Komatsu ARTICULATED DUMP TRUCK HM400-5E0 Shop Manual SEN06747-00 PDF

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Komatsu ARTICULATED DUMP TRUCK HM400-5E0 Shop Manual SEN06747-00 – PDF DOWNLOAD

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Komatsu ARTICULATED DUMP TRUCK HM400-5E0 Shop Manual SEN06747-00 – PDF DOWNLOAD

Language : English
Pages :3256
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu ARTICULATED DUMP TRUCK HM400-5E0 Shop Manual SEN06747-00 – PDF DOWNLOAD

SERIAL NUMBERS 20001 and up

TABLE OF CONTENTS:

Komatsu ARTICULATED DUMP TRUCK HM400-5E0 Shop Manual SEN06747-00 – PDF DOWNLOAD

SERIAL NUMBERS 20001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: HM400-5E0 103
SPECIFICATIONS 105
SPECIFICATIONS: HM400-5E0 105
WEIGHT TABLE 111
WEIGHT TABLE: HM400-5E0 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK 142
AdBlue/DEF PUMP 144
AdBlue/DEF INJECTOR 145
AdBlue/DEF HOSE 146
AdBlue/DEF TANK HEATING VALVE 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH 151
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 151
FUNCTION OF BATTERY DISCONNECT SWITCH 151
ENGINE SYSTEM 153
LAYOUT DRAWING OF ENGINE SYSTEM 153
FUNCTION OF ENGINE SYSTEM 155
AUTOMATIC IDLE STOP SYSTEM 156
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 156
COMPONENT PARTS OF ENGINE SYSTEM 158
OUTPUT SHAFT 158
VGT 159
EGR SYSTEM 162
EGR VALVE 164
EGR COOLER 166
KCCV SYSTEM 167
KCCV VENTILATOR 169
KDPF 171
COOLING SYSTEM 176
LAYOUT DRAWING OF COOLING SYSTEM 176
SPECIFICATIONS OF COOLING SYSTEM 177
RADIATOR FAN CONTROL SYSTEM 178
RADIATOR FAN CONTROL SYSTEM DIAGRAM 178
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 178
AFTERCOOLER FAN CONTROL SYSTEM 180
AFTERCOOLER FAN CONTROL SYSTEM DIAGRAM 180
FUNCTION OF AFTERCOOLER FAN CONTROL SYSTEM 180
COMPONENT PARTS OF COOLING SYSTEM 182
RADIATOR FAN PUMP 182
RADIATOR FAN MOTOR 188
AFTERCOOLER FAN MOTOR 193
CENTER BRAKE COOLING REMOTE MOTOR 204
CENTER BRAKE COOLING REMOTE PUMP 207
HYDRAULIC OIL COOLER BYPASS VALVE 208
CONTROL SYSTEM 209
LAYOUT DRAWING OF CONTROL SYSTEM 209
RETARDER AND HOIST CONTROL SYSTEM 210
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 210
MACHINE MONITOR SYSTEM 211
MACHINE MONITOR SYSTEM DIAGRAM 211
FUNCTION OF MACHINE MONITOR SYSTEM 212
REARVIEW MONITOR SYSTEM 213
REARVIEW MONITOR SYSTEM DIAGRAM 213
FUNCTION OF REARVIEW MONITOR SYSTEM 213
KOMTRAX SYSTEM 214
KOMTRAX SYSTEM DIAGRAM 214
FUNCTION OF KOMTRAX SYSTEM 214
PAYLOAD METER SYSTEM 215
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 215
PAYLOAD METER SYSTEM DIAGRAM 216
FUNCTION OF PAYLOAD METER SYSTEM 216
MACHINE WEIGHT MEASURING METHOD IN PAYLOAD METER SYSTEM 216
MACHINE WEIGHT CALIBRATION METHOD IN PAYLOAD METER SYSTEM 218
COMPONENT PARTS OF CONTROL SYSTEM 219
MACHINE MONITOR 219
SWITCH PANEL 239
REARVIEW MONITOR 240
REARVIEW CAMERA 241
KOMTRAX TERMINAL 242
TRANSMISSION CONTROLLER 244
RETARDER AND HOIST CONTROLLER 248
MONITOR CONTROLLER 252
ENGINE CONTROLLER 257
PAYLOAD METER CONTROLLER 263
ACCELERATOR PEDAL 268
SHIFT LEVER 269
RETARDER CONTROL LEVER 270
HYDRAULIC SYSTEM 271
LAYOUT DRAWING OF HYDRAULIC SYSTEM 271
COMPONENT PARTS OF HYDRAULIC SYSTEM 272
HYDRAULIC TANK 272
