUNCTION)...2722
      FAILURE CODE [2F00KM] (PARKING BRAKE: ERROR IN OPERATION OR SETTING)...2724
      FAILURE CODE [2G42ZG] (FRONT ACCUMULATOR: OIL PRESSURE TOO LOW)...2726
      FAILURE CODE [2G43ZG] (REAR ACCUMULATOR: OIL PRESSURE TOO LOW)...2726
      FAILURE CODE [989A00] (ENGINE OVER RUN PREVENTION COMMAND SIGNAL: OPERATING)...2727
      FAILURE CODE [989D00] (REAR SECTION TIPPING OVER ALARM: ALARM IS ACTIVATED.)...2727
      FAILURE CODE [AA10NX] (AIR CLEANER ELEMENT: CLOGGED)...2728
      FAILURE CODE [AB00MA] (ALTERNATOR: MALFUNCTION)...2730
      FAILURE CODE [B@BAZK] (ENGINE OIL: LOW TOO LOW)...2731
      FAILURE CODE [B@BCNS] (ENGINE: OVERHEAT)...2732
      FAILURE CODE [B@BCZK] (RADIATOR COOLANT: LEVEL TOO LOW)...2733
      FAILURE CODE [B@BFZK] (FUEL LEVEL: LEVEL TOO LOW)...2734
      FAILURE CODE [B@C6NS] (FRONT BRAKE OIL: OVERHEAT)...2735
      FAILURE CODE [B@C8NS] (CENTER BRAKE OIL: OVERHEAT)...2735
      FAILURE CODE [B@CENS] (TORQUE CONVERTER: OVERHEAT)...2736
      FAILURE CODE [B@HAZK] (HYDRAULIC TANK OIL: LEVEL TOO LOW)...2737
      FAILURE CODE [B@JANS] (STEERING OIL: OVERHEAT)...2738
    TROUBLESHOOTING BY FAILURE CODE, PART 2...2741
      FAILURE CODE [CA111] (ABNORMALITY IN ENGINE CONTROLLER)...2743
      FAILURE CODE [CA115] (ABNORMAL ENGINE NE AND BKUP SENSORS)...2744
      FAILURE CODE [CA122] (CHARGE PRESSURE SENSOR TOO HIGH)...2746
      FAILURE CODE [CA123] (CHARGE PRESSURE SENSOR TOO LOW)...2748
      FAILURE CODE [CA131] (THROTTLE SENSOR TOO HIGH)...2750
      FAILURE CODE [CA132] (THROTTLE SENSOR TOOL LOW)...2752
      FAILURE CODE [CA135] (OIL PRESSURE SENSOR TOO HIGH)...2754
      FAILURE CODE [CA141] (OIL PRESSURE SENSOR TOO LOW)...2756
      FAILURE CODE [CA144] (COOLANT TEMPERATURE SENSOR TOO HIGH)...2758
      FAILURE CODE [CA145] (COOLANT TEMPERATURE SENSOR TOO LOW)...2760
      FAILURE CODE [CA153] (CHARGE TEMPERATURE SENSOR TOO HIGH)...2762
      FAILURE CODE [CA154] (CHARGE TEMPERATURE SENSOR TOO LOW)...2764
      FAILURE CODE [CA187] (SENSOR POWER SOURCE 2 TOO LOW)...2764
      FAILURE CODE [CA221] (ATMOSPHERIC SENSOR TOO HIGH)...2766
      FAILURE CODE [CA222] (ATMOSPHERIC SENSOR TOO LOW)...2768
      FAILURE CODE [CA227] (SENSOR POWER SOURCE 2 TOO HIGH)...2770
      FAILURE CODE [CA234] (ENGINE OVER SPEED)...2772
      FAILURE CODE [CA238] (ABNORMAL POWER SOURCE FOR NE SPEED SENSOR)...2774
      FAILURE CODE [CA263] (FUEL TEMPERATURE SENSOR TOO HIGH)...2776
      FAILURE CODE [CA265] (FUEL TEMPERATURE SENSOR TOO LOW)...2778
      FAILURE CODE [CA271] (PCV1 SHORT CIRCUIT)...2779
      FAILURE CODE [CA272] (PCV1 SHORT DISCONNECTION)...2780
      FAILURE CODE [CA273] (PCV2 SHORT CIRCUIT)...2781
      FAILURE CODE [CA274] (PCV2 DISCONNECTION)...2782
      FAILURE CODE [CA322] (INJECTOR NO.1 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2784
      FAILURE CODE [CA323] (INJECTOR NO.5 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2786
      FAILURE CODE [CA324] (INJECTOR NO.3 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2788
      FAILURE CODE [CA325] (INJECTOR NO.6 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2790
      FAILURE CODE [CA331] (INJECTOR NO.2 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2792
      FAILURE CODE [CA332] (INJECTOR NO.4 SYSTEM DISCONNECTION OR SHORT CIRCUIT)...2794
      FAILURE CODE [CA342] (ABNORMAL ENGINE CONTROLLER DATA CONSISTENCY)...2796
      FAILURE CODE [CA351] (ABNORMAL INJECTOR DRIVE CIRCUIT)...2797
      FAILURE CODE [CA352] (SENSOR POWER SOURCE 1 TOO LOW)...2798
      FAILURE CODE [CA386] (SENSOR POWER SOURCE 1 TOO HIGH)...2800
      FAILURE CODE [CA431] (ABNORMAL IDLE VALIDATION SWITCH)...2802
      FAILURE CODE [CA432] (ABNORMAL PROCESS WITH IDLE VALIDATION SWITCH)...2804
      FAILURE CODE [CA441] (POWER SOURCE VOLTAGE TOO LOW)...2805
      FAILURE CODE [CA442] (POWER SOURCE VOLTAGE TOO HIGH)...2805
      FAILURE CODE [CA449] (COMMON RAIL PRESSURE TOO HIGH 2)...2806
      FAILURE CODE [CA451] (COMMON RAIL PRESSURE SENSOR TOO HIGH)...2808
      FAILURE CODE [CA452] (COMMON RAIL PRESSURE SENSOR TOO LOW)...2810
      FAILURE CODE [CA553] (COMMON RAIL PRESSURE TOO HIGH 1)...2810
      FAILURE CODE [CA554] (IN-RANGE ERROR OF COMMON RAIL PRESSURE SENSOR)...2811
      FAILURE CODE [CA559] (LOSS OF PRESSURE FEED FROM SUPPLY PUMP 1)...2812
      FAILURE CODE [CA689] (ABNORMAL ENGINE NE SPEED SENSOR)...2816
      FAILURE CODE [CA697] (ENGINE CONTROLLER INSIDE TEMPERATURE SENSOR TOO HIGH)...2818
      FAILURE CODE [CA698] (ENGINE CONTROLLER INSIDE TEMPERATURE SENSOR TOO LOW)...2818
      FAILURE CODE [CA731] (ABNORMAL ENGINE BKUP SPEED SENSOR PHASE)...2819
      FAILURE CODE [CA757] (LOSS OF ALL ENGINE CONTROLLER DATA)...2819
      FAILURE CODE [CA778] (ABNORMAL ENGINE BKUP SPEED SENSOR)...2820
      FAILURE CODE [CA1117] (LOSS OF PARTIAL ENGINE CONTROLLER DATA)...2822
      FAILURE CODE [CA1228] (ABNORMAL EGR VALVE SERVO 1)...2823
      FAILURE CODE [CA1625] (ABNORMAL EGR VALVE SERVO 2)...2824
      FAILURE CODE [CA1626] (SHORT CIRCUIT OF BYPASS VALVE SOLENOID DRIVE)...2826
      FAILURE CODE [CA1627] (DISCONNECTION IN BYPASS VALVE SOLENOID DRIVE)...2828
      FAILURE CODE [CA1628] (ABNORMAL BYPASS VALVE SERVO 1)...2829
      FAILURE CODE [CA1629] (ABNORMAL BYPASS VALVE SERVO 2)...2830
    TROUBLESHOOTING BY FAILURE CODE, PART 3...2833
      FAILURE CODE [CA1631] (BYPASS VALVE LIFT SENSOR TOO HIGH)...2836
      FAILURE CODE [CA1632] (BYPASS VALVE LIFT SENSOR TOO LOW)...2838
      FAILURE CODE [CA1633] (ABNORMAL KOMNET)...2840
      FAILURE CODE [CA1642] (EGR INLET PRESSURE SENSOR TOO LOW)...2842
      FAILURE CODE [CA1653] (EGR INLET PRESSURE SENSOR TOO HIGH)...2844
      FAILURE CODE [CA2185] (THROTTLE SENSOR POWER SOURCE TOO HIGH)...2846
      FAILURE CODE [CA2186] (THROTTLE SENSOR POWER SOURCE TOO LOW)...2848
      FAILURE CODE [CA2249] (LOSS OF PRESSURE FEED FROM SUPPLY PUMP 2)...2848
      FAILURE CODE [CA2271] (EGR VALVE LIFT SENSOR TOO HIGH)...2850
      FAILURE CODE [CA2272] (EGR VALVE LIFT SENSOR TOO LOW)...2852
      FAILURE CODE [CA2351] (EGR VALVE SOLENOID DRIVE SHORT CIRCUT)...2854
      FAILURE CODE [CA2352] (EGR VALVE SOLENOID DRIVE DISCONNECTION)...2856
      FAILURE CODE [CA2555] (INTAKE AIR HEATER RELAY DISCONNECTION)...2856
      FAILURE CODE [CA2556] (INTAKE AIR HEATER RELAY SHORT CIRCUIT)...2858
      FAILURE CODE [DAF9KM] (MACHINE MONITOR CONNECTOR: ERROR IN OPERATION OR SETTING)...2860
      FAILURE CODE [DAFRKR] (ABNORMAL CAN COMMUNICATION (MACHINE MONITOR): ABNORMAL COMMUNICATION)...2862
      FAILURE CODE [DAQ0KK] (TRANSMISSION CONTROLLER: POWER SOURCE VOLTAGE TOO LOW)...2864
      FAILURE CODE [DAQ0KT] (TRANSMISSION NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)...2866
      FAILURE CODE [DAQ2KK] (TRANSMISSION CONTROLLER SOLENOID POWER SOURCE: VOLTAGE TOO LOW)...2867
      FAILURE CODE [DAQRKR] (COMMUNICATION LOST: DEFECTIVE COMMUNICATION)...2868
      FAILURE CODE [DAQRMA] (TRANSMISSION CONTROLLER OPTION SETTING: MALFUNCTION)...2870
      FAILURE CODE [DB10KT] (RETARDER CONTROLLER NONVOLATILE MEMORY: ABNORMALITY IN CONTROLLER)...2870
      FAILURE CODE [DB12KK] (RETARDER CONTROLLER SOLENOID POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)...2871
      FAILURE CODE [DB13KK] (RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: POWER SOURCE VOLTAGE TOO LOW)...2872
      FAILURE CODE [DB19KQ] (RETARDER CONTROLLER MODEL SELECT SIGNAL: INCONSISTENT MODEL SELECTION SIGNAL)...2873
      FAILURE CODE [DB1QMA] (RETARDER CONTROLLER OPTION SETTING: MALFUNCTION)...2873
      FAILURE CODE [DB1RKR] (CAN COMMUNICATION (RETARDER CONTROLLER): COMMUNICATION DISABLED)...2874
      FAILURE CODE [DB2RKR] (CAN COMMUNICATION (ENGINE CONTROLLER): COMMUNICATION DISABLED)...2876
      FAILURE CODE [DDTHKA] (FILL SWITCH FOR HI CLUTCH: DISCONNECTION)...2878
      FAILURE CODE [DDTJKA] (FILL SWITCH FOR LO CLUTCH: DISCONNECTION)...2880
      FAILURE CODE [DDTKKA] (FILL SWITCH FOR 1ST CLUTCH: DISCONNECTION)...2882
      FAILURE CODE [DDTLKA] (FILL SWITCH FOR 2ND CLUTCH: DISCONNECTION)...2883
      FAILURE CODE [DDTMKA] (FILL SWITCH FOR 3RD CLUTCH: DISCONNECTION)...2884
      FAILURE CODE [DDTNKA] (FILL SWITCH FOR R CLUTCH: DISCONNECTION)...2885
      FAILURE CODE [DF10KA] (GEAR SHIFT LEVER: DISCONNECTION)...2886
      FAILURE CODE [DF10KB] (GEAR SHIFT LEVER: SHORT CIRCUIT)...2889
      FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2892
      FAILURE CODE [DGR3KZ] (CENTER BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION OR SHORT CIRCUIT)...2894
      FAILURE CODE [DGR3L8] (CENTER BRAKE OIL TEMPERATURE SENSOR: INCONSISTENT ANALOG SIGNALS)...2896
      FAILURE CODE [DGR4KZ] (FRONT BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION OR SHORT CIRCUIT)...2898
      FAILURE CODE [DGR4L8] (FRONT BRAKE OIL TEMPERATURE SENSOR: INCONSISTENT ANALOG SIGNALS)...2900
      FAILURE CODE [DGR6KX] (STEERING OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2902
      FAILURE CODE [DGT1KX] (TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2904
      FAILURE CODE [DGT5KX] (TORQUE CONVERTER OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2906
      FAILURE CODE [DHT5L6] (TORQUE CONVERTER OIL PRESSURE SENSOR: INCONSISTENT SIGNALS DURING A TRAVEL AND STOP)...2908
      FAILURE CODE [DHU2KX] (FRONT ACCUMULATOR OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2910
      FAILURE CODE [DHU3KX] (REAR ACCUMULATOR OIL PRESSURE SENSOR: INPUT SIGNAL OUT OF RANGE)...2912
      FAILURE CODE [DJF1KA] (FUEL LEVEL SENSOR: DISCONNECTION)...2914
      FAILURE CODE [DK51L5] (RETARDER LEVER POTENTIOMETER: POTENTIOMETER SIGNAL IS INCONSISTENT WITH SWITCH SIGNAL)...2916
      FAILURE CODE [DK52KX] (DUMP LEVER POTENTIOMETER FAILURE 1: INPUT SIGNAL OUT OF RANGE)...2918
      FAILURE CODE [DK53L8] (DUMP LEVER POTENTIOMETER FAILURE 2: INCONSISTENT ANALOG SIGNAL)...2920
      FAILURE CODE [DK54KX] (BODY POSITIONER SENSOR: INPUT SIGNAL OUT OF RANGE)...2922
    TROUBLESHOOTING BY FAILURE CODE, PART 4...2925
      FAILURE CODE [DKH0KX] (PITCH ANGLE SENSOR: INCLINATION OUT OF RANGE)...2927
      FAILURE CODE [DLF1KA] (TRANSMISSION INPUT SHAFT SPEED SENSOR: DISCONNECTION)...2929
      FAILURE CODE [DLF1LC] (TRANSMISSION INPUT SHAFT SPEED SENSOR: INCONSISTENT ROTATION SPEED SIGNAL)...2930
      FAILURE CODE [DLF2KA] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: DISCONNECTION)...2931
      FAILURE CODE [DLF2LC] (TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: INCONSISTENT SPEED SIGNAL)...2932
      FAILURE CODE [DLF4KA] (DIFFERENTIAL SPEED SENSOR: DISCONNECTION)...2933
      FAILURE CODE [DLT3KA] (TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISCONNECTION)...2934
      FAILUTE CODE [DV00KB] (ALARM BUZZER OUTPUT: SHORT CIRCUIT)...2935
      FAILURE CODE [DW72KZ] (KICK-OUT SOLENOID OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)...2936
      FAILURE CODE [DW73KZ] (HOIST SELECTOR VALVE OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)...2938
      FAILURE CODE [DW78KZ] (REAR BRAKE BCV COMMAND OUTPUT SYSTEM: DISCONNECTION OR SHORT CIRCUIT)...2940
      FAILURE CODE [DW79KZ] (FRONT BRAKE BCV COMMAND OUTPUT SYSTEM: DISCONNECTION OF SHORT CIRCUIT)...2942
      FAILURE CODE [DX11K4] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL)...2944
      FAILURE CODE [DX11KA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT: DISCONNECTION)...2946
      FAILURE CODE [DX11KB] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT)...2947
      FAILURE CODE [DX11KY] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)...2948
      FAILURE CODE [DX11MA] (REAR BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: MALFUNCTION)...2949
      FAILURE CODE [DX12K4] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: OUT OF CONTROL)...2951
      FAILURE CODE [DX12KA] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE OUTPUT CIRCUIT: DISCONNECTION)...2953
      FAILURE CODE [DX12KB] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT)...2954
      FAILURE CODE [DX12KY] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)...2955
      FAILURE CODE [DX12MA] (FRONT BRAKE PROPORTIONAL PRESSURE REDUCING SOLENOID VALVE: MALFUNCTION)...2956
      FAILURE CODE [DX13KA] (HOIST EPC VALVE OUTPUT CIRCUIT: DISCONNECTION)...2958
      FAILURE CODE [DX13KB] (HOIST EPC VALVE OUTPUT CIRCUIT: SHORT CIRCUIT)...2959
      FAILURE CODE [DX13KY] (HOIST EPC VALVE OUTPUT CIRCUIT: SHORT CIRCUIT IN POWER SOURCE LINE)...2960
      FAILURE CODE [DXH0KA] (INTER-AXLE DIFFERENTIAL LOCK PRESSURE CONTROL VALVE: DISCONNECTION)...2961
      FAILURE CODE [DXH0KB] (INTER-AXLE DIFFERENTIAL LOCK PRESSURE CONTROL VALVE: SHORT CIRCUIT)...2962
      FAILURE CODE [DXH0KY] (INTER-AXLE DIFFERENTIAL LOCKUP PRESSURE CONTROL VALVE: SHORT CIRCUIT TO POWER SOURCE LINE)...2963
      FAILURE CODE [DXH1KA] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2964
      FAILURE CODE [DXH1KB] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2965
      FAILURE CODE [DXH1KY] (LOCKUP CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2966
      FAILURE CODE [DXH2KA] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2967
      FAILURE CODE [DXH2KB] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2969
      FAILURE CODE [DXH2KY] (HI CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2971
      FAILURE CODE [DXH3KA] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2974
      FAILURE CODE [DXH3KB] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2976
      FAILURE CODE [DXH3KY] (LO CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2978
      FAILURE CODE [DXH4KA] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2981
      FAILURE CODE [DXH4KB] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2983
      FAILURE CODE [DXH4KY] (1ST CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2985
      FAILURE CODE [DXH5KA] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2988
      FAILURE CODE [DXH5KB] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2990
      FAILURE CODE [DXH5KY] (2ND CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2992
      FAILURE CODE [DXH6KA] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...2995
      FAILURE CODE [DXH6KB] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...2997
      FAILURE CODE [DXH6KY] (3RD CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...2999
      FAILURE CODE [DXH7KA] (R CLUTCH SOLENOID OUTPUT CIRCUIT: DISCONNECTION)...3002
      FAILURE CODE [DXH7KB] (R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT)...3004
      FAILURE CODE [DXH7KY] (R CLUTCH SOLENOID OUTPUT CIRCUIT: SHORT CIRCUIT TO POWER SOURCE LINE)...3006
    TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...3010
      BEFORE TROUBLESHOOTING OF ELECTRIC SYSTEM...3012
      CONTENTS OF TROUBLESHOOTING TABLE...3015
      E-1 ENGINE DOES NOT SHART...3016
      E-2 AUTOMATIC PREHEATING DOES NOT OPERATE...3019
      E-3 MACHINE MONITOR DOES NOT DISPLAY ALL, WHEN STARTING SWITCH IS TURNED ON...3023
      E-4 MACHINE MONITOR DOES NOT OPERATE WHEN STARTING SWITCH IS OFF...3025
      E-5 ALARM BUZZER DOES NOT SOUND...3027
      E-6 GAUGES OF MACHINE MONITOR, CAUTION LAMPS OR CHARACTER DISPLAY SECTION DO NOT DISPLAY PROPERLY...3028
      E-7 SELECTION OF DISPLAY IN CHARACTER DISPLAY SECTION CANNOT BE CHANGED...3029
      E-8 POWER MODE SELECTING FUNCTION DOES NOT OPERATE PROPERLY...3033
      E-9 ALSS FUNCTION DOES NOT OPERATE PROPERLY...3034
      E-10 SEAT BELT CAUTION LAMP DOES DISPLAY PROPERLY...3035
      E-11 TURN SIGNAL LAMP OR TURNING LAMP (HAZARD LAMP) DO NOT WORK PROPERLY...3036
      E-12 NIGHT ILLUMINATION (LIGHTING) DOES NOT WORK PROPERLY...3039
      E-13 EMERGENCY STEERING DOES NOT OPERATE...3046
    TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...3052
      CONTENTS OF TROUBLESHOOTING TABLE...3054
      H-1 MACHINE DOES NOT START...3055
      H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE JERKS)...3057
      H-3 LOCKUP CANNOT BE CANCELLED...3057
      H-4 EXCESSIVE SHOCK WHEN STARTING OR SHIFTING...3058
      H-5 TRANSMISSION DOES NOT SHIFT UP...3059
      H-6 MACHINE LACKS POWER OR SPEED WHEN TRAVELING...3060
      H-7 TIME LAG IS EXCESSIVE WHEN STARTING OR SHIFTING GEAR...3062
      H-8 TORQUE CONVERTER OIL TEMPERATURE IS HIGH...3063
      H-9 TORQUE CONVERTER OIL PRESSURE IS LOW...3064
      H-10 FRONT BRAKE IS INEFFECTIVE...3065
      H-11 CENTER BRAKE IS INEFFECTIVE...3066
      H-12 STEERING WHEEL IS HEAVY...3067
      H-13 STEERING WHEEL DOES NOT WORK...3068
      H-14 STEERING WHEEL VIBRATES...3069
      H-15 DUMP BODY LIFTING SPEED IS SLOW...3070
      H-16 DUMP BODY DOES NOT WORK...3071
      H-17 EXCESSIVE HYDRAULIC DRIFT OF DUMP BODY...3072
    TROUBLESHOOTING OF ENGINE (S-MODE)...3074
      HOW TO USR A TROUBLESHOOTING CHART...3076
      S-1 ENGINE IS HARD TO START...3079
      S-2 ENGINE DOES NOT START...3081
      S-3 ENGINE DOES NOT PICK UP SMOOTHLY...3085
      S-4 ENGINE STOPS DURING OPERATIONS...3086
      S-5 ENGINE DOES NOT ROTATE SMOOTHLY...3087
      S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...3088
      S-7 EXHAUST GAS COLOR IS BLACK (INCOMPLETE COMBUSTION)...3089
      S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS COLOR IS BLUE)...3091
      S-9 OIL GETS CONTAMINATED PREMATURELY...3092
      S-10 FUEL CONSUMPTION IS EXCESSIVE...3093
      S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...3094
      S-12 OIL PRESSURE DROPS...3095
      S-13 OIL LEVEL RISES (COOLANT OR FUEL MIXES)...3096
      S-14 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)...3098
      S-15 ABNORMAL NOISE COMES OUT...3099
      S-16 VIBRATION IS EXCESSIVE...3100
  50 DISASSEMBLY AND ASSEMBLY...0
    GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY...3102
      HOW TO READ THIS MANUAL...3103
      COATING MATERIALS LIST...3105
      SPECIAL TOOL LIST...3108
      SKETCHES OF SPECIAL TOOLS...3113
    ENGINE (SAA6D125E-5)...3128
      REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY...3129
      REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY...3134
      REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...3139
      REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...3152
      REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...3154
    ENGINE AND COOLING SYSTEM (SAA6D125E-5)...3160
      REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...3161
      REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...3169
      REMOVAL AND INSTALLATION OF COOLING ASSEMBLY...3171
      REMOVAL AND INSTALLATION OF OUTPUT SHAFT ASSEMBLY...3174
      DISASSEMBLY AND ASSEMBLY OF OUTPUT SHAFT ASSEMBLY...3179
    POWER TRAIN, PART 1...3184
      REMOVAL AND INSTALLATION OF TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...3185
      DISCONNECTION AND CONNECTION OF FRONT DIFFERENTIAL ASSEMBLY AND TRANSMISSION ASSEMBLY...3191
      DISASSEMBLY AND ASSEMBLY OF FRONT DIFFERENTIAL ASSEMBLY...3193
      DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY...3208
    POWER TRAIN, PART 2...3216
      DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY...3217
    POWER TRAIN, PART 3...3260
      REMOVAL AND INSTALLATION OF CENTER DIFFERENTIAL ASSEMBLY...3261
      DISASSEMBLY AND ASSEMBLY OF CENTER DIFFERENTIAL ASSEMBLY...3265
      REMOVAL AND INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY...3282
      DISASSEMBLY AND ASSEMBLY OF REAR DIFFERENTIAL ASSEMBLY...3284
    POWER TRAIN, PART 4...3300
      REMOVAL AND INSTALLATION OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY...3301
      DISASSEMBLY AND ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE ASSEMBLY...3304
      REMOVAL AND INSTALLATION OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY...3314
      DISASSEMBLY AND ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE ASSEMBLY...3316
    POWER TRAIN, PART 5...3326
      DISASSEMBLY AND ASSEMBLY OF REAR FINAL DRIVE ASSEMBLY...3327
      REMOVAL AND INSTALLATION OF CENTER AXLE ASSEMBLY...3334
      REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...3337
    UNDERCARRIAGE AND FRAME...3340
      REMOVAL AND INSTALLATION OF FRONT SUSPENSION CYLINDER ASSEMBLY...3341
      REMOVAL AND INSTALLATION OF REAR SUSPENSION CYLINDER ASSEMBLY...3343
      REMOVAL AND INSTALLATION OF EQUALIZER BAR...3344
      REMOVAL AND INSTALLATION OF HITCH FRAME ASSEMBLY...3346
      DISASSEMBLY AND ASSEMBLY OF HITCH FRAME ASSEMBLY...3356
    HYDRAULIC SYSTEM...3364
      REMOVAL AND INSTALLATION OF FLOW AMP VALVE...3365
      REMOVAL AND INSTALLATION OF HOIST VALVE ASSEMBLY...3367
      DISASSEMBLY AND ASSEMBLY OF STEERING CYLINDER ASSEMBLY...3370
      DISASSEMBLY AND ASSEMBLY OF HOIST CYLINDER ASSEMBLY...3374
    BODY...3380
      REMOVAL AND INSTALLATION OF BODY ASSEMBLY...3381
    CAB AND ITS ATTACHMENTS...3384
      REMOVAL AND INSTALLATION OF OPERATOR'S CAB...3385
      REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)...3390
      DISASSEMBLY AND ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY (IF EQUIPPED)...3397
    ELECTRICAL SYSTEM...3408
      REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...3409
      REMOVAL AND INSTALLATION OF ENGINE CONTROLLER...3414
      REMOVAL AND INSTALLATION OF RETARDER CONTROLLER...3416
      REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY...3418
  90 DIAGRAMS AND DRAWINGS...0
    HYDRAULIC DIAGRAMS AND DRAWINGS...3420
      POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...3422
      STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM...3424
      BRAKE HYDRAULIC CIRCUIT DIAGRAM...3426
      BRAKE COOLING HYDRAULIC CIRCUIT DIAGRAM...3428
    ELECTRICAL DIAGRAMS AND DRAWINGS...3430
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (1/4)...3432
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4) (SERIAL NO.: 2001 - 2241)...3433
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (2/4) (SERIAL NO.: 2242 AND UP)...3434
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: 2001 - 2241)...3435
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (3/4) (SERIAL NO.: 2242 AND UP)...3436
      ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE CAB (4/4)...3437
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (1/3)...3438
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (2/3)...3439
      ELECTRICAL CIRCUIT DIAGRAM FOR OUTSIDE CAB (3/3)...3440
      CONNECTORS TABLE AND ARRANGEMENT DRAWING...3441
SEN00237-13 - Articulated Dump Truck HM300-2 Shop Manual...3444
  COVER ...3444
  00 Index and foreword...0
    Index...3446
      Composition of shop manual...3447
      Table of contents...3449
    Foreword and general information...3460
      Safety notice...3461
      How to read the shop manual...3466
      Explanation of terms for maintenance standard...3468
      Handling of electric equipment and hydraulic component...3470
      Handling of connectors newly used for engines...3479
      How to read electric wire code...3482
      Precautions when carrying out operation...3485
      Method of disassembling and connecting push-pull type coupler...3488
      Standard tightening torque table...3491
      Conversion table...3495
  01 Specification...0
    Specification and technical data...3502
      Specification drawings...3503
      Specifications...3504
      Weight table...3507
      Fuel, coolant and lubricants...3508
  10 Structure, function and maintenance standard...0
    Engine and cooling system...3512
      Radiator, oil cooler, aftercooler...3513
      Output shaft...3514
    Power train, Part 1...3518
      Power train skeleton...3519
      Torque converter and transmission hydraulic piping...3521
      Brake cooling oil control valve (BCV)...3523
      Power train pump...3524
      Torque converter...3527
      Transmission...3533
      Transmission control valve...3561
      ECMV...3562
      Main relief, torque converter relief valve...3569
    Power train, Part 2...3572
      Drive shaft...3573
      Axle...3574
      Differential...3577
      Limited slip differential...3583
      Final drive...3587
    Steering system...3594
      Steering column...3595
    Brake system...3598
      Brake piping...3599
      Brake valve...3601
      Accumulator charge valve...3604
      Accumulator...3608
      Slack adjuster...3609
      Brake...3611
      Proportional reducing valve...3616
      Brake system tank...3617
      Parking brake...3619
      Parking brake solenoid...3623
    Undercarriage and frame...3626
      Suspension...3627
      Suspension cylinder...3633
      Oscillation hitch...3635
    Hydraulic system...3640
      Steering, hoist oil pressure piping diagram...3641
      Dump body control...3642
      Hydraulic tank and filter...3643
      Flow amp valve...3644
      Steering valve...3647
      Steering cylinder...3651
      Hoist valve...3653
      Dump control valve (EPC valve)...3659
      Hoist cylinder...3663
      Hydraulic pump...3664
    Cab and its attachments...3668
      ROPS cab...3669
      Cab tilt...3670
      Air conditioner...3671
      Rear view monitor...3679
      Controller related...3682
    Electrical system, Part 1...3684
      Machine monitor system...3685
    Electrical system, Part 2...3706
      Automatic shift control system...3707
      Retarder control system...3739
      Auto emergency steering system...3751
      Battery disconnector switch...3753
      Dump control lever...3755
    Electrical system, Part 3...3760
      Payload meter (Card type)...3761
    Electrical system, Part 4...3794
      Sensors, switches...3795
      KOMTRAX terminal system (If equipped)...3803
  20 Standard value table...0
    Standard service value table...3806
      Standard value table for engine...3807
      Standard value table for chassis...3808
  30 Testing and adjusting...0
    Testing and adjusting, Part 1...3814
      Tools for testing, adjusting, and troubleshooting...3816
      Sketches of special tools...3820
      Testing engine speed...3821
      Testing intake air pressure (boostpressure)...3822
      Testing exhaust temperature...3823
      Testing exhaust gas color...3825
      Adjusting valve clearance...3826
      Testing compression pressure...3828
      Testing blow-by pressure...3830
      Testing engine oil pressure...3831
      Testing EGR valve and bypass valve drive oil pressure...3832
      Handling of fuel system devices...3833
      Releasing residual pressure from fuel system...3833
      Testing fuel pressure...3834
      Handling during cylinder cut-out operation...3835
      Handling during no injection cranking operation...3835
      Testing fuel return and leak amount...3836
      Bleeding air from fuel circuit...3839
      Testing fuel circuit for leakage...3840
      Testing and adjusting alternator belt tension...3841
      Testing and adjusting air conditioner compressor belt tension...3841
      Adjusting the body mount...3841
    Testing and adjusting, Part 2...3844
      Testing torque converter stallspeed...3845
      Testing power train oil pressure...3846
      Adjusting transmission speed sensor...3854
      Testing and adjusting brake oilpressure...3856
      Testing of accumulator nitrogengas pressure and procedure forcharging accumulator withnitrogen gas...3860
      Testing brake performance...3864
      Bleeding air from brake circuit...3865
      Testing wear of wheel brake disc...3866
      Testing wear of parking brake pad...3867
      Method for emergency release ofparking brake...3869
      Testing and adjusting steeringcircuit oil pressure...3870
      Testing and adjusting suspensioncylinder...3872
      Method of tilting cab up...3876
      Testing and adjusting dumpcircuit oil pressure...3878
      Adjusting body positioner sensor...3881
      Procedure for adjusting length ofspring in body heating sphericaljoint...3882
      Handling engine controller highvoltage circuit...3882
      Adjusting transmission controller...3883
      Method for emergency escape at electrical system failure...3884
    Testing and adjusting, Part 3...3890
      Setting and adjusting various equipments...3891
      Special function of machine monitor (EMMS)...3903
      Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal...4231
      Failure code [DDTHKA] (Fill switch for Hi clutch: Disconnection)...4233
      Failure code [DDTJKA] (Fill switch for Lo clutch: Disconnection )...4235
      Failure code [DDTKKA] (Fill switch for 1st clutch: Disconnection)...4237
      Failure code [DDTLKA] (Fill switch for 2nd clutch: Disconnection)...4238
      Failure code [DDTMKA] (Fill switch for 3rd clutch: Disconnection)...4239
      Failure code [DDTNKA] (Fill switch for R clutch: Disconnection)...4240
      Failure code [DF10KA] (Gear shift lever: Disconnection)...4241
      Failure code [DF10KB] (Gear shift lever: Short circuit)...4244
      Failure code [DGF1KX] (Transmission oil temperature sensor: Input signal out of range)...4247
      Failure code [DGR3KZ] (Center brake oil temperature sensor: Disconnection or short circuit)...4249
      Failure code [DGR3L8] (Center brake oil temperature sensor: Inconsistent analog signals)...4251
      Failure code [DGR4KZ] (Front brake oil temperature sensor: Disconnection or short circuit)...4253
      Failure code [DGR4L8] (Front brake oil temperature sensor: Inconsistent analog signals)...4255
      Failure code [DGR6KX] (Steering oil temperature sensor: Input signal out of range)...4257
      Failure code [DGT1KX] (Torque converter oil temperature sensor: Input signal out of range)...4259
      Failure code [DHT5KX] (Torque converter oil pressure sensor: Input signal out of range)...4261
      Failure code [DHT5L6] (Torque converter oil pressure sensor: Inconsistent signals during a travel and stop)...4263
      Failure code [DHU2KX] (Front accumulator oil pressure sensor: Input signal out of range)...4265
      Failure code [DHU3KX] (Rear accumulator oil pressure sensor: Input signal out of range)...4267
      Failure code [DJF1KA] (Fuel level sensor: Disconnection)...4269
      Failure code [DK51L5] (Retarder lever potentiometer : Potentiometer signal is inconsistent with switch signal)...4271
      Failure code [DK52KX] (Dump lever potentiometer failure 1: Input signal out of range)...4273
      Failure code [DK53L8] (Dump lever potentiometer failure 2: Inconsistent analog signal)...4275
      Failure code [DK54KX] (Body positioner sensor: Input signal out of range)...4277
    Troubleshooting by failure code, Part 4...4280
      Failure code [DKH0KX] (Inclination sensor: Inclination out of range)...4283
      Failure code [DLF1KA] (Transmission input shaft speed sensor: Disconnection)...4285
      Failure code [DLF1LC] (Transmission input shaft speed sensor: Inconsistent rotation speed signal)...4286
      Failure code [DLF2KA] (Transmission intermediate shaft speed sensor: Disconnection)...4287
      Failure code [DLF2LC] (Transmission intermediate shaft speed sensor: Inconsistent speed signal)...4288
      Failure code [DLF4KA] (Differential speed sensor: Disconnection)...4289
      Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)...4290
      Failure code [DV00KB] (Alarm buzzer output: Short circuit)...4291
      Failure code [DW72KZ] (Kick-out solenoid output system: Disconnection or short circuit)...4293
      Failure code [DW73KZ] (Hoist selector valve output system: Disconnection or short circuit)...4295
      Failure code [DW78KZ] (Rear brake BCV command output system: Disconnection or short circuit)...4297
      Failure code [DW79KZ] (Front brake BCV command output system: Disconnection or short circuit)...4299
      Failure code [DX11K4] (Rear brake proportional pressure reducing solenoid valve: Out of control)...4301
      Failure code [DX11KA] (Rear brake proportional pressure reducing solenoid valve output circuit: Disconnection)...4303
      Failure code [DX11KB] (Rear brake proportional pressure reducing solenoid valve: Short circuit)...4304
      Failure code [DX11KY] (Rear brake proportional pressure reducing solenoid valve: Short circuit to power source line)...4305
      Failure code [DX11MA] (Rear brake proportional pressure reducing solenoid valve: Malfunction)...4307
      Failure code [DX12K4] (Front brake proportional pressure reducing solenoid valve: Out of control)...4309
      Failure code [DX12KA] (Front brake proportional pressure reducing solenoid valve output circuit: Disconnection)...4311
      Failure code [DX12KB] (Front brake proportional pressure reducing solenoid valve: Short circuit)...4312
      Failure code [DX12KY] (Front brake proportional pressure reducing solenoid valve: Short circuit to power source line)...4313
      Failure code [DX12MA] (Front brake proportional pressure reducing solenoid valve: Malfunction)...4315
      Failure code [DX13KA] (Hoist EPC valve output circuit: Disconnection)...4317
      Failure code [DX13KB] (Hoist EPC valve output circuit: Short circuit)...4318
      Failure code [DX13KY] (Hoist EPC valve output circuit: Short circuit in power source line)...4319
      Failure code [DXH0KA] (Inter-axle differential lock pressure control valve: Disconnection)...4320
      Failure code [DXH0KB] (Inter-axle differential lock pressure control valve: Short circuit)...4321
      Failure code [DXH0KY] (Inter-axle differential lockup pressure control valve: Short circuit to power source line)...4322
      Failure code [DXH1KA] (Lockup clutch solenoid output circuit: Disconnection)...4323
      Failure code [DXH1KB] (Lockup clutch solenoid output circuit: Short circuit)...4324
      Failure code [DXH1KY] (Lockup clutch solenoid output circuit: Short circuit to power source line)...4325
      Failure code [DXH2KA] (Hi clutch solenoid output circuit: Disconnection)...4327
      Failure code [DXH2KB] (Hi clutch solenoid output circuit: Short circuit)...4329
      Failure code [DXH2KY] (Hi clutch solenoid output circuit: Short circuit to power source line)...4331
      Failure code [DXH3KA] (Lo clutch solenoid output circuit: Disconnection)...4335
      Failure code [DXH3KB] (Lo clutch solenoid output circuit: Short circuit)...4337
      Failure code [DXH3KY] (Lo clutch solenoid output circuit: Short circuit in power source line)...4339
      Failure code [DXH4KA] (1st clutch solenoid output circuit: Disconnection)...4343
      Failure code [DXH4KB] (1st clutch solenoid output circuit: Short circuit)...4345
      Failure code [DXH4KY] (1st clutch solenoid output circuit: Short circuit to power source line)...4347
      Failure code [DXH5KA] (2nd clutch solenoid output circuit: Disconnection)...4351
      Failure code [DXH5KB] (2nd clutch solenoid output circuit: Short circuit)...4353
      Failure code [DXH5KY] (2nd clutch solenoid output circuit: Short circuit in power source line)...4355
      Failure code [DXH6KA] (3rd clutch solenoid output circuit: Disconnection)...4359
      Failure code [DXH6KB] (3rd clutch solenoid output circuit: Short circuit)...4361
      Failure code [DXH6KY] (3rd clutch solenoid output circuit: Short circuit to power source line)...4363
      Failure code [DXH7KA] (R clutch solenoid output circuit: Disconnection)...4367
      Failure code [DXH7KB] (R clutch solenoid output circuit: Short circuit)...4369
      Failure code [DXH7KY] (R clutch solenoid output circuit: Short circuit to power source line)...4371
    Troubleshooting of electrical system (E-mode)...4376
      Information in troubleshooting table...4377
      E-1 Engine does not start...4378
      E-2 Automatic preheating does not operate...4381
      E-3 Machine monitor does not display all, when starting switch is turned ON...4384
      E-4 Machine monitor does not operate when starting switch is OFF...4386
      E-5 Alarm buzzer does not stop sounding...4388
      E-6 Gauges of machine monitor, caution lamps or character display section do not display properly...4389
      E-7 Selection of display in character display section cannot be changed...4390
      E-8 Power mode selecting function does not operate properly...4394
      E-9 AISS function does not operate properly...4395
      E-10 Seat belt caution lamp does not display properly...4396
      E-11 Turn signal lamp or turning lamp (hazard lamp) does not work properly...4397
      E-12 Night illumination (lighting) does not work properly...4400
      E-13 Emergency steering does not operate...4407
      E-14 Air conditioner does not operate normally...4411
    Troubleshooting of hydraulic and mechanical system (H-mode)...4418
      Contents of troubleshooting table...4420
      H-1 Machine does not start...4421
      H-2 Machine does not travel smoothly (machine jerks)...4423
      H-3 Lockup cannot be cancelled...4423
      H-4 Excessive shock when starting or shifting...4424
      H-5 Transmission does not shift up...4425
      H-6 Machine lacks power or speed when traveling...4426
      H-7 Time lag is excessive when starting or shifting gear...4428
      H-8 Torque converter oil temperature is high...4429
      H-9 Torque converter oil pressure is low...4430
      H-10 Front brake is ineffective...4431