STEERING AND HOIST PUMP 273
LS VALVE 279
PC VALVE 280
POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP, AFTERCOOLER FAN PUMP, AND CENTER BRAKE COOLING REMOTE MOTOR DRIVE PUMP 284
HOIST VALVE 286
POWER TRAIN SYSTEM 291
LAYOUT DRAWING OF POWER TRAIN SYSTEM 291
TRANSMISSION CONTROL SYSTEM 293
TRANSMISSION CONTROL SYSTEM DIAGRAM 293
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 294
GEAR SHIFT CONTROL SYSTEM 298
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 298
SHIFT HOLD SYSTEM 301
FUNCTION OF SHIFT HOLD SYSTEM 301
DIRECTION CONTROL SYSTEM 302
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 302
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 302
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 303
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 303
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 303
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 304
COMPONENT PARTS OF POWER TRAIN SYSTEM 306
DRIVE SHAFT 306
TORQUE CONVERTER AND PTO 308
LOCKUP CLUTCH ECMV 311
TRANSMISSION 315
TRANSMISSION CONTROL VALVE 336
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 337
DIFFERENTIAL LOCK CLUTCH ECMV 342
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 346
AXLE 350
DIFFERENTIAL 353
FINAL DRIVE 357
WORK EQUIPMENT SYSTEM 361
WORK EQUIPMENT CONTROL 361
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 361
FUNCTION OF WORK EQUIPMENT CONTROL 361
HOIST CONTROL 362
HOIST CONTROL SYSTEM DIAGRAM 362
FUNCTION OF HOIST CONTROL 362
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 364
DUMP LEVER 365
DUMP EPC VALVE 370
STEERING SYSTEM 372
LAYOUT DRAWING OF STEERING SYSTEM 372
FUNCTION OF STEERING SYSTEM 373
STEERING COLUMN 374
STRUCTURE OF STEERING COLUMN 374
COMPONENT PARTS OF STEERING SYSTEM 375
FLOW AMPLIFIER VALVE 375
STEERING VALVE 379
STEERING PUMP SELECTOR SOLENOID VALVE 384
SECONDARY STEERING PUMP 385
SECONDARY STEERING MOTOR 386
BRAKE SYSTEM 387
LAYOUT DRAWING OF BRAKE SYSTEM 387
RETARDER CONTROL 389
RETARDER CONTROL SYSTEM DIAGRAM 389
FUNCTION OF RETARDER CONTROL 390
PARKING BRAKE INTERLOCK FUNCTION 392
FUNCTION OF PARKING BRAKE INTERLOCK FUNCTION 392
OPERATION OF PARKING BRAKE INTERLOCK FUNCTION 392
ARAC SYSTEM 393
ARAC SYSTEM DIAGRAM 393
FUNCTION OF ARAC SYSTEM 393
COMPONENT PARTS OF BRAKE SYSTEM 394
BRAKE CHARGE PUMP 394
PARKING BRAKE SOLENOID VALVE AND ACCUMULATOR CHARGE VALVE 395
PARKING BRAKE SOLENOID VALVE 396
ACCUMULATOR CHARGE VALVE 396
BRAKE CIRCUIT ACCUMULATOR 399
SHUT OFF SOLENOID VALVE 401
BRAKE VALVE 402
PROPORTIONAL PRESSURE REDUCING VALVE 405
SLACK ADJUSTER 406
BRAKE 409
FRONT BRAKE COOLING RELIEF VALVE 411
CENTER BRAKE COOLING RELIEF VALVE 412
BRAKE SYSTEM TANK 413
PARKING BRAKE 414
SPRING CYLINDER 415
PARKING BRAKE CALIPER 417
UNDERCARRIAGE AND FRAME 419
FRONT SUSPENSION 419
STRUCTURE OF FRONT SUSPENSION 419
FUNCTION OF FRONT SUSPENSION 419
CENTER AND REAR SUSPENSIONS 421
STRUCTURE OF CENTER AND REAR SUSPENSIONS 421
FUNCTION OF CENTER SUSPENSION 421
FUNCTION OF REAR SUSPENSION 422
SUSPENSION CYLINDER 423
STRUCTURE OF SUSPENSION CYLINDER 423
FUNCTION OF SUSPENSION CYLINDER 423
OPERATION OF SUSPENSION CYLINDER 424
OSCILLATION HITCH 426