      H-11 Center brake is ineffective...4432
      H-12 Steering wheel is heavy...4433
      H-13 Steering wheel does not work...4434
      H-14 Steering wheel vibrates...4435
      H-15 Dump body lifting speed is slow...4436
      H-16 Dump body does not work...4437
      H-17 Excessive hydraulic drift of dump body...4438
    Troubleshooting of engine (S-mode)...4440
      How to use a troubleshooting chart...4442
      S-1 Engine is hard to start...4445
      S-2 Engine does not start...4447
      S-3 Engine does not pick up smoothly...4451
      S-4 Engine stops during operations...4452
      S-5 Engine does not rotate smoothly...4453
      S-6 Engine lacks output (or lacks power)...4454
      S-7 Exhaust gas color is black (incomplete combustion)...4455
      S-8 Oil consumption is excessive (or exhaust gas color is blue)...4457
      S-9 Oil gets contaminated prematurely...4458
      S-10 Fuel consumption is excessive...4459
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...4460
      S-12 Oil pressure drops...4461
      S-13 Oil level rises (coolant or fuel mixes)...4463
      S-14 Coolant temperature rises too high (overheat)...4465
      S-15 Abnormal noise comes out...4466
      S-16 Vibration is excessive...4467
  50 Disassembly and assembly...0
    General information on disassembly and assembly...4470
      How to read this manual...4471
      Coating materials list...4473
      Special tool list...4476
      Sketches of special tools...4480
    Engine and cooling system, Part 1...4494
      Removal and installation of fuel supply pump assembly...4495
      Removal and installation of fuel injector assembly...4500
      Removal and installation of cylinder head assembly...4505
      Removal and installation of engine front seal...4518
      Removal and installation of engine rear seal...4520
    Engine and cooling system, Part 2...4526
      Removal and installation of engine assembly...4527
      Removal and installation of radiator assembly...4535
      Removal and installation of cooling assembly...4537
      Removal and installation of output shaft assembly...4540
      Disassembly and assembly of output shaft assembly...4545
    Power train, Part 1...4550
      Removal and installation of transmission and front differential assembly...4551
      Disconnection and connection of front differential assembly and transmission assembly...4557
      Disassembly and assembly of front differential assembly...4559
      Disassembly and assembly of torque converter assembly...4574
    Power train, Part 2...4582
      Disassembly and assembly of transmission assembly...4583
    Power train, Part 3...4626
      Removal and installation of center differential assembly...4627
      Disassembly and assembly of center differential assembly...4631
      Removal and installation of rear differential assembly...4648
      Disassembly and assembly of rear differential assembly...4650
    Power train, Part 4...4666
      Removal and installation of front final drive and brake assembly...4667
      Disassembly and assembly of front final drive and brake assembly...4670
      Removal and installation of center final drive and brake assembly...4680
      Disassembly and assembly of center final drive and brake assembly...4682
    Power train, Part 5...4692
      Disassembly and assembly of rear final drive assembly...4693
      Removal and installation of center axle assembly...4700
      Removal and installation of rear axle assembly...4703
    Undercarriage and frame...4706
      Removal and installation of front suspension cylinder assembly...4707
      Removal and installation of rear suspension cylinder assembly...4709
      Disassembly and assembly of front and rear suspension cylinder assembly...4710
      Removal and installation of equalizer bar...4712
      Removal and installation of hitch frame assembly...4714
      Disassembly and assembly of hitch frame assembly...4724
    Hydraulic system...4732
      Removal and installation of flow amp valve...4733
      Removal and installation of hoist valve assembly...4735
      Disassembly and assembly of steering cylinder assembly...4738
      Disassembly and assembly of hoist cylinder assembly...4742
    Body...4748
      Removal and installation of body assembly...4749
    Cab and its attachments...4752
      Removal and installation of operator’s cab...4753
      Removal and installation of operator’s cab glass (Stuck glass)...4758
      Disassembly and assembly of operator’s seat assembly (If equipped)...4765
    Electrical system...4776
      Removal and installation of air conditioner unit assembly...4777
      Removal and installation of engine controller...4782
      Removal and installation of retarder controller...4784
      Removal and installation of transmission controller assembly...4786
  90 Diagrams and drawings...0
    Hydraulic diagrams and drawings...4788
      Power train hydraulic circuit diagram...4790
      Steering and hoist hydraulic circuit diagram...4791
      Brake hydraulic circuit diagram...4793
      Brake cooling hydraulic circuit diagram...4794
    Electrical diagrams and drawings...4796
      Electrical circuit diagram for inside cab (1/4)...4798
      Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 - 2241)...4799
      Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)...4800
      Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 - 2241)...4801
      Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)...4802
      Electrical circuit diagram for inside cab (4/4)...4803
      Electrical circuit diagram for outside cab (1/3)...4804
      Electrical circuit diagram for outside cab (2/3)...4805
      Electrical circuit diagram for outside cab (3/3)...4806
      Electrical circuit diagram for payload meter...4807
      Connectors table and arrangement drawing...4808
SEN00237-14 - Articulated Dump Truck HM300-2 Shop Manual...4811
  COVER ...4811
  00 Index and foreword...0
    Index...4813
      Composition of shop manual...4814
      Table of contents...4816
    Foreword and general information...4827
      Safety notice...4828
      How to read the shop manual...4833
      Explanation of terms for maintenance standard...4835
      Handling of electric equipment and hydraulic component...4837
      Handling of connectors newly used for engines...4846
      How to read electric wire code...4849
      Precautions when carrying out operation...4852
      Method of disassembling and connecting push-pull type coupler...4855
      Standard tightening torque table...4858
      Conversion table...4862
  01 Specification...0
    Specification and technical data...4869
      Specification drawings...4870
      Specifications...4871
      Weight table...4874
      Fuel, coolant and lubricants...4875
  10 Structure, function and maintenance standard...0
    Engine and cooling system...4879
      Radiator, oil cooler, aftercooler...4880
      Output shaft...4881
    Power train, Part 1...4885
      Power train skeleton...4886
      Torque converter and transmission hydraulic piping...4888
      Brake cooling oil control valve (BCV)...4890
      Power train pump...4891
      Torque converter...4894
      Transmission...4900
      Transmission control valve...4928
      ECMV...4929
      Main relief, torque converter relief valve...4936
    Power train, Part 2...4939
      Drive shaft...4940
      Axle...4941
      Differential...4944
      Limited slip differential...4950
      Final drive...4954
    Steering system...4961
      Steering column...4962
    Brake system...4965
      Brake piping...4966
      Brake valve...4968
      Accumulator charge valve...4971
      Accumulator...4975
      Slack adjuster...4976
      Brake...4978
      Proportional reducing valve...4983
      Brake system tank...4984
      Parking brake...4986
      Parking brake solenoid...4990
    Undercarriage and frame...4993
      Suspension...4994
      Suspension cylinder...5000
      Oscillation hitch...5002
    Hydraulic system...5007
      Steering, hoist oil pressure piping diagram...5008
      Dump body control...5009
      Hydraulic tank and filter...5010
      Flow amp valve...5011
      Steering valve...5014
      Steering cylinder...5018
      Hoist valve...5020
      Dump control valve (EPC valve)...5026
      Hoist cylinder...5030
      Hydraulic pump...5031
    Cab and its attachments...5035
      ROPS cab...5036
      Cab tilt...5037
      Air conditioner...5038
      Rear view monitor...5046
      Controller related...5049
    Electrical system, Part 1...5051
      Machine monitor system...5052
    Electrical system, Part 2...5073
      Automatic shift control system...5074
      Retarder control system...5106
      Auto emergency steering system...5118
      Battery disconnector switch...5120
      Dump control lever...5122
    Electrical system, Part 3...5127
      Payload meter (Card type)...5128
    Electrical system, Part 4...5161
      Sensors, switches...5162
      KOMTRAX terminal system (If equipped)...5170
  20 Standard value table...0
    Standard service value table...5173
      Standard value table for engine...5174
      Standard value table for chassis...5175
  30 Testing and adjusting...0
    Testing and adjusting, Part 1...5181
      Tools for testing, adjusting, and troubleshooting...5183
      Sketches of special tools...5187
      Testing engine speed...5188
      Testing intake air pressure (boostpressure)...5189
      Testing exhaust temperature...5190
      Testing exhaust gas color...5192
      Adjusting valve clearance...5193
      Testing compression pressure...5195
      Testing blow-by pressure...5197
      Testing engine oil pressure...5198
      Testing EGR valve and bypass valve drive oil pressure...5199
      Handling of fuel system devices...5200
      Releasing residual pressure from fuel system...5200
      Testing fuel pressure...5201
      Handling during cylinder cut-out operation...5202
      Handling during no injection cranking operation...5202
      Testing fuel return and leak amount...5203
      Bleeding air from fuel circuit...5206
      Testing fuel circuit for leakage...5207
      Testing and adjusting alternator belt tension...5208
      Testing and adjusting air conditioner compressor belt tension...5208
      Adjusting the body mount...5208
    Testing and adjusting, Part 2...5211
      Testing torque converter stallspeed...5212
      Testing power train oil pressure...5213
      Adjusting transmission speed sensor...5221
      Testing and adjusting brake oilpressure...5223
      Testing of accumulator nitrogengas pressure and procedure forcharging accumulator withnitrogen gas...5227
      Testing brake performance...5231
      Bleeding air from brake circuit...5232
      Testing wear of wheel brake disc...5233
      Testing wear of parking brake pad...5234
      Method for emergency release ofparking brake...5236
      Testing and adjusting steeringcircuit oil pressure...5237
      Testing and adjusting suspensioncylinder...5239
      Method of tilting cab up...5243
      Testing and adjusting dumpcircuit oil pressure...5245
      Adjusting body positioner sensor...5248
      Procedure for adjusting length ofspring in body heating sphericaljoint...5249
      Handling engine controller highvoltage circuit...5249
      Adjusting transmission controller...5250
      S-1 Engine is hard to start...5812
      S-2 Engine does not start...5814
      S-3 Engine does not pick up smoothly...5818
      S-4 Engine stops during operations...5819
      S-5 Engine does not rotate smoothly...5820
      S-6 Engine lacks output (or lacks power)...5821
      S-7 Exhaust gas color is black (incomplete combustion)...5822
      S-8 Oil consumption is excessive (or exhaust gas color is blue)...5824
      S-9 Oil gets contaminated prematurely...5825
      S-10 Fuel consumption is excessive...5826
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...5827
      S-12 Oil pressure drops...5828
      S-13 Oil level rises (coolant or fuel mixes)...5830
      S-14 Coolant temperature rises too high (overheat)...5832
      S-15 Abnormal noise comes out...5833
      S-16 Vibration is excessive...5834
  50 Disassembly and assembly...0
    General information on disassembly and assembly...5837
      How to read this manual...5838
      Coating materials list...5840
      Special tool list...5843
      Sketches of special tools...5847
    Engine and cooling system, Part 1...5861
      Removal and installation of fuel supply pump assembly...5862
      Removal and installation of fuel injector assembly...5867
      Removal and installation of cylinder head assembly...5872
      Removal and installation of engine front seal...5885
      Removal and installation of engine rear seal...5887
    Engine and cooling system, Part 2...5893
      Removal and installation of engine assembly...5894
      Removal and installation of radiator assembly...5902
      Removal and installation of cooling assembly...5904
      Removal and installation of output shaft assembly...5907
      Disassembly and assembly of output shaft assembly...5912
    Power train, Part 1...5917
      Removal and installation of transmission and front differential assembly...5918
      Disconnection and connection of front differential assembly and transmission assembly...5924
      Disassembly and assembly of front differential assembly...5926
      Disassembly and assembly of torque converter assembly...5941
    Power train, Part 2...5949
      Disassembly and assembly of transmission assembly...5950
    Power train, Part 3...5993
      Removal and installation of center differential assembly...5994
      Disassembly and assembly of center differential assembly...5998
      Removal and installation of rear differential assembly...6015
      Disassembly and assembly of rear differential assembly...6017
    Power train, Part 4...6033
      Removal and installation of front final drive and brake assembly...6034
      Disassembly and assembly of front final drive and brake assembly...6037
      Removal and installation of center final drive and brake assembly...6047
      Disassembly and assembly of center final drive and brake assembly...6049
    Power train, Part 5...6059
      Disassembly and assembly of rear final drive assembly...6060
      Removal and installation of center axle assembly...6067
      Removal and installation of rear axle assembly...6070
    Undercarriage and frame...6073
      Removal and installation of front suspension cylinder assembly...6074
      Removal and installation of rear suspension cylinder assembly...6076
      Disassembly and assembly of front and rear suspension cylinder assembly...6077
      Removal and installation of equalizer bar...6079
      Removal and installation of hitch frame assembly...6081
      Disassembly and assembly of hitch frame assembly...6091
    Hydraulic system...6099
      Removal and installation of flow amp valve...6100
      Removal and installation of hoist valve assembly...6102
      Disassembly and assembly of steering cylinder assembly...6105
      Disassembly and assembly of hoist cylinder assembly...6109
    Body...6115
      Removal and installation of body assembly...6116
    Cab and its attachments...6119
      Removal and installation of operator’s cab...6120
      Removal and installation of operator’s cab glass (Stuck glass)...6125
      Disassembly and assembly of operator’s seat assembly (If equipped)...6132
    Electrical system...6143
      Removal and installation of air conditioner unit assembly...6144
      Removal and installation of engine controller...6149
      Removal and installation of retarder controller...6151
      Removal and installation of transmission controller assembly...6153
  90 Diagrams and drawings...0
    Hydraulic diagrams and drawings...6155
      Power train hydraulic circuit diagram...6157
      Steering and hoist hydraulic circuit diagram...6158
      Brake hydraulic circuit diagram...6160
      Brake cooling hydraulic circuit diagram...6161
    Electrical diagrams and drawings...6163
      Electrical circuit diagram for inside cab (1/4)...6165
      Electrical circuit diagram for inside cab (2/4) (Serial No.: 2001 - 2241)...6166
      Electrical circuit diagram for inside cab (2/4) (Serial No.: 2242 and up)...6167
      Electrical circuit diagram for inside cab (3/4) (Serial No.: 2001 - 2241)...6168
      Electrical circuit diagram for inside cab (3/4) (Serial No.: 2242 and up)...6169
      Electrical circuit diagram for inside cab (4/4)...6170
      Electrical circuit diagram for outside cab (1/3)...6171
      Electrical circuit diagram for outside cab (2/3)...6172
      Electrical circuit diagram for outside cab (3/3)...6173
      Electrical circuit diagram for payload meter...6174
      Connectors table and arrangement drawing...6175
SEN05629-04 - Articulated Dump Truck HM300-3 Shop Manual...6178
  Cover...6178
  00 Index and foreword ...6180
    Index ...6181
    Foreword, safety and general information ...6196
      Important safety notice ...6196
      How to read the shop manual ...6203
      Explanation of terms for maintenance standard ...6205
      Handling equipment of fuel system devices ...6207
      Handling of intake system parts ...6208
      Handling of hydraulic equipment ...6209
      Method of disconnecting and connecting of push-pull type coupler ...6211
      Handling of electrical equipment ...6214
      How to read electric wire code ...6222
      Precautions when performing operation ...6225
      Practical use of KOMTRAX ...6230
      Standard tightening torque table ...6231
      List of abbreviation ...6237
      Conversion table ...6242
  01 Specification ...6248
    Table of contents ...6249
    Specifications ...6250
      Specification drawing ...6250
      Specifications ...6252
      Weight table ...6258
      Table of fuel, coolant, and lubricants ...6259
  10 Structure and function ...6262
    Table of contents ...6263
    Engine and cooling system ...6265
      Engine related parts ...6265
      Output shaft ...6267
      KVGT ...6268
      EGR system piping drawing ...6274
      EGR system circuit diagram ...6276
      EGR valve ...6278
      EGR cooler ...6280
      KCCV layout drawing ...6282
      KCCV ventilator ...6284
      KDPF ...6286
      Cooling system ...6292
      Radiator fan pump ...6294
      Aftercooler fan motor ...6304
      Radiator fan motor ...6315
      Oil cooler bypass valve ...6321
    Power train ...6322
      Power train system ...6322
      Drive shaft ...6324
      Torque converter and transmission hydraulic piping ...6325
      Torque converter ...6327
      Transmission ...6333
      Transmission control valve ...6357
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...6360
      Lockup clutch ECMV ...6367
      Differential lock clutch ECMV ...6371
      Main relief valve, torque converter relief valve, and main flow selector valve ...6375
      Axle ...6381
      Differential ...6384
      Final drive ...6388
    Steering system ...6391
      Layout of steering devices ...6391
      Steering column ...6392
      Flow amplifier valve ...6393
      Steering valve ...6397
      Emergency steering pump ...6402
    Brake system ...6404
      Layout of brake parts ...6404
      Parking brake solenoid and accumulator charge valve ...6406
      Accumulator ...6412
      Shut off solenoid valve ...6413
      Brake valve ...6414
      Proportional pressure reducing valve ...6419
      Slack adjuster ...6421
      Brake ...6425
      Brake system tank ...6428
      Parking brake ...6429
    Undercarriage and frame ...6432
      Suspension ...6432
      Suspension cylinder ...6438
      Oscillation hitch ...6440
    Hydraulic system ...6442
      Hydraulic component layout ...6442
      Dump body control ...6443
      Hydraulic tank ...6444
      Steering and hoist control pump ...6445
      Hoist valve ...6457
      Steering pump selector solenoid valve ...6463
      Hoist and radiator fan direction selector solenoid valve ...6464
      Dump EPC valve ...6465
      Brake cooling oil control valve ...6467
      Front brake cooling relief valve ...6468
    Cab and its attachments ...6469
      ROPS cab ...6469
      Cab tilt ...6470
    Electrical system ...6471
      Electrical control system ...6471
      Machine monitor system ...6497
      Rear view monitor system ...6521
      KOMTRAX system ...6525
      System component parts ...6529
      Sensor ...6549
  20 Standard value tables ...6586
    Table of contents ...6587
    Standard service value table ...6588
      Standard value table for engine ...6588
      Standard value table for machine ...6590
  30 Testing and adjusting ...6598
    Table of contents ...6599
    Related information on testing and adjusting ...6601
      Tools for testing and adjusting ...6601
      Sketch of tools for testing and adjusting ...6607
    Engine and cooling system ...6610
      Testing engine speed ...6610
      Testing boost pressure ...6611
      Testing exhaust gas temperature ...6613
      Testing exhaust gas color ...6615
      Testing and adjusting valve clearance ...6617
      Testing compression pressure ...6619
      Testing blowby pressure ...6622
      Testing engine oil pressure ...6624
      Testing EGR valve and KVGT driving oil pressure ...6625
      Testing fuel pressure ...6626
      Handling cylinder cutout mode operation ...6627
      Handling no‐injection cranking operation ...6628
      Testing fuel return rate and leakage ...6629
      Bleeding air from fuel system ...6632
      Testing fuel circuit for leakage ...6634
      Checking and adjusting air conditioner compressor belt tension ...6635
      Replacing alternator belt ...6636
      Procedures for cleaning fuel doser ...6637
      Writing compensation values at replacement of injector and engine controller ...6640
    Power train ...6644
      Testing torque converter stall speed ...6644
      Testing power train oil pressure ...6646
      Adjusting transmission speed sensor ...6656
      Adjusting transmission controller ...6659
      Retrieval of disabled machine that resulted from a trouble in electrical system ...6660
      Retrieval of disabled machine due to traction control system (KTCS) failure ...6664
    Steering system ...6666
      Testing and adjusting steering circuit oil pressure ...6666
    Brake system ...6668
      Testing and adjusting brake oil pressure ...6668
      Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas ...6671
      Testing braking performance ...6675
      Bleeding air from brake circuit ...6676
      Testing wear of wheel brake disc ...6677
      Parking brake emergency releasing procedure ...6678
      Testing wear of parking brake pad and adjusting clearance ...6679
    Hydraulic system ...6681
      Testing and adjusting suspension cylinder ...6681
      Testing and adjusting dump circuit oil pressure ...6687
    Work equipment ...6690
      Adjusting dump body positioner sensor ...6690
      Testing and adjusting body mount ...6691
    Cab and its attachments ...6693
      Cab tilt-up procedure ...6693
    Electrical system ...6696
      Setting and adjusting each equipment ...6696
      Special functions of machine monitor ...6706
      KOMTRAX terminal start-up procedure ...6771
      Handling voltage circuit of engine controller ...6775
      Handling battery disconnect switch ...6776
    Pm clinic ...6777
      Pm Clinic service ...6777
  40 Troubleshooting ...6784
    Table of contents ...6785
    Related information on troubleshooting ...6794
      Troubleshooting points ...6794
      Sequence of events in troubleshooting ...6796
      Check before troubleshooting ...6798
      Inspection procedure before troubleshooting ...6800
      Preparation for troubleshooting of electrical system ...6818
      Classification and procedures for troubleshooting ...6824
      Symptom and troubleshooting numbers ...6827
      Information in troubleshooting table ...6830
      Connector list and layout ...6832
      Connector contact identification ...6848
      T-branch box and T-branch adapter table ...6886
      Table of fuse locations ...6891
      Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...6895
      Precautions on troubleshooting of machine monitor ...6898
      Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...6900
      Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...6905
      Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...6906
      Failure codes table ...6907
      E-1 Engine does not start (Engine does not rotate) ...7654
      E-2 Manual preheating system does not work ...7660
      E-3 Automatic preheating system does not work ...7663
      E-4 While preheating is working, preheating monitor does not light up ...7665
      E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ...7667
      E-6 LCD unit on machine monitor displays nothing ...7670
      E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...7672
      E-8 LCD on machine monitor does not display properly ...7674
      E-9 Meter unit display on machine monitor is abnormal ...7676
      E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...7679
      E-11 LED unit lamp on machine monitor is abnormal ...7682
      E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly ...7684
      E-13 2 switches operation of switch panel on machine monitor does not function ...7686
      E-14 Switch panel buzzer of machine monitor is abnormal ...7688
      E-15 Rear view monitor does not light up or backlight flickers ...7690
      E-16 Rear view monitor images are not displayed clearly ...7692
      E-17 Rear view monitor brightness cannot be adjusted ...7695
      E-18 Night lighting lamp of rear view monitor is abnormal ...7698
      E-19 Rearview monitor does not display images while reverse linked display function is enabled ...7700
      E-20 Guide line on rear view monitor is not displayed while guide line is set ...7703
      E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly ...7705
      E-22 Fuel level gauge does not indicate correct level ...7706
      E-23 Seat belt caution lamp indication is abnormal ...7708
      E-24 Machine monitor cannot be operated when starting switch is in OFF position ...7709
      E-25 Alarm buzzer does not sound ...7710
      E-26 Alarm buzzer does not stop sounding ...7712
      E-27 Engine mode selector function does not operate properly ...7714
      E-28 AISS function does not operate properly ...7715
      E-29 Hoist lever does not operate properly ...7716
      E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ...7718
      E-31 None of headlamp, clearance lamp, and tail lamp lights ...7722
      E-32 Clearance lamp does not light up ...7724
      E-33 Tail lamp does not light up ...7726
      E-34 Low beam of headlamp does not light up ...7728
      E-35 High beam of headlamp does not light up ...7730
      E-36 Neither Low beam nor High beam of headlamp lights up ...7732
      E-37 High beams do not light up while passing switch is operated ...7734
      E-38 KOMTRAX does not operate properly ...7736
    Troubleshooting of hydraulic and mechanical system (H-mode) ...7737
      Information described in troubleshooting table (H-mode) ...7737
      System diagram of hydraulic and mechanical systems ...7738
      Failure mode and cause table ...7740
      H-1 Machine does not start ...7744
      H-2 Machine does not travel smoothly (machine hunts) ...7746
      H-3 Lockup is not released ...7747
      H-4 Abnormally large shocks result from starting of machine and gear shifting ...7748
      H-5 Gear is not shifted up ...7749
      H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds ...7751
      H-7 Machine lacks travel speed or power when traveling in torque converter drive mode ...7752
      H-8 Machine lacks travel speed or power when traveling at some gear speed ...7753
      H-9 Large time lag is observed when machine starts and gear is shifted ...7754
      H-10 Oil temperature of torque converter is high ...7756
      H-11 Oil pressure of torque converter is low ...7757
      H-12 Front brake does not work enough ...7758
      H-13 Center brake does not work enough ...7759
      H-14 Steering wheel is heavy ...7760
      H-15 Steering wheel does not turn ...7761
      H-16 Steering wheel waggles ...7762
      H-17 Dump body rising speed is low ...7763
      H-18 Dump body does not move ...7764
      H-19 Hydraulic drift of dump body is large ...7765
      H-20 Radiator fan speed is unusual (excessively high or low, or fan stops) ...7766
      H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) ...7767
      H-22 Unusual noise is heard from around radiator fan ...7768
      H-23 Unusual noise is heard from around aftercooler fan ...7769
    Troubleshooting of engine (S-mode) ...7770
      Information mentioned in troubleshooting table (S mode) ...7770
      S-1 When starting switch is turned to START position, engine is not cranked ...7771
      S-2 The engine cranks but exhaust smoke does not come out ...7772
      S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ...7773
      S-4 Engine startability is poor ...7774
      S-5 Engine does not pick-up smoothly ...7776
      S-6 Engine stops during operation ...7778
      S-7 Engine runs rough or is unstable ...7780
      S-8 Engine lacks power ...7781
      S-9 KDPF gets clogged in a short time ...7783
      S-10 Engine oil consumption is excessive ...7785
      S-11 Engine oil becomes contaminated early ...7786
      S-12 Fuel consumption is excessive ...7787
      S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...7788
      S-14 Oil pressure drops ...7789
      S-15 Fuel mixes into engine oil ...7790
      S-16 Water mixes into engine oil (milky) ...7791
      S-17 Coolant temperature rises too high (overheating) ...7792
      S-18 Unusual noise is heard ...7793
      S-19 Vibration is excessive ...7794
      S-20 Air cannot be bled from fuel circuit ...7795
      S-21 Active regeneration is executed frequently ...7796
      S-22 Active regeneration takes a long time ...7797
      S-23 White smoke is exhausted during active regeneration ...7798
  50 Disassembly and assembly ...7800
    Table of contents ...7801
    Related information on disassembly and assembly ...7803
      How to read this manual ...7803
      Coating materials list ...7805
      Special tools list ...7809
      Sketches of special tools ...7814
    Engine and cooling system ...7832
      Removal and installation of supply pump assembly ...7832
      Removal and installation of injector assembly ...7839
      Removal and installation of cylinder head assembly ...7851
      Removal and installation of radiator assembly ...7863
      Removal and installation of radiator fan and fan motor ...7866
      Removal and installation of aftercooler assembly ...7869
      Removal and installation of aftercooler fan and fan motor assembly ...7873
      Removal and installation of engine assembly ...7876
      Removal and installation of engine front oil seal ...7883
      Removal and installation of engine rear oil seal ...7888
      Removal and installation of output shaft assembly ...7894
      Disassembly and assembly of output shaft assembly ...7898
      Removal and installation of KDPF assembly ...7901
      Disassembly and assembly of KDPF assembly ...7905
      Removal and installation of KCCV assembly ...7914
      Removal and installation of air cleaner assembly ...7915
    Power train ...7917
      Removal and installation of transmission and front differential assembly ...7917
      Disconnection and connection of front differential assembly and transmission assembly ...7929
      Disassembly and assembly of front differential assembly ...7930
      Disassembly and assembly of torque converter assembly ...7941
      Disassembly and assembly of transmission assembly ...7948
      Removal and installation of center differential assembly ...7984
      Disassembly and assembly of center differential assembly ...7988
      Removal and installation of rear differential assembly ...8000
      Disassembly and assembly of rear differential assembly ...8002
      Removal and installation of front final drive and brake assembly ...8012
      Disassembly and assembly of front final drive and brake assembly ...8018
      Removal and installation of center final drive and brake assembly ...8028
      Disassembly and assembly of center final drive and brake assembly ...8030
      Disassembly and assembly of rear final drive assembly ...8037
      Removal and installation of center axle assembly ...8043
      Removal and installation of rear axle assembly ...8046
    Steering system ...8048
      Disassembly and assembly of steering cylinder assembly ...8048
    Undercarriage and frame ...8054
      Removal and installation of front suspension cylinder assembly ...8054
      Removal and installation of rear suspension assembly ...8060
      Disassembly and assembly of suspension cylinder assembly ...8062
      Removal and installation of equalizer bar assembly ...8064
      Removal and installation of hitch frame assembly ...8067
      Disassembly and assembly of hitch frame assembly ...8076
    Hydraulic system ...8081
      Removal and installation of flow amplifier valve assembly ...8081
      Removal and installation of hoist valve assembly ...8084
      Disassembly and assembly of hoist cylinder assembly ...8087
    Body ...8093
      Removal and installation of dump body assembly ...8093
    Cab and its attachments ...8095
      Removal and installation of operator's cab assembly ...8095
      Removal and installation of operator's cab glass (adhered glass) ...8099
      Removal and installation of operator's seat assembly ...8105
    Electrical system ...8107
      Removal and installation of machine monitor assembly ...8107
      Removal and installation of engine controller assembly ...8109
      Removal and installation of retarder and hoist controller assembly ...8111
      Removal and installation of transmission controller assembly ...8112
      Removal and installation of mass air flow and temperature sensor ...8113
      Removal and installation of KOMTRAX terminal assembly ...8114
    Air conditioner unit ...8115
      Removal and installation of air conditioner unit assembly ...8115
      Removal and installation of air conditioner compressor assembly ...8120
  60 Maintenance standard ...8122
    Table of contents ...8123
    Engine and cooling system ...8124
      Engine mount ...8124
      Output shaft ...8125
      Radiator fan pump ...8126
      Radiator fan motor ...8128
      Aftercooler fan motor ...8130
    Power train ...8132
      Drive shaft ...8132
      Torque converter and transmission mount ...8133
      Torque converter ...8134
      Transmission ...8137
      Transmission control valve ...8146
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...8147
      Lockup clutch ECMV ...8148
      Differential lock clutch ECMV ...8149
      Main relief valve, torque converter relief valve, and main flow selector valve ...8150
      Axle ...8152
      Differential ...8155
      Final drive ...8158
    Steering system ...8162
      Steering column ...8162
      Steering cylinder ...8163
    Brake system ...8164
      Slack adjuster ...8164
      Brake ...8166
      Parking brake ...8168
    Undercarriage and frame ...8170
      Suspension ...8170
      Suspension cylinder ...8174
      Oscillation hitch ...8175
    Hydraulic system ...8177
      Steering and hoist control pump ...8177
      Front brake cooling duplex pump and aftercooler fan pump ...8180
      Center brake cooling pump ...8181
      Brake charge pump ...8182
      Hoist valve ...8183
      Hoist cylinder ...8185
  80 Appendix ...8186
    Table of contents ...8187
    Air conditioner components ...8188
      Precautions for refrigerant ...8188
      Air conditioner component ...8189
      Configuration and function of refrigeration cycle ...8192
      Outline of refrigeration cycle ...8193
      Air conditioner unit ...8195
      Dual pressure switch ...8200
      Air conditioner controller ...8201
      Compressor ...8202
      Condenser ...8203
      Receiver drier ...8204
      Outer temperature sensor (outside air temperature sensor) ...8205
      Procedure for testing and troubleshooting ...8206
      Circuit diagram and arrangement of connector pins ...8208
      System diagram ...8210
      Input and output signals of the air conditioner controller ...8211
      Parts and connectors layout ...8213
      Details ...8214
      Testing air leakage (duct) ...8218
      Testing with self-diagnosis function ...8221
      How to open the electrical system abnormality record screen in service mode of the machine monitor ...8222
      Testing vent (mode) changeover ...8224
      Testing FRESH/RECIRC air changeover ...8225
      Testing (dual) pressure switch for refrigerant ...8226
      Testing relays ...8228
      Troubleshooting chart 1 ...8230