STRUCTURE OF OSCILLATION HITCH 426
FUNCTION OF OSCILLATION HITCH 427
WORK EQUIPMENT 428
STRUCTURE OF WORK EQUIPMENT 428
FUNCTION OF WORK EQUIPMENT 429
CAB AND ITS ATTACHMENTS 430
ROPS CAB 430
STRUCTURE OF ROPS CAB 430
FUNCTION OF ROPS CAB 430
CAB TILT 431
STRUCTURE OF CAB TILT 431
20 STANDARD VALUE TABLE 433
CONTENTS 434
ABBREVIATION LIST 435
STANDARD VALUE TABLE FOR ENGINE 441
STANDARD VALUE TABLE FOR ENGINE: HM400-5E0 441
STANDARD VALUE TABLE FOR MACHINE 445
STANDARD VALUE TABLE FOR MACHINE: HM400-5E0 445
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 459
STANDARD VALUE TABLE FOR ELECTRICAL 460
STANDARD VALUE TABLE FOR ELECTRICITY 460
30 TESTING AND ADJUSTING 477
CONTENTS 478
ABBREVIATION LIST 481
RELATED INFORMATION ON TESTING AND ADJUSTING 487
TOOLS FOR TESTING AND ADJUSTING 487
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 495
ENGINE AND COOLING SYSTEM 496
TEST ENGINE SPEED 496
METHOD FOR TESTING ENGINE SPEED 496
TEST BOOST PRESSURE 499
METHOD FOR TESTING BOOST PRESSURE 499
TEST EXHAUST GAS TEMPERATURE 501
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 501
TEST EXHAUST GAS COLOR 504
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 504
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 505
TEST AND ADJUST VALVE CLEARANCE 507
METHOD FOR TESTING VALVE CLEARANCE 507
METHOD FOR ADJUSTING VALVE CLEARANCE 508
TEST COMPRESSION PRESSURE 509
METHOD FOR TESTING COMPRESSION PRESSURE 509
TEST BLOWBY PRESSURE 512
METHOD FOR TESTING BLOWBY PRESSURE 512
TEST ENGINE OIL PRESSURE 514
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 514
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 514
TEST EGR VALVE AND VGT OIL PRESSURE 516
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 516
TEST FUEL PRESSURE 518
METHOD FOR TESTING FUEL PRESSURE 518
TEST FUEL RETURN RATE AND LEAKAGE 520
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 521
BLEED AIR FROM FUEL SYSTEM 526
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 526
TEST FUEL CIRCUIT FOR LEAKAGE 528
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 528
HANDLE CYLINDER CUT-OUT MODE OPERATION 530
HANDLE NO-INJECTION CRANKING OPERATION 531
CLEAN FUEL DOSER 532
METHOD FOR CLEANING FUEL DOSER 532
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 535
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 535
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 542
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 542
TEST SCR RELATED FUNCTIONS 543
TEST AdBlue/DEF PUMP RAISED PRESSURE 547
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 550
TEST AdBlue/DEF LINE HEATER RELAY 1 555
TEST AdBlue/DEF LINE HEATER RELAY 2 559
TEST AdBlue/DEF PUMP HEATER RELAY 563
TEST AdBlue/DEF TANK HEATER VALVE 567
TEST DENITRATION EFFICIENCY OF SCR 571
CLEAN AdBlue/DEF TANK 575
METHOD FOR CLEANING AdBlue/DEF TANK 575
TEST TORQUE CONVERTER STALL SPEED 580
METHOD FOR TESTING TORQUE CONVERTER STALL SPEED 580
TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED 585
METHOD FOR TESTING RADIATOR FAN AND AFTERCOOLER FAN SPEED 585
POWER TRAIN 587
TEST POWER TRAIN OIL PRESSURE 587
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 590