      Troubleshooting chart 2 ...8231
      Information in troubleshooting table ...8234
      Failure code list related to air conditioner ...8235
      Failure code [879AKA] A/C Inner Sensor Open Circuit ...8236
      Failure code [879AKB] A/C Inner Sensor Short Circuit ...8237
      Failure code [879BKA] A/C Outer sensor Open Circuit ...8238
      Failure code [879BKB] A/C Outer sensor Short Circuit ...8240
      Failure code [879CKA] Ventilating Sensor Open Circuit ...8242
      Failure code [879CKB] Ventilating Sensor Short Circuit ...8243
      Failure code [879EMC] Ventilation Damper Abnormality ...8244
      Failure code [879FMC] Air Mix Damper Abnormality ...8245
      Failure code [879GKX] Refrigerant Abnormality ...8246
      A-1 Troubleshooting for power supply system (Air conditioner does not operate) ...8248
      A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...8250
      A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...8253
      A-4 Troubleshooting for FRESH/RECIRC air changeover ...8255
      Troubleshooting with gauge pressure ...8257
      Connection of service tool ...8260
      Precautions for disconnecting and connecting air conditioner piping ...8262
      Handling of compressor oil ...8264
  90 Diagrams and drawings ...8266
    Table of contents ...8267
    Hydraulic circuit diagram ...8268
      Symbols in hydraulic circuit diagram ...8268
      Power train hydraulic circuit diagram...8272
      Steering and hoist hydraulic circuit diagram ...8273
      Brake hydraulic circuit diagram ...8274
      Brake cooling system hydraulic circuit diagram ...8275
    Electric circuit diagram ...8277
      Symbols in electric circuit diagram ...8277
      Inside cab electric circuit diagram...8281
      Outside cab electrical circuit diagram...8288
  INDEX...8295
SEN05629-05 - Articulated Dump Truck HM300-3 Shop Manual...8309
  Cover...8309
  00 Index and foreword ...8311
    Index ...8312
    Foreword, safety and general information ...8327
      Important safety notice ...8327
      How to read the shop manual ...8334
      Explanation of terms for maintenance standard ...8336
      Handling equipment of fuel system devices ...8338
      Handling of intake system parts ...8339
      Handling of hydraulic equipment ...8340
      Method of disconnecting and connecting of push-pull type coupler ...8342
      Handling of electrical equipment ...8345
      How to read electric wire code ...8353
      Precautions when performing operation ...8356
      Practical use of KOMTRAX ...8361
      Standard tightening torque table ...8362
      List of abbreviation ...8368
      Conversion table ...8373
  01 Specification ...8379
    Table of contents ...8380
    Specifications ...8381
      Specification drawing ...8381
      Specifications ...8383
      Weight table ...8389
      Table of fuel, coolant, and lubricants ...8390
  10 Structure and function ...8393
    Table of contents ...8394
    Engine and cooling system ...8396
      Engine related parts ...8396
      Output shaft ...8398
      KVGT ...8399
      EGR system piping drawing ...8405
      EGR system circuit diagram ...8407
      EGR valve ...8409
      EGR cooler ...8411
      KCCV layout drawing ...8413
      KCCV ventilator ...8415
      KDPF ...8417
      Cooling system ...8423
      Radiator fan pump ...8425
      Aftercooler fan motor ...8435
      Radiator fan motor ...8446
      Oil cooler bypass valve ...8452
    Power train ...8453
      Power train system ...8453
      Drive shaft ...8455
      Torque converter and transmission hydraulic piping ...8456
      Torque converter ...8458
      Transmission ...8464
      Transmission control valve ...8488
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...8491
      Lockup clutch ECMV ...8498
      Differential lock clutch ECMV ...8502
      Main relief valve, torque converter relief valve, and main flow selector valve ...8506
      Axle ...8512
      Differential ...8515
      Final drive ...8519
    Steering system ...8522
      Layout of steering devices ...8522
      Steering column ...8523
      Flow amplifier valve ...8524
      Steering valve ...8528
      Emergency steering pump ...8533
    Brake system ...8535
      Layout of brake parts ...8535
      Parking brake solenoid and accumulator charge valve ...8537
      Accumulator ...8543
      Shut off solenoid valve ...8544
      Brake valve ...8545
      Proportional pressure reducing valve ...8550
      Slack adjuster ...8552
      Brake ...8556
      Brake system tank ...8559
      Parking brake ...8560
    Undercarriage and frame ...8563
      Suspension ...8563
      Suspension cylinder ...8569
      Oscillation hitch ...8571
    Hydraulic system ...8573
      Hydraulic component layout ...8573
      Dump body control ...8574
      Hydraulic tank ...8575
      Steering and hoist control pump ...8576
      Hoist valve ...8588
      Steering pump selector solenoid valve ...8594
      Hoist and radiator fan direction selector solenoid valve ...8595
      Dump EPC valve ...8596
      Brake cooling oil control valve ...8598
      Front brake cooling relief valve ...8599
    Cab and its attachments ...8600
      ROPS cab ...8600
      Cab tilt ...8601
    Electrical system ...8602
      Electrical control system ...8602
      Machine monitor system ...8632
      Rear view monitor system ...8656
      KOMTRAX system ...8660
      System component parts ...8664
      Sensor ...8689
  20 Standard value tables ...8735
    Table of contents ...8736
    Standard service value table ...8737
      Standard value table for engine ...8737
      Standard value table for machine ...8739
  30 Testing and adjusting ...8747
    Table of contents ...8748
    Related information on testing and adjusting ...8750
      Tools for testing and adjusting ...8750
      Sketch of tools for testing and adjusting ...8756
    Engine and cooling system ...8759
      Testing engine speed ...8759
      Testing boost pressure ...8760
      Testing exhaust gas temperature ...8762
      Testing exhaust gas color ...8764
      Testing and adjusting valve clearance ...8766
      Testing compression pressure ...8768
      Testing blowby pressure ...8771
      Testing engine oil pressure ...8773
      Testing EGR valve and KVGT driving oil pressure ...8774
      Testing fuel pressure ...8775
      Handling cylinder cutout mode operation ...8776
      Handling no‐injection cranking operation ...8777
      Testing fuel return rate and leakage ...8778
      Bleeding air from fuel system ...8781
      Testing fuel circuit for leakage ...8783
      Checking and adjusting air conditioner compressor belt tension ...8784
      Replacing alternator belt ...8785
      Procedures for cleaning fuel doser ...8786
      Writing compensation values at replacement of injector and engine controller ...8789
    Power train ...8793
      Testing torque converter stall speed ...8793
      Testing power train oil pressure ...8795
      Adjusting transmission speed sensor ...8805
      Adjusting transmission controller ...8808
      Retrieval of disabled machine that resulted from a trouble in electrical system ...8809
      Retrieval of disabled machine due to traction control system (KTCS) failure ...8813
    Steering system ...8815
      Testing and adjusting steering circuit oil pressure ...8815
    Brake system ...8817
      Testing and adjusting brake oil pressure ...8817
      Testing accumulator nitrogen gas pressure and charging procedure for accumulator nitrogen gas ...8820
      Testing braking performance ...8824
      Bleeding air from brake circuit ...8825
      Testing wear of wheel brake disc ...8826
      Parking brake emergency releasing procedure ...8827
      Testing wear of parking brake pad and adjusting clearance ...8828
    Hydraulic system ...8830
      Testing and adjusting suspension cylinder ...8830
      Testing and adjusting dump circuit oil pressure ...8836
    Work equipment ...8839
      Adjusting dump body positioner sensor ...8839
      Testing and adjusting body mount ...8840
    Cab and its attachments ...8842
      Cab tilt-up procedure ...8842
    Electrical system ...8846
      Setting and adjusting each equipment ...8846
      Special functions of machine monitor ...8857
      KOMTRAX terminal start-up procedure ...8931
      Handling voltage circuit of engine controller ...8935
      Handling battery disconnect switch ...8936
    Pm clinic ...8937
      Pm Clinic service ...8937
  40 Troubleshooting ...8945
    Table of contents ...8946
    Related information on troubleshooting ...8955
      Troubleshooting points ...8955
      Sequence of events in troubleshooting ...8957
      Check before troubleshooting ...8959
      Inspection procedure before troubleshooting ...8961
      Preparation for troubleshooting of electrical system ...8979
      Classification and procedures for troubleshooting ...8985
      Symptom and troubleshooting numbers ...8988
      Information in troubleshooting table ...8991
      Connector list and layout ...8993
      Connector contact identification ...9009
      T-branch box and T-branch adapter table ...9048
      Table of fuse locations ...9053
      Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ...9057
      Precautions on troubleshooting of machine monitor ...9060
      Processing procedure of harness checker for troubleshooting of machine monitor LCD unit ...9062
      Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...9067
      Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ...9068
      E-2 Manual preheating system does not work ...9823
      E-3 Automatic preheating system does not work ...9826
      E-4 While preheating is working, preheating monitor does not light up ...9828
      E-5 All of LCD unit, LED unit and meter unit on machine monitor display nothing ...9830
      E-6 LCD unit on machine monitor displays nothing ...9833
      E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers) ...9835
      E-8 LCD on machine monitor does not display properly ...9837
      E-9 Meter unit display on machine monitor is abnormal ...9839
      E-10 Night lighting lamp of meter unit on machine monitor is abnormal ...9842
      E-11 LED unit lamp on machine monitor is abnormal ...9845
      E-12 Night lighting lamp of switch panel on machine monitor is abnormal or switches does not operate properly ...9847
      E-13 2 switches operation of switch panel on machine monitor does not function ...9849
      E-14 Switch panel buzzer of machine monitor is abnormal ...9851
      E-15 Rear view monitor does not light up or backlight flickers ...9853
      E-16 Rear view monitor images are not displayed clearly ...9855
      E-17 Rear view monitor brightness cannot be adjusted ...9858
      E-18 Night lighting lamp of rear view monitor is abnormal ...9861
      E-19 Rearview monitor does not display images while reverse linked display function is enabled ...9863
      E-20 Guide line on rear view monitor is not displayed while guide line is set ...9866
      E-21 Some items of gauges and caution lamps on machine monitor are not displayed properly ...9868
      E-22 Fuel level gauge does not indicate correct level ...9869
      E-23 Seat belt caution lamp indication is abnormal ...9871
      E-24 Machine monitor cannot be operated when starting switch is in OFF position ...9872
      E-25 Alarm buzzer does not sound ...9873
      E-26 Alarm buzzer does not stop sounding ...9875
      E-27 Engine mode selector function does not operate properly ...9877
      E-28 AISS function does not operate properly ...9878
      E-29 Hoist lever does not operate properly ...9879
      E-30 Turn signal lamp and winker lamp (hazard lamp) do not operate properly ...9881
      E-31 None of headlamp, clearance lamp, and tail lamp lights ...9885
      E-32 Clearance lamp does not light up ...9887
      E-33 Tail lamp does not light up ...9889
      E-34 Low beam of headlamp does not light up ...9891
      E-35 High beam of headlamp does not light up ...9893
      E-36 Neither Low beam nor High beam of headlamp lights up ...9895
      E-37 High beams do not light up while passing switch is operated ...9897
      E-38 KOMTRAX does not operate properly ...9899
    Troubleshooting of hydraulic and mechanical system (H-mode) ...9900
      Information described in troubleshooting table (H-mode) ...9900
      System diagram of hydraulic and mechanical systems ...9901
      Failure mode and cause table ...9903
      H-1 Machine does not start ...9907
      H-2 Machine does not travel smoothly (machine hunts) ...9909
      H-3 Lockup is not released ...9910
      H-4 Abnormally large shocks result from starting of machine and gear shifting ...9911
      H-5 Gear is not shifted up ...9912
      H-6 Machine lacks travel speed or power when traveling in lockup drive mode at all gear speeds ...9914
      H-7 Machine lacks travel speed or power when traveling in torque converter drive mode ...9915
      H-8 Machine lacks travel speed or power when traveling at some gear speed ...9916
      H-9 Large time lag is observed when machine starts and gear is shifted ...9917
      H-10 Oil temperature of torque converter is high ...9919
      H-11 Oil pressure of torque converter is low ...9920
      H-12 Front brake does not work enough ...9921
      H-13 Center brake does not work enough ...9922
      H-14 Steering wheel is heavy ...9923
      H-15 Steering wheel does not turn ...9924
      H-16 Steering wheel waggles ...9925
      H-17 Dump body rising speed is low ...9926
      H-18 Dump body does not move ...9927
      H-19 Hydraulic drift of dump body is large ...9928
      H-20 Radiator fan speed is unusual (excessively high or low, or fan stops) ...9929
      H-21 Aftercooler fan speed is unusual (excessively high or low, or fan stops) ...9930
      H-22 Unusual noise is heard from around radiator fan ...9931
      H-23 Unusual noise is heard from around aftercooler fan ...9932
    Troubleshooting of engine (S-mode) ...9933
      Information mentioned in troubleshooting table (S mode) ...9933
      S-1 When starting switch is turned to START position, engine is not cranked ...9934
      S-2 The engine cranks but exhaust smoke does not come out ...9935
      S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ...9936
      S-4 Engine startability is poor ...9937
      S-5 Engine does not pick-up smoothly ...9939
      S-6 Engine stops during operation ...9941
      S-7 Engine runs rough or is unstable ...9943
      S-8 Engine lacks power ...9944
      S-9 KDPF gets clogged in a short time ...9946
      S-10 Engine oil consumption is excessive ...9948
      S-11 Engine oil becomes contaminated early ...9949
      S-12 Fuel consumption is excessive ...9950
      S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...9951
      S-14 Oil pressure drops ...9952
      S-15 Fuel mixes into engine oil ...9953
      S-16 Water mixes into engine oil (milky) ...9954
      S-17 Coolant temperature rises too high (overheating) ...9955
      S-18 Unusual noise is heard ...9956
      S-19 Vibration is excessive ...9957
      S-20 Air cannot be bled from fuel circuit ...9958
      S-21 Active regeneration is executed frequently ...9959
      S-22 Active regeneration takes a long time ...9960
      S-23 White smoke is exhausted during active regeneration ...9961
  50 Disassembly and assembly ...9963
    Table of contents ...9964
    Related information on disassembly and assembly ...9966
      How to read this manual ...9966
      Coating materials list ...9968
      Special tools list ...9972
      Sketches of special tools ...9977
    Engine and cooling system ...9995
      Removal and installation of supply pump assembly ...9995
      Removal and installation of injector assembly ...10002
      Removal and installation of cylinder head assembly ...10014
      Removal and installation of radiator assembly ...10026
      Removal and installation of radiator fan and fan motor ...10029
      Removal and installation of aftercooler assembly ...10032
      Removal and installation of aftercooler fan and fan motor assembly ...10036
      Removal and installation of engine assembly ...10039
      Removal and installation of engine front oil seal ...10046
      Removal and installation of engine rear oil seal ...10051
      Removal and installation of output shaft assembly ...10057
      Disassembly and assembly of output shaft assembly ...10061
      Removal and installation of KDPF assembly ...10064
      Disassembly and assembly of KDPF assembly ...10068
      Removal and installation of KCCV assembly ...10077
      Removal and installation of air cleaner assembly ...10078
    Power train ...10080
      Removal and installation of transmission and front differential assembly ...10080
      Disconnection and connection of front differential assembly and transmission assembly ...10092
      Disassembly and assembly of front differential assembly ...10093
      Disassembly and assembly of torque converter assembly ...10104
      Disassembly and assembly of transmission assembly ...10111
      Removal and installation of center differential assembly ...10147
      Disassembly and assembly of center differential assembly ...10151
      Removal and installation of rear differential assembly ...10163
      Disassembly and assembly of rear differential assembly ...10165
      Removal and installation of front final drive and brake assembly ...10175
      Disassembly and assembly of front final drive and brake assembly ...10181
      Removal and installation of center final drive and brake assembly ...10191
      Disassembly and assembly of center final drive and brake assembly ...10193
      Disassembly and assembly of rear final drive assembly ...10200
      Removal and installation of center axle assembly ...10206
      Removal and installation of rear axle assembly ...10209
    Steering system ...10211
      Disassembly and assembly of steering cylinder assembly ...10211
    Undercarriage and frame ...10217
      Removal and installation of front suspension cylinder assembly ...10217
      Removal and installation of rear suspension assembly ...10223
      Disassembly and assembly of suspension cylinder assembly ...10225
      Removal and installation of equalizer bar assembly ...10227
      Removal and installation of hitch frame assembly ...10230
      Disassembly and assembly of hitch frame assembly ...10239
    Hydraulic system ...10244
      Removal and installation of flow amplifier valve assembly ...10244
      Removal and installation of hoist valve assembly ...10247
      Disassembly and assembly of hoist cylinder assembly ...10250
    Body ...10256
      Removal and installation of dump body assembly ...10256
    Cab and its attachments ...10258
      Removal and installation of operator's cab assembly ...10258
      Removal and installation of operator's cab glass (adhered glass) ...10262
      Removal and installation of operator's seat assembly (GRAMMER) ...10268
      Removal and installation of operator's seat assembly (SEARS) ...10270
    Electrical system ...10272
      Removal and installation of machine monitor assembly ...10272
      Removal and installation of engine controller assembly ...10274
      Removal and installation of retarder and hoist controller assembly ...10276
      Removal and installation of transmission controller assembly ...10277
      Removal and installation of mass air flow and temperature sensor ...10278
      Removal and installation of KOMTRAX terminal assembly ...10279
    Air conditioner unit ...10280
      Removal and installation of air conditioner unit assembly ...10280
      Removal and installation of air conditioner compressor assembly ...10285
  60 Maintenance standard ...10287
    Table of contents ...10288
    Engine and cooling system ...10289
      Engine mount ...10289
      Output shaft ...10290
      Radiator fan pump ...10291
      Radiator fan motor ...10293
      Aftercooler fan motor ...10295
    Power train ...10297
      Drive shaft ...10297
      Torque converter and transmission mount ...10298
      Torque converter ...10299
      Transmission ...10302
      Transmission control valve ...10311
      Forward and reverse clutch ECMV and gear speed clutch ECMV ...10312
      Lockup clutch ECMV ...10313
      Differential lock clutch ECMV ...10314
      Main relief valve, torque converter relief valve, and main flow selector valve ...10315
      Axle ...10317
      Differential ...10320
      Final drive ...10323
    Steering system ...10327
      Steering column ...10327
      Steering cylinder ...10328
    Brake system ...10329
      Slack adjuster ...10329
      Brake ...10331
      Parking brake ...10333
    Undercarriage and frame ...10335
      Suspension ...10335
      Suspension cylinder ...10339
      Oscillation hitch ...10340
    Hydraulic system ...10342
      Steering and hoist control pump ...10342
      Front brake cooling duplex pump and aftercooler fan pump ...10345
      Center brake cooling pump ...10346
      Brake charge pump ...10347
      Hoist valve ...10348
      Hoist cylinder ...10350
  80 Appendix ...10351
    Table of contents ...10352
    Air conditioner components ...10353
      Precautions for refrigerant ...10353
      Air conditioner component ...10354
      Configuration and function of refrigeration cycle ...10357
      Outline of refrigeration cycle ...10358
      Air conditioner unit ...10360
      Dual pressure switch ...10365
      Air conditioner controller ...10366
      Compressor ...10367
      Condenser ...10368
      Receiver drier ...10369
      Outer temperature sensor (outside air temperature sensor) ...10370
      Procedure for testing and troubleshooting ...10371
      Circuit diagram and arrangement of connector pins ...10373
      System diagram ...10375
      Input and output signals of the air conditioner controller ...10376
      Parts and connectors layout ...10378
      Details ...10379
      Testing air leakage (duct) ...10383
      Testing with self-diagnosis function ...10386
      How to open the electrical system abnormality record screen in service mode of the machine monitor ...10387
      Testing vent (mode) changeover ...10389
      Testing FRESH/RECIRC air changeover ...10390
      Testing (dual) pressure switch for refrigerant ...10391
      Testing relays ...10393
      Troubleshooting chart 1 ...10395
      Troubleshooting chart 2 ...10396
      Information in troubleshooting table ...10399
      Failure code list related to air conditioner ...10400
      Failure code [879AKA] A/C Inner Sensor Open Circuit ...10401
      Failure code [879AKB] A/C Inner Sensor Short Circuit ...10402
      Failure code [879BKA] A/C Outer sensor Open Circuit ...10403
      Failure code [879BKB] A/C Outer sensor Short Circuit ...10405
      Failure code [879CKA] Ventilating Sensor Open Circuit ...10407
      Failure code [879CKB] Ventilating Sensor Short Circuit ...10408
      Failure code [879EMC] Ventilation Damper Abnormality ...10409
      Failure code [879FMC] Air Mix Damper Abnormality ...10410
      Failure code [879GKX] Refrigerant Abnormality ...10411
      A-1 Troubleshooting for power supply system (Air conditioner does not operate) ...10413
      A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...10415
      A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...10418
      A-4 Troubleshooting for FRESH/RECIRC air changeover ...10420
      Troubleshooting with gauge pressure ...10422
      Connection of service tool ...10425
      Precautions for disconnecting and connecting air conditioner piping ...10427
      Handling of compressor oil ...10429
  90 Diagrams and drawings ...10431
    Table of contents ...10432
    Hydraulic circuit diagram ...10433
      Symbols in hydraulic circuit diagram ...10433
      Power train hydraulic circuit diagram ...10437
      Steering and hoist hydraulic circuit diagram ...10438
      Brake hydraulic circuit diagram ...10439
      Brake cooling system hydraulic circuit diagram ...10440
    Electric circuit diagram ...10442
      Symbols in electric circuit diagram ...10442
      Inside cab electric circuit diagram ...10446
      Outside cab electric circuit diagram ...10453
      Circuit diagram related to payload meter ...10460
  INDEX...10461
SEN06511-05 - Articulated Dump Truck HM300-5 Shop Manual...10475
  COVER...10475
  00 INDEX AND FOREWORD...10477
    INDEX...10478
    ABBREVIATION LIST...10497
    FOREWORD, SAFETY, BASIC INFORMATION...10502
      HOW TO READ THE SHOP MANUAL...10502
      SAFETY NOTICE FOR OPERATION...10504
      PRECAUTIONS TO PREVENT FIRE...10512
      ACTIONS IF FIRE OCCURS...10514
      PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...10515
      ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...10516
      PRECAUTIONS FOR DEF...10517
        GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...10517
        PRECAUTIONS FOR ADDING...10517
        PRECAUTIONS FOR STORING...10517
        PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...10517
        THE OTHER PRECAUTIONS...10517
      STORE AdBlue/DEF...10518
      PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...10519
      PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...10522
      PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...10528
      PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...10530
      PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...10531
      PRACTICAL USE OF KOMTRAX...10532
      DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...10533
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...10533
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...10534
        METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...10535
      PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...10537
      METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...10541
      METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...10542
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...10544
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...10545
      METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...10547
      HOW TO READ ELECTRICAL WIRE CODE...10548
      EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...10552
      STANDARD TIGHTENING TORQUE TABLE...10555
      CONVERSION TABLE...10562
  01 SPECIFICATIONS...10567
    CONTENTS...10568
    ABBREVIATION LIST...10569
    SPECIFICATIONS...10574
      SPECIFICATION DRAWING...10574
        SPECIFICATION DRAWING: HM300-5...10574
      SPECIFICATIONS...10576
        SPECIFICATIONS: HM300-5...10576
      WEIGHT TABLE...10582
        WEIGHT TABLE: HM300-5...10582
      TABLE OF FUEL, COOLANT, AND LUBRICANTS...10584
  10 STRUCTURE AND FUNCTION...10587
    CONTENTS...10588
    ABBREVIATION LIST...10592
    UREA SCR SYSTEM...10597
      LAYOUT DRAWING OF UREA SCR SYSTEM...10597
      UREA SCR SYSTEM DIAGRAM...10600
      FUNCTION OF UREA SCR SYSTEM...10601
        FUNCTION OF AdBlue/DEF SYSTEM...10601
        INDUCEMENT STRATEGY...10603
      COMPONENT PARTS OF UREA SCR SYSTEM...10618
        AdBlue/DEF MIXING TUBE...10618
        SCR ASSEMBLY...10618
        AdBlue/DEF TANK...10621
        AdBlue/DEF PUMP...10623
        AdBlue/DEF INJECTOR...10624
        AdBlue/DEF HOSE...10625
        AdBlue/DEF TANK HEATING VALVE...10626
    BOOT-UP SYSTEM...10627
      LAYOUT DRAWING OF BOOT-UP SYSTEM...10627
      SYSTEM OPERATING LAMP SYSTEM...10629
        SYSTEM OPERATING LAMP SYSTEM DIAGRAM...10629
        FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...10629
      BATTERY DISCONNECT SWITCH...10630
        LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH...10630
        FUNCTION OF BATTERY DISCONNECT SWITCH...10630
    ENGINE SYSTEM...10632
      LAYOUT DRAWING OF ENGINE SYSTEM...10632
        FUNCTION OF ENGINE SYSTEM...10634
      AUTOMATIC IDLE STOP SYSTEM...10635
        FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...10635
      COMPONENT PARTS OF ENGINE SYSTEM...10637
        OUTPUT SHAFT...10637
        VGT...10638
        EGR SYSTEM...10641
        EGR VALVE...10643
        EGR COOLER...10645
        KCCV SYSTEM...10646
        KCCV VENTILATOR...10648
        KDPF...10650
    COOLING SYSTEM...10655
      LAYOUT DRAWING OF COOLING SYSTEM...10655
        SPECIFICATIONS OF COOLING SYSTEM...10656
      RADIATOR FAN CONTROL SYSTEM...10658
        RADIATOR FAN CONTROL SYSTEM DIAGRAM...10658
        FUNCTION OF RADIATOR FAN CONTROL SYSTEM...10658
      AFTERCOOLER FAN CONTROL SYSTEM...10660
        AFTERCOOLER FAN CONTROL SYSTEM DIAGRAM...10660
        FUNCTION OF AFTERCOOLER FAN CONTROL SYSTEM...10660
      COMPONENT PARTS OF COOLING SYSTEM...10662
        RADIATOR FAN PUMP...10662
        RADIATOR FAN MOTOR...10669
        AFTERCOOLER FAN MOTOR...10674
        HYDRAULIC OIL COOLER BYPASS VALVE...10684
    CONTROL SYSTEM...10686
      LAYOUT DRAWING OF CONTROL SYSTEM...10686
      RETARDER AND HOIST CONTROL SYSTEM...10688
        RETARDER AND HOIST CONTROL SYSTEM DIAGRAM...10688
      MACHINE MONITOR SYSTEM...10689
        MACHINE MONITOR SYSTEM DIAGRAM...10689
        FUNCTION OF MACHINE MONITOR SYSTEM...10690
      REARVIEW MONITOR SYSTEM...10691
        REARVIEW MONITOR SYSTEM DIAGRAM...10691
        FUNCTION OF REARVIEW MONITOR SYSTEM...10691
      KOMTRAX SYSTEM...10692
        KOMTRAX SYSTEM DIAGRAM...10692
        FUNCTION OF KOMTRAX SYSTEM...10692
      COMPONENT PARTS OF CONTROL SYSTEM...10693
        MACHINE MONITOR...10693
        SWITCH PANEL...10713
        REARVIEW MONITOR...10714
        REARVIEW CAMERA...10715
        KOMTRAX TERMINAL...10716
        TRANSMISSION CONTROLLER...10718
        RETARDER AND HOIST CONTROLLER...10722
        MONITOR CONTROLLER...10726
        ENGINE CONTROLLER...10730
        ACCELERATOR PEDAL...10737
        SHIFT LEVER...10738
        RETARDER CONTROL LEVER...10739
    HYDRAULIC SYSTEM...10740
      LAYOUT DRAWING OF HYDRAULIC SYSTEM...10740
      COMPONENT PARTS OF HYDRAULIC SYSTEM...10742
        HYDRAULIC TANK...10742
        STEERING AND HOIST PUMP...10743
        LS VALVE...10749
        PC VALVE...10751
        POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP...10755
        HOIST VALVE...10757
    POWER TRAIN SYSTEM...10763
      LAYOUT DRAWING OF POWER TRAIN SYSTEM...10763
      TRANSMISSION CONTROL SYSTEM...10766
        TRANSMISSION CONTROL SYSTEM DIAGRAM...10766
        SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE...10767
      GEAR SHIFT CONTROL SYSTEM...10771
        AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM...10771
      SHIFT HOLD SYSTEM...10774
        FUNCTION OF SHIFT HOLD SYSTEM...10774
      DIRECTION CONTROL SYSTEM...10775
        RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM...10775
        FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM...10775
      KOMATSU TRACTION CONTROL SYSTEM (KTCS)...10776
        KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM...10776
        FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)...10776
        OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC...10777
      COMPONENT PARTS OF POWER TRAIN SYSTEM...10779
        DRIVE SHAFT...10779
        TORQUE CONVERTER AND PTO...10780
        LOCKUP CLUTCH ECMV...10784
        TRANSMISSION...10788
        TRANSMISSION CONTROL VALVE...10810
        FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV...10811
        DIFFERENTIAL LOCK CLUTCH ECMV...10816
        MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE...10820
        AXLE...10824
        DIFFERENTIAL...10827
        FINAL DRIVE...10831
    WORK EQUIPMENT SYSTEM...10835
      WORK EQUIPMENT CONTROL...10835
        WORK EQUIPMENT CONTROL SYSTEM DIAGRAM...10835
        FUNCTION OF WORK EQUIPMENT CONTROL...10836
      HOIST CONTROL...10837
        HOIST CONTROL SYSTEM DIAGRAM...10837
        FUNCTION OF HOIST CONTROL...10837
      COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...10839
        HOIST AND RADIATOR FAN DIRECTION SELECTOR SOLENOID VALVE...10839
        DUMP LEVER...10841
        DUMP EPC VALVE...10845
    STEERING SYSTEM...10847
      LAYOUT DRAWING OF STEERING SYSTEM...10847
      FUNCTION OF STEERING SYSTEM...10848
      STEERING COLUMN...10849
        STRUCTURE OF STEERING COLUMN...10849
      COMPONENT PARTS OF STEERING SYSTEM...10850
        FLOW AMPLIFIER VALVE...10850
        STEERING VALVE...10854
        STEERING PUMP SELECTOR SOLENOID VALVE...10859
        SECONDARY STEERING PUMP...10860
        SECONDARY STEERING MOTOR...10861
    BRAKE SYSTEM...10862
      LAYOUT DRAWING OF BRAKE SYSTEM...10862
      RETARDER CONTROL...10863
        RETARDER CONTROL SYSTEM DIAGRAM...10863
        FUNCTION OF RETARDER CONTROL...10864
      PARKING BRAKE INTERLOCK FUNCTION...10866
        FUNCTION OF PARKING BRAKE INTERLOCK FUNCTION...10866
        OPERATION OF PARKING BRAKE INTERLOCK FUNCTION...10866
      ARAC SYSTEM...10867
        ARAC SYSTEM DIAGRAM...10867
        FUNCTION OF ARAC SYSTEM...10867
      COMPONENT PARTS OF BRAKE SYSTEM...10868
        BRAKE CHARGE PUMP...10868
        PARKING BRAKE SOLENOID VALVE AND ACCUMULATOR CHARGE VALVE...10868
        PARKING BRAKE SOLENOID VALVE...10870
        ACCUMULATOR CHARGE VALVE...10870
        BRAKE CIRCUIT ACCUMULATOR...10873
        SHUT OFF SOLENOID VALVE...10875
        BRAKE VALVE...10876
        PROPORTIONAL PRESSURE REDUCING VALVE...10879
        SLACK ADJUSTER...10880
        BRAKE...10883
        BRAKE COOLING OIL CONTROL VALVE...10885
        FRONT BRAKE COOLING RELIEF VALVE...10887
        BRAKE SYSTEM TANK...10888
        PARKING BRAKE...10889
        SPRING CYLINDER...10890
        PARKING BRAKE CALIPER...10892
    UNDERCARRIAGE AND FRAME...10894
      FRONT SUSPENSION...10894
        STRUCTURE OF FRONT SUSPENSION...10894
        FUNCTION OF FRONT SUSPENSION...10895
      CENTER AND REAR SUSPENSIONS...10896
        STRUCTURE OF CENTER AND REAR SUSPENSIONS...10896
        FUNCTION OF CENTER SUSPENSION...10897
        FUNCTION OF REAR SUSPENSION...10898
      SUSPENSION CYLINDER...10899
        STRUCTURE OF SUSPENSION CYLINDER...10899
        FUNCTION OF SUSPENSION CYLINDER...10900
        OPERATION OF SUSPENSION CYLINDER...10900
      OSCILLATION HITCH...10902
        STRUCTURE OF OSCILLATION HITCH...10902
        FUNCTION OF OSCILLATION HITCH...10903
    WORK EQUIPMENT...10904
      STRUCTURE OF WORK EQUIPMENT...10904
      FUNCTION OF WORK EQUIPMENT...10905
    CAB AND ITS ATTACHMENTS...10906
      ROPS CAB...10906
        STRUCTURE OF ROPS CAB...10906
        FUNCTION OF ROPS CAB...10906
      CAB TILT...10907
        STRUCTURE OF CAB TILT...10907
  20 STANDARD VALUE TABLE...10909
    CONTENTS...10910
    ABBREVIATION LIST...10911
    STANDARD VALUE TABLE FOR ENGINE...10916
      STANDARD VALUE TABLE FOR ENGINE: HM300-5...10916
    STANDARD VALUE TABLE FOR MACHINE...10920
      STANDARD VALUE TABLE FOR MACHINE: HM300-5...10920
      MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...10934
    STANDARD VALUE TABLE FOR ELECTRICAL...10935
      STANDARD VALUE TABLE FOR ELECTRICITY...10935
  30 TESTING AND ADJUSTING...10951
    CONTENTS...10952
    ABBREVIATION LIST...10955
    RELATED INFORMATION ON TESTING AND ADJUSTING...10960
      TOOLS FOR TESTING AND ADJUSTING...10960
      SKETCH OF TOOLS FOR TESTING AND ADJUSTING...10967
    ENGINE AND COOLING SYSTEM...10968
      TEST ENGINE SPEED...10968
        METHOD FOR TESTING ENGINE SPEED...10968
      TEST BOOST PRESSURE...10971
        METHOD FOR TESTING BOOST PRESSURE...10971
      TEST EXHAUST GAS TEMPERATURE...10973
        METHOD FOR TESTING EXHAUST GAS TEMPERATURE...10973
      TEST EXHAUST GAS COLOR...10976
        METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...10976
        METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...10977
      TEST AND ADJUST VALVE CLEARANCE...10979
        METHOD FOR TESTING VALVE CLEARANCE...10979
        METHOD FOR ADJUSTING VALVE CLEARANCE...10980
      TEST COMPRESSION PRESSURE...10982
        METHOD FOR TESTING COMPRESSION PRESSURE...10982
      TEST BLOWBY PRESSURE...10985
        METHOD FOR TESTING BLOWBY PRESSURE...10985
      TEST ENGINE OIL PRESSURE...10988
        METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR...10988
        METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL...10988
      TEST EGR VALVE AND VGT OIL PRESSURE...10990
        METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE...10990
      TEST FUEL PRESSURE...10992
        METHOD FOR TESTING FUEL PRESSURE...10992
      TEST FUEL RETURN RATE AND LEAKAGE...10994
        METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE...10995
      BLEED AIR FROM FUEL SYSTEM...11000
        METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...11000
      TEST FUEL CIRCUIT FOR LEAKAGE...11002
        METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...11002
      HANDLE CYLINDER CUT-OUT MODE OPERATION...11004