ADJUST TRANSMISSION SPEED SENSOR 605
METHOD FOR ADJUSTING TRANSMISSION SPEED SENSOR 606
ADJUST TRANSMISSION CONTROLLER 608
METHOD FOR ADJUSTING TRANSMISSION CONTROLLER 608
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM 609
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN ENGINE CONTROL SYSTEM 609
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN TRANSMISSION CONTROL SYSTEM 610
MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS) 616
METHOD FOR MOVING MACHINE WITH SECONDARY KTCS OPERATION CONNECTOR 618
STEERING SYSTEM 619
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 619
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 619
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 620
BRAKE SYSTEM 621
TEST AND ADJUST BRAKE OIL PRESSURE 621
METHOD FOR TESTING BRAKE OIL PRESSURE 621
METHOD FOR ADJUSTING BRAKE OIL PRESSURE 625
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE GAS 627
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE 627
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 631
BLEED AIR FROM BRAKE CIRCUIT 636
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 636
TEST BRAKE PERFORMANCE 638
METHOD FOR TESTING BRAKE PERFORMANCE 638
TEST WEAR OF WHEEL BRAKE DISC 642
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 642
RELEASE PARKING BRAKE MANUALLY 644
METHOD FOR RELEASING PARKING BRAKE MANUALLY 644
TEST AND ADJUST WEAR OF PARKING BRAKE PAD 645
METHOD FOR TESTING WEAR OF PARKING BRAKE PAD 645
METHOD FOR ADJUSTING CLEARANCE OF PARKING BRAKE PAD 646
HYDRAULIC SYSTEM 648
TEST AND ADJUST SUSPENSION CYLINDER 648
METHOD FOR TESTING SUSPENSION CYLINDER 649
METHOD FOR ADJUSTING SUSPENSION CYLINDER 649
TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE 653
METHOD FOR TESTING DUMP CIRCUIT OIL PRESSURE 653
METHOD FOR ADJUSTING DUMP CIRCUIT OIL PRESSURE 654
WORK EQUIPMENT 656
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 656
METHOD FOR TESTING BODY POSITIONER SENSOR 656
METHOD FOR ADJUSTING DUMP BODY POSITIONER SENSOR 656
TEST AND ADJUST DUMP BODY MOUNT 659
METHOD FOR TESTING DUMP BODY MOUNT 659
METHOD FOR ADJUSTING DUMP BODY MOUNT 660
CAB AND ITS ATTACHMENTS 661
CAB TILT UP 661
METHOD FOR TILTING UP CAB 662
ADJUST STEERING WHEEL TILT LOCK LEVER 668
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 668
ADJUST RATTLING OPERATOR’S SEAT 670
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 670
ELECTRICAL SYSTEM 671
SET AND ADJUST EACH EQUIPMENT 671
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 673
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 674
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 677
METHOD FOR SETTING CHARACTERISTIC VALUE OF ARAC (Automatic Retarder Accelerator Control) 682
METHOD FOR PERFORMING SYSTEM CHECK OF KTCS (Komatsu Traction Control System) 685
SET AND OPERATE OF MACHINE MONITOR 687
OPERATOR MODE 691
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 691
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 691
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 692
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 693
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 693
SERVICE MODE 697