      HANDLE NO-INJECTION CRANKING OPERATION...11005
      TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...11006
        METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION...11006
        METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...11006
      CLEAN FUEL DOSER...11007
        METHOD FOR CLEANING FUEL DOSER...11007
      WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER...11010
        METHOD FOR WRITING INJECTOR COMPENSATION VALUE...11010
      WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...11017
        METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...11017
      TEST SCR RELATED FUNCTIONS...11018
        TEST AdBlue/DEF PUMP RAISED PRESSURE...11022
        TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...11025
        TEST AdBlue/DEF LINE HEATER RELAY 1...11029
        TEST AdBlue/DEF LINE HEATER RELAY 2...11033
        TEST AdBlue/DEF PUMP HEATER RELAY...11037
        TEST AdBlue/DEF TANK HEATER VALVE...11041
        TEST DENITRATION EFFICIENCY OF SCR...11045
      CLEAN AdBlue/DEF TANK...11049
        METHOD FOR CLEANING AdBlue/DEF TANK...11049
      TEST TORQUE CONVERTER STALL SPEED...11054
        METHOD FOR TESTING TORQUE CONVERTER STALL SPEED...11054
      TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED...11059
        METHOD FOR TESTING RADIATOR FAN AND AFTERCOOLER FAN SPEED...11059
    POWER TRAIN...11061
      TEST POWER TRAIN OIL PRESSURE...11061
        METHOD FOR TESTING POWER TRAIN OIL PRESSURE...11064
      ADJUST TRANSMISSION SPEED SENSOR...11079
        METHOD FOR ADJUSTING TRANSMISSION SPEED SENSOR...11079
      ADJUST TRANSMISSION CONTROLLER...11082
        METHOD FOR ADJUSTING TRANSMISSION CONTROLLER...11082
      MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM...11083
        METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN ENGINE CONTROL SYSTEM...11083
        METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN TRANSMISSION CONTROL SYSTEM...11084
      MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS)...11090
        METHOD FOR MOVING MACHINE WITH SECONDARY KTCS OPERATION CONNECTOR...11092
    STEERING SYSTEM...11093
      TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...11093
        METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE...11093
        METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...11094
    BRAKE SYSTEM...11095
      TEST AND ADJUST BRAKE OIL PRESSURE...11095
        METHOD FOR TESTING BRAKE OIL PRESSURE...11095
        METHOD FOR ADJUSTING BRAKE OIL PRESSURE...11099
      TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...11100
        METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE...11100
        METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE...11102
      TEST BRAKE PERFORMANCE...11105
        METHOD FOR TESTING BRAKE PERFORMANCE...11105
      BLEED AIR FROM BRAKE CIRCUIT...11109
        METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT...11109
      TEST WEAR OF WHEEL BRAKE DISC...11111
        METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC...11111
      RELEASE PARKING BRAKE MANUALLY...11112
        METHOD FOR RELEASING PARKING BRAKE MANUALLY...11112
      TEST AND ADJUST WEAR OF PARKING BRAKE PAD...11113
        METHOD FOR TESTING WEAR OF PARKING BRAKE PAD...11113
        METHOD FOR ADJUSTING CLEARANCE OF PARKING BRAKE PAD...11114
    HYDRAULIC SYSTEM...11116
      TEST AND ADJUST SUSPENSION CYLINDER...11116
        METHOD FOR TESTING SUSPENSION CYLINDER...11117
        METHOD FOR ADJUSTING SUSPENSION CYLINDER...11117
      TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE...11122
        METHOD FOR TESTING DUMP CIRCUIT OIL PRESSURE...11122
        METHOD FOR ADJUSTING DUMP CIRCUIT OIL PRESSURE...11123
    WORK EQUIPMENT...11125
      TEST AND ADJUST DUMP BODY POSITIONER SENSOR...11125
        METHOD FOR TESTING BODY POSITIONER SENSOR...11125
        METHOD FOR ADJUSTING DUMP BODY POSITIONER SENSOR...11125
      TEST AND ADJUST DUMP BODY MOUNT...11127
        METHOD FOR TESTING DUMP BODY MOUNT...11127
        METHOD FOR ADJUSTING DUMP BODY MOUNT...11128
    CAB AND ITS ATTACHMENTS...11129
      CAB TILT UP...11129
        METHOD FOR TILTING UP CAB...11130
    ELECTRICAL SYSTEM...11136
      SET AND ADJUST EACH EQUIPMENT...11136
        PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT...11138
        METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT...11139
        METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING...11142
        METHOD FOR SETTING CHARACTERISTIC VALUE OF ARAC (Automatic Retarder Accelerator Control)...11147
        METHOD FOR PERFORMING SYSTEM CHECK OF KTCS (Komatsu Traction Control System)...11150
      SET AND OPERATE MACHINE MONITOR...11152
        OPERATOR MODE...11156
        DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...11156
        DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...11156
        CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...11157
        CHECKING FUNCTION OF SERVICE METER AND ODOMETER...11158
        METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...11158
        SERVICE MODE...11162
        METHOD FOR OPERATING SERVICE MODE...11162
        METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...11165
        METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...11173
        ABNORMALITY RECORD MENU...11189
        METHOD FOR CONFIRMING MAINTENANCE RECORD...11194
        METHOD FOR OPERATING MAINTENANCE MODE SETTING...11196
        METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...11200
        DEFAULT MENU...11202
        DIAGNOSTIC TESTS MENU...11217
        ADJUSTMENT MENU...11229
        METHOD FOR PERFORMING NO-INJECTION CRANKING...11238
        PAYLOAD METER SETTING...11240
        KOMTRAX SETTINGS MENU...11263
        METHOD FOR DISPLAYING SERVICE MESSAGE...11265
      METHOD FOR STARTING UP KOMTRAX TERMINAL...11267
      HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...11272
      HANDLE BATTERY DISCONNECT SWITCH...11273
      TEST DIODES...11274
        METHOD FOR TESTING DIODE USING DIGITAL TESTER...11274
        METHOD FOR TESTING DIODE USING ANALOG TESTER...11274
    Pm CLINIC...11275
      Pm CLINIC SERVICE...11275
        Pm CLINIC CHECK SHEET...11278
  40 TROUBLESHOOTING...11287
    CONTENTS...11288
    ABBREVIATION LIST...11300
    RELATED INFORMATION ON TROUBLESHOOTING...11305
      GENERAL TROUBLESHOOTING POINTS...11305
      TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...11306
      SEQUENCE OF EVENTS IN TROUBLESHOOTING...11318
      CHECKS BEFORE TROUBLESHOOTING...11320
      INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...11322
        WALK-AROUND CHECK...11322
      TESTING IN ACCORDANCE WITH TESTING PROCEDURE...11324
        CHECK FUEL LEVEL AND TYPE...11324
        CHECK IMPURE INGREDIENT IN FUEL...11324
        CHECK AdBule/DEF LEVEL AND TYPE...11325
        CHECK FUEL PREFILTER...11325
        CHECK MAIN FILTER...11327
        OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE...11328
        CHECK COOLANT LEVEL (RESERVOIR TANK)...11329
        CHECK CLOGGING OF AIR CLEANER...11330
        OUTER ELEMENT - CLEAN...11330
        REPLACE ELEMENT...11332
        CHECK HYDRAULIC OIL LEVEL...11334
        CHECK HYDRAULIC OIL STRAINER...11334
        CHECK HYDRAULIC FILTER...11335
        CHECK OIL LEVEL IN TRANSMISSION CASE...11336
        CHECK OIL LEVEL IN DIFFERENTIAL CASE...11336
        CHECK OIL LEVEL IN FINAL DRIVE CASE...11337
        BLEED AIR FROM FUEL SYSTEM...11338
        BLEED AIR FROM HYDRAULIC SYSTEM...11338
        METHOD FOR CHECKING ELECTRIC EQUIPMENTMETHOD...11338
      ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...11347
      PROCEDURE FOR TESTING AND TROUBLESHOOTING...11356
      SYMPTOM AND TROUBLESHOOTING NUMBERS...11358
      INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...11361
      CONNECTORS LIST AND LAYOUT...11363
      CONNECTOR CONTACT IDENTIFICATION...11382
      T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...11422
    TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...12525
      E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...12525
      E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...12531
      E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...12534
      E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...12536
      E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING...12538
      E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING...12541
      E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...12544
      E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY...12547
      E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL...12550
      E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL...12553
      E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL...12557
      E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...12559
      E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...12562
      E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...12565
      E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...12568
      E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS...12569
      E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY...12571
      E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...12574
      E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL...12577
      E-20 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED...12579
      E-21 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET...12582
      E-22 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...12584
      E-23 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL...12586
      E-24 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION...12587
      E-25 ALARM BUZZER DOES NOT SOUND...12588
      E-26 ALARM BUZZER DOES NOT STOP SOUNDING...12589
      E-27 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY...12591
      E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY...12593
      E-29 HOIST LEVER DOES NOT OPERATE PROPERLY...12595
      E-30 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY...12597
      E-31 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...12601
      E-32 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP...12603
      E-33 TAIL LAMP DOES NOT LIGHT UP...12605
      E-34 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP...12607
      E-35 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP...12609
      E-36 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP...12611
      E-37 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED...12613
      E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...12615
    TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...12616
      INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...12616
      SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS...12617
      FAILURE MODE AND CAUSE TABLE...12619
      H-1 MACHINE DOES NOT START...12629
      H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)...12631
      H-3 LOCKUP IS NOT RELEASED...12632
      H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING...12633
      H-5 GEAR IS NOT SHIFTED UP...12634
      H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS...12636
      H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE...12637
      H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED...12638
      H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED...12640
      H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH...12643
      H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW...12644
      H-12 STEERING WHEEL IS HEAVY TO OPERATE...12645
      H-13 STEERING WHEEL CANNOT BE OPERATED...12646
      H-14 STEERING WHEEL WAGGLES...12647
      H-15 FRONT BRAKE DOES NOT WORK ENOUGH...12648
      H-16 CENTER BRAKE DOES NOT WORK ENOUGH...12649
      H-17 DUMP BODY RISING SPEED IS LOW...12650
      H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE...12652
      H-19 DUMP BODY DOES NOT MOVE...12653
      H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)...12655
      H-21 AFTERCOOLER FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)...12656
      H-22 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN...12657
      H-23 UNUSUAL NOISE IS HEARD FROM AROUND AFTERCOOLER FAN...12658
    TROUBLESHOOTING OF ENGINE (S-MODE)...12659
      INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...12659
      S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...12660
      S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...12661
      S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...12662
      S-4 ENGINE STARTABILITY IS POOR...12663
      S-5 ENGINE DOES NOT PICK UP SMOOTHLY...12665
      S-6 ENGINE STOPS DURING OPERATION...12667
      S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...12669
      S-8 ENGINE LACKS POWER...12670
      S-9 KDPF GETS CLOGGED IN A SHORT TIME...12672
      S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...12674
      S-11 OIL BECOMES CONTAMINATED QUICKLY...12675
      S-12 FUEL CONSUMPTION IS EXCESSIVE...12676
      S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...12677
      S-14 OIL PRESSURE DROPS...12678
      S-15 FUEL MIXES INTO ENGINE OIL...12680
      S-16 WATER MIXES INTO ENGINE OIL (MILKY)...12681
      S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...12682
      S-18 UNUSUAL NOISE IS HEARD...12683
      S-19 VIBRATION IS EXCESSIVE...12684
      S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...12685
      S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...12686
      S-22 ACTIVE REGENERATION TAKES TIME...12688
      S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...12690
      S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...12691
      S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...12693
      S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...12694
  50 DISASSEMBLY AND ASSEMBLY...12695
    CONTENTS...12696
    ABBREVIATION LIST...12701
    RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...12706
      HOW TO READ THIS MANUAL...12706
      COATING MATERIALS LIST...12708
      SPECIAL TOOLS LIST...12713
      SKETCHES OF SPECIAL TOOLS...12731
    ENGINE AND COOLING SYSTEM...12749
      REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...12749
        METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...12750
        METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...12755
      REMOVE AND INSTALL INJECTOR ASSEMBLY...12761
        METHOD FOR REMOVING INJECTOR ASSEMBLY...12761
        METHOD FOR INSTALLING INJECTOR ASSEMBLY...12772
      REMOVE AND INSTALL FUEL DOSER ASSEMBLY...12786
        METHOD FOR REMOVING FUEL DOSER ASSEMBLY...12786
        METHOD FOR INSTALLING FUEL DOSER ASSEMBLY...12787
      REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...12789
        METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...12790
        METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...12801
      REMOVE AND INSTALL EGR VALVE ASSEMBLY...12816
        METHOD FOR REMOVING EGR VALVE ASSEMBLY...12816
        METHOD FOR INSTALLING EGR VALVE ASSEMBLY...12817
      REMOVE AND INSTALL EGR COOLER ASSEMBLY...12819
        METHOD FOR REMOVING EGR COOLER ASSEMBLY...12819
        METHOD FOR INSTALLING EGR COOLER ASSEMBLY...12823
      REMOVE AND INSTALL STARTER ASSEMBLY...12827
        METHOD FOR REMOVING STARTER ASSEMBLY...12827
        METHOD FOR INSTALLING STARTER ASSEMBLY...12829
      REMOVE AND INSTALL ALTERNATOR BELT...12831
        METHOD FOR REMOVING ALTERNATOR BELT...12831
        METHOD FOR INSTALLING ALTERNATOR BELT...12833
      REMOVE AND INSTALL RADIATOR ASSEMBLY...12835
        METHOD FOR REMOVING RADIATOR ASSEMBLY...12835
        METHOD FOR INSTALLING RADIATOR ASSEMBLY...12837
      REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...12841
        METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...12841
        METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...12844
      REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...12849
        METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...12850
        METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...12853
      REMOVE AND INSTALL AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY...12857
        METHOD FOR REMOVING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY...12857
        METHOD FOR INSTALLING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY...12858
      REMOVE AND INSTALL ENGINE ASSEMBLY...12862
        METHOD FOR REMOVING ENGINE ASSEMBLY...12864
        METHOD FOR INSTALLING ENGINE ASSEMBLY...12869
      REMOVE AND INSTALL ENGINE FRONT OIL SEAL...12876
        METHOD FOR REMOVING ENGINE FRONT OIL SEAL...12876
        METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...12880
      REMOVE AND INSTALL ENGINE REAR OIL SEAL...12886
        METHOD FOR REMOVING ENGINE REAR OIL SEAL...12886
        METHOD FOR INSTALLING ENGINE REAR OIL SEAL...12888
      REMOVE AND INSTALL OUTPUT SHAFT...12894
        METHOD FOR REMOVING OUTPUT SHAFT...12895
        METHOD FOR INSTALLING OUTPUT SHAFT...12897
      DISASSEMBLE AND ASSEMBLE OUTPUT SHAFT...12902
        METHOD FOR DISASSEMBLING OUTPUT SHAFT...12902
        METHOD FOR ASSEMBLING OUTPUT SHAFT...12904
      REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...12907
        METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...12907
        METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...12911
      REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...12915
        METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...12915
        METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...12920
      REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...12924
        METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...12924
        METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...12924
      REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...12926
        METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...12926
        METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...12926
      REMOVE AND INSTALL KDPF ASSEMBLY...12927
        METHOD FOR REMOVING KDPF ASSEMBLY...12927
        METHOD FOR INSTALLING KDPF ASSEMBLY...12931
      DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...12935
        METHOD FOR DISASSEMBLING KDPF ASSEMBLY...12935
        METHOD FOR ASSEMBLING KDPF ASSEMBLY...12939
      REMOVE AND INSTALL SCR ASSEMBLY...12944
        METHOD FOR REMOVING SCR ASSEMBLY...12944
        METHOD FOR INSTALLING SCR ASSEMBLY...12948
      REMOVE AND INSTALL KCCV ASSEMBLY...12953
        METHOD FOR REMOVING KCCV ASSEMBLY...12953
        METHOD FOR INSTALLING KCCV ASSEMBLY...12954
      REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...12955
        METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...12955
        METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...12961
      REMOVE AND INSTALL AdBlue/DEF INJECTOR...12968
        METHOD FOR REMOVING AdBlue/DEF INJECTOR...12968
        METHOD FOR INSTALLING AdBlue/DEF INJECTOR...12971
      REMOVE AND INSTALL AdBlue/DEF PUMP...12974
        METHOD FOR REMOVING AdBlue/DEF PUMP...12974
        METHOD FOR INSTALLING AdBlue/DEF PUMP...12977
      REMOVE AND INSTALL AdBlue/DEF HOSE...12982
        METHOD FOR REMOVING AdBlue/DEF HOSE...12982
        METHOD FOR INSTALLING AdBlue/DEF HOSE...12986
      REMOVE AND INSTALL AIR CLEANER ASSEMBLY...12990
        METHOD FOR REMOVING AIR CLEANER ASSEMBLY...12990
        METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...12993
      REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...12996
        METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...12996
        METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...12998
      REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...13000
        METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...13000
        METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...13001
    POWER TRAIN...13002
      REMOVE AND INSTALL TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13002
        METHOD FOR REMOVING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13003
        METHOD FOR INSTALLING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13015
      DISCONNECT AND CONNECT TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13029
        METHOD FOR DISCONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13029
        METHOD FOR CONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY...13030
      DISASSEMBLE AND ASSEMBLE FRONT DIFFERENTIAL ASSEMBLY...13032
        METHOD FOR DISASSEMBLING FRONT DIFFERENTIAL ASSEMBLY...13032
        METHOD FOR ASSEMBLING FRONT DIFFERENTIAL ASSEMBLY...13037
      DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY...13048
        METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY...13048
        METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY...13053
      DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY...13058
        METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY...13059
        METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY...13084
      REMOVE AND INSTALL CENTER DIFFERENTIAL ASSEMBLY...13111
        METHOD FOR REMOVING CENTER DIFFERENTIAL ASSEMBLY...13111
        METHOD FOR INSTALLING CENTER DIFFERENTIAL ASSEMBLY...13114
      DISASSEMBLE AND ASSEMBLE CENTER DIFFERENTIAL ASSEMBLY...13118
        METHOD FOR DISASSEMBLING CENTER DIFFERENTIAL ASSEMBLY...13119
        METHOD FOR ASSEMBLING CENTER DIFFERENTIAL ASSEMBLY...13124
      REMOVE AND INSTALL REAR DIFFERENTIAL ASSEMBLY...13135
        METHOD FOR REMOVING REAR DIFFERENTIAL ASSEMBLY...13135
        METHOD FOR INSTALLING REAR DIFFERENTIAL ASSEMBLY...13137
      DISASSEMBLE AND ASSEMBLE REAR DIFFERENTIAL ASSEMBLY...13139
        METHOD FOR DISASSEMBLING REAR DIFFERENTIAL ASSEMBLY...13139
        METHOD FOR ASSEMBLING REAR DIFFERENTIAL ASSEMBLY...13143
      REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13152
        METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13152
        METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13157
      DISASSEMBLE AND ASSEMBLE FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13162
        METHOD FOR DISASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13163
        METHOD FOR ASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY...13169
      REMOVE AND INSTALL CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13178
        METHOD FOR REMOVING CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13178
        METHOD FOR INSTALLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13180
      DISASSEMBLE AND ASSEMBLE CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13182
        METHOD FOR DISASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13183
        METHOD FOR ASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY...13186
      DISASSEMBLE AND ASSEMBLE REAR FINAL DRIVE ASSEMBLY...13193
        METHOD FOR DISASSEMBLING REAR FINAL DRIVE ASSEMBLY...13193
        METHOD FOR ASSEMBLING REAR FINAL DRIVE ASSEMBLY...13197
      REMOVE AND INSTALL CENTER AXLE ASSEMBLY...13202
        METHOD FOR REMOVING CENTER AXLE ASSEMBLY...13202
        METHOD FOR INSTALLING CENTER AXLE ASSEMBLY...13205
      REMOVE AND INSTALL REAR AXLE ASSEMBLY...13208
        METHOD FOR REMOVING REAR AXLE ASSEMBLY...13208
        METHOD FOR INSTALLING REAR AXLE ASSEMBLY...13210
    STEERING SYSTEM...13213
      DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY...13213
        METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY...13214
        METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY...13217
    UNDERCARRIAGE AND FRAME...13222
      REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY...13222
        METHOD FOR REMOVING FRONT SUSPENSION CYLINDER ASSEMBLY...13223
        METHOD FOR INSTALLING FRONT SUSPENSION CYLINDER ASSEMBLY...13226
      REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY...13231
        METHOD FOR REMOVING REAR SUSPENSION CYLINDER ASSEMBLY...13231
        METHOD FOR INSTALLING REAR SUSPENSION CYLINDER ASSEMBLY...13232
      DISASSEMBLE AND ASSEMBLE SUSPENSION CYLINDER ASSEMBLY...13234
        METHOD FOR DISASSEMBLING SUSPENSION CYLINDER ASSEMBLY...13234
        METHOD FOR ASSEMBLING SUSPENSION CYLINDER ASSEMBLY...13234
      REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY...13236
        METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY...13236
        METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY...13238
      REMOVE AND INSTALL HITCH FRAME ASSEMBLY...13240
        METHOD FOR REMOVING HITCH FRAME ASSEMBLY...13241
        METHOD FOR INSTALLING HITCH FRAME ASSEMBLY...13250
      DISASSEMBLE AND ASSEMBLE HITCH FRAME ASSEMBLY...13261
        METHOD FOR DISASSEMBLING HITCH FRAME ASSEMBLY...13261
        METHOD FOR ASSEMBLING HITCH FRAME ASSEMBLY...13263
    HYDRAULIC SYSTEM...13268
      REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...13268
        METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...13268
        METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...13273
      REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY...13277
        METHOD FOR REMOVING FLOW AMPLIFIER VALVE ASSEMBLY...13277
        METHOD FOR INSTALLING FLOW AMPLIFIER VALVE ASSEMBLY...13279
      REMOVE AND INSTALL HOIST VALVE ASSEMBLY...13282
        METHOD FOR REMOVING HOIST VALVE ASSEMBLY...13282
        METHOD FOR INSTALLING HOIST VALVE ASSEMBLY...13285
      DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY...13287
        METHOD FOR DISASSEMBLING HOIST CYLINDER ASSEMBLY...13287
        METHOD FOR ASSEMBLING HOIST CYLINDER ASSEMBLY...13290
    WORK EQUIPMENT...13296
      REMOVE AND INSTALL DUMP BODY ASSEMBLY...13296
        METHOD FOR REMOVING DUMP BODY ASSEMBLY...13296
        METHOD FOR INSTALLING DUMP BODY ASSEMBLY...13298
    CAB AND ITS ATTACHMENTS...13300
      REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...13300
        METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...13301
        METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY...13303
      REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...13307
        METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)...13308
        METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...13308
      REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...13313
        METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...13314
        METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...13320
      REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY (MANUFACTURED BY GRAMMER)...13327
        METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...13327
        METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...13328
      REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY (MANUFACTURED BY SEARS)...13330
        METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY...13330
        METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...13332
      REMOVE AND INSTALL SEAT BELT...13335
        METHOD FOR REMOVING SEAT BELT...13335
        METHOD FOR INSTALLING SEAT BELT...13336
    ELECTRICAL SYSTEM...13337
      REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...13337
        METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...13337
        METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...13339
      REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY...13342
        METHOD FOR REMOVING RETARDER AND HOIST CONTROLLER ASSEMBLY...13342
        METHOD FOR INSTALLING RETARDER AND HOIST CONTROLLER ASSEMBLY...13343
      REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...13344
        METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY...13344
        METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY...13345
      REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...13346
        METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...13346
        METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...13348
      REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...13351
        METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...13351
        METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...13353
      REMOVE AND INSTALL SCR TEMPERATURE SENSOR...13355
        METHOD FOR REMOVING SCR TEMPERATURE SENSOR...13355
        METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...13357
      REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...13359
        METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...13359
        METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...13360
  60 MAINTENANCE STANDARD...13361
    CONTENTS...13362
    ABBREVIATION LIST...13364
    ENGINE AND COOLING SYSTEM...13369
      MAINTENANCE STANDARD OF ENGINE MOUNT...13369
      MAINTENANCE STANDARD OF OUTPUT SHAFT...13370
      MAINTENANCE STANDARD OF RADIATOR FAN PUMP...13371
        MAINTENANCE STANDARD OF SERVO VALVE OF RADIATOR FAN PUMP...13372
      MAINTENANCE STANDARD OF RADIATOR FAN MOTOR...13373
      MAINTENANCE STANDARD OF AFTERCOOLER FAN MOTOR...13375
    POWER TRAIN...13378
      MAINTENANCE STANDARD OF DRIVE SHAFT...13378
      MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT...13379
      MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO...13380
      MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV...13383
      MAINTENANCE STANDARD OF TRANSMISSION...13384
        MAINTENANCE STANDARD OF FL, R CLUTCH...13388
        MAINTENANCE STANDARD OF FH, 1ST CLUTCH...13389
        MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH...13390
        MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH...13392
      MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE...13394
      MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV...13395
      MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH ECMV...13396
      MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE...13397
      MAINTENANCE STANDARD OF FRONT AXLE...13399
      MAINTENANCE STANDARD OF CENTER AXLE...13400
      MAINTENANCE STANDARD OF REAR AXLE...13401
      MAINTENANCE STANDARD OF FRONT DIFFERENTIAL...13402
      MAINTENANCE STANDARD OF CENTER DIFFERENTIAL...13403
      MAINTENANCE STANDARD OF REAR DIFFERENTIAL...13404
      MAINTENANCE STANDARD OF FRONT FINAL DRIVE...13405
      MAINTENANCE STANDARD OF CENTER FINAL DRIVE...13407
      MAINTENANCE STANDARD OF REAR FINAL DRIVE...13408
    STEERING SYSTEM...13409
      MAINTENANCE STANDARD OF STEERING COLUMN...13409
      MAINTENANCE STANDARD OF STEERING CYLINDER...13410
    BRAKE SYSTEM...13411
      MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER...13411
      MAINTENANCE STANDARD OF CENTER SLACK ADJUSTER...13412
      MAINTENANCE STANDARD OF FRONT BRAKE...13413
      MAINTENANCE STANDARD OF CENTER BRAKE...13415
      MAINTENANCE STANDARD OF PARKING BRAKE...13417
    UNDERCARRIAGE AND FRAME...13419
      MAINTENANCE STANDARD OF FRONT SUSPENSION...13419
      MAINTENANCE STANDARD OF CENTER AND REAR SUSPENSIONS...13421
      MAINTENANCE STANDARD OF SUSPENSION CYLINDER...13424
      MAINTENANCE STANDARD OF OSCILLATION HITCH...13426
    HYDRAULIC SYSTEM...13428
      MAINTENANCE STANDARD OF STEERING AND HOIST PUMP...13428
        MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP...13429
      MAINTENANCE STANDARD OF POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP...13431
      MAINTENANCE STANDARD OF CENTER BRAKE COOLING PUMP...13433
      MAINTENANCE STANDARD OF BRAKE CHARGE PUMP...13434
      MAINTENANCE STANDARD OF HOIST VALVE...13435
    WORK EQUIPMENT...13437
      MAINTENANCE STANDARD OF HOIST CYLINDER...13437
  80 APPENDIX...13439
    CONTENTS...13440
    ABBREVIATION LIST...13442
    AIR CONDITIONER SYSTEM...13447
      PRECAUTIONS FOR REFRIGERANT...13447
      AIR CONDITIONER COMPONENT...13448
      SPECIFICATIONS OF AIR CONDITIONER...13450
      CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...13451
      OUTLINE OF REFRIGERATION CYCLE...13452
    COMPONENT PARTS OF AIR CONDITIONER SYSTEM...13454
      AIR CONDITIONER UNIT...13454
        CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...13454
        FUNCTION OF AIR CONDITIONER UNIT...13456
      COMPONENT PARTS OF AIR CONDITIONER UNIT...13458
        FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...13459
        FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...13459
        FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...13459
        FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...13459
        STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...13460
        FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...13460
        OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...13460
        FUNCTION OF DUAL PRESSURE SWITCH...13461
      AIR CONDITIONER CONTROLLER...13462
        STRUCTURE OF AIR CONDITIONER CONTROLLER...13462
      COMPRESSOR...13463
        STRUCTURE OF COMPRESSOR...13463
        SPECIFICATIONS OF COMPRESSOR...13463
        FUNCTION OF COMPRESSOR...13463
      CONDENSER...13464
        STRUCTURE OF CONDENSER...13464
        SPECIFICATIONS OF CONDENSER...13464
        FUNCTION OF CONDENSER...13464
      RECEIVER DRIER...13465
        STRUCTURE OF RECEIVER DRIER...13465
        SPECIFICATIONS OF RECEIVER DRIER...13465
        FUNCTION OF RECEIVER DRIER...13465
      SENSORS FOR AIR CONDITIONER SYSTEM...13466
        STRUCTURE OF AMBIENT TEMPERATURE SENSOR...13466
        FUNCTION OF AMBIENT TEMPERATURE SENSOR...13466
    EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...13467
    CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...13469
    AIR CONDITIONER SYSTEM DIAGRAM...13471
      INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...13472
        FUNCTION OF AIR CONDITIONER CONTROLLER...13473
    INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...13474
    TESTING AIR LEAKAGE (DUCT)...13477
      METHOD FOR TESTING AIR LEAKAGE (DUCT)...13477
    TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...13481
    HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...13482
    TEST VENT (MODE) CHANGEOVER...13484
      METHOD FOR TESTING VENT (MODE) CHANGEOVER...13484
    TESTING FRESH/RECIRC AIR CHANGEOVER...13485
      METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...13485
    TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT...13486
      METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...13486
    TEST RELAYS...13487
      METHOD FOR TESTING RELAYS...13487
    AIR CONDITIONER TROUBLESHOOTING CHART 1...13489
    AIR CONDITIONER TROUBLESHOOTING CHART 2...13490
    INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...13493
    A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...13507
    A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...13509
    A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...13512
    A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...13514
    TROUBLESHOOTING USING GAUGE PRESSURE...13516
    CONNECTION OF SERVICE TOOL...13519
      METHOD FOR CONNECTING SERVICE TOOL...13519
    PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...13521
    HANDLE COMPRESSOR OIL...13523
  90 CIRCUIT DIAGRAMS...13525
    CONTENTS...13526
    ABBREVIATION LIST...13527
    HYDRAULIC CIRCUIT DIAGRAM...13532
      SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...13532
      HYDRAULIC CIRCUIT DIAGRAM...13537
      POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...13538
    ELECTRICAL CIRCUIT DIAGRAM...13539
      SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...13539
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/8)...13543
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/8)...13544
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/8)...13545
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/8)...13546
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/8)...13547
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/8)...13548
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/8)...13549
      INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/8)...13550
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/7)...13551
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/7)...13552
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/7)...13553
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/7)...13554
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/7)...13555
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/7)...13556
      OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/7)...13557
  INDEX...13558

Komatsu Articulated Dump Truck HM300 Repair Service Manuals