METHOD FOR OPERATING SERVICE MODE 697
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 700
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 708
ABNORMALITY RECORD MENU 724
METHOD FOR CONFIRMING MAINTENANCE RECORD 729
METHOD FOR OPERATING MAINTENANCE MODE SETTING 731
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 735
DEFAULT MENU 737
DIAGNOSTIC TESTS MENU 752
ADJUSTMENT MENU 764
METHOD FOR PERFORMING NO-INJECTION CRANKING 773
PAYLOAD METER SETTING 775
KOMTRAX SETTINGS MENU 798
METHOD FOR DISPLAYING SERVICE MESSAGE 800
METHOD FOR STARTING UP KOMTRAX TERMINAL 802
ADJUST OPTICAL AXIS OF HEAD LAMP 807
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 807
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 811
HANDLE BATTERY DISCONNECT SWITCH 812
TEST DIODES 813
METHOD FOR TESTING DIODE USING DIGITAL TESTER 813
METHOD FOR TESTING DIODE USING ANALOG TESTER 813
Pm CLINIC 814
Pm CLINIC SERVICE 814
Pm-CLINIC CHECK SHEET: HM400-5E0 817
40 TROUBLESHOOTING 827
CONTENTS 828
ABBREVIATION LIST 840
RELATED INFORMATION ON TROUBLESHOOTING 846
GENERAL TROUBLESHOOTING POINTS 846
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 847
SEQUENCE OF EVENTS IN TROUBLESHOOTING 859
CHECKS BEFORE TROUBLESHOOTING 861
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 863
WALK-AROUND CHECK 863
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 865
CHECK FUEL LEVEL AND TYPE 865
CHECK IMPURE INGREDIENT IN FUEL 865
CHECK AdBule/DEF LEVEL AND TYPE 866
CHECK FUEL PREFILTER 866
CHECK MAIN FILTER 868
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 869
CHECK COOLANT LEVEL (RESERVOIR TANK) 870
CHECK CLOGGING OF AIR CLEANER 871
OUTER ELEMENT – CLEAN 871
REPLACE ELEMENT 873
CHECK HYDRAULIC OIL LEVEL 875
CHECK HYDRAULIC OIL STRAINER 875
CHECK HYDRAULIC FILTER 876
CHECK OIL LEVEL IN TRANSMISSION CASE 877
CHECK OIL LEVEL IN DIFFERENTIAL CASE 877
CHECK OIL LEVEL IN FINAL DRIVE CASE 878
BLEED AIR FROM FUEL SYSTEM 879
BLEED AIR FROM HYDRAULIC SYSTEM 879
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 879
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 887
PROCEDURE FOR TESTING AND TROUBLESHOOTING 896
SYMPTOM AND TROUBLESHOOTING NUMBERS 898
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 901
CONNECTORS LIST AND LAYOUT 903
CONNECTOR CONTACT IDENTIFICATION 928
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 968
FUSE LOCATION TABLE 974
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 978
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 982
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 984
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 990
FAILURE CODES TABLE 992
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1016
FAILURE CODE [1500L0]1016
FAILURE CODE [15B0NX]1017
FAILURE CODE [15F0KM]1019
FAILURE CODE [15F0MB]1020
FAILURE CODE [15F7KM]1021
FAILURE CODE [15G0MW]1022
FAILURE CODE [15G7KM]1025
FAILURE CODE [15H0MW]1026
FAILURE CODE [15J0MW]1029
FAILURE CODE [15K0MW]1032
FAILURE CODE [15L0MW]1035
FAILURE CODE [15M0MW]1038
FAILURE CODE [15SBL1]1041
FAILURE CODE [15SBMA]1044
FAILURE CODE [15SCL1]1045
FAILURE CODE [15SCMA]1048
FAILURE CODE [15SDL1]1049
FAILURE CODE [15SDMA]1052
FAILURE CODE [15SEL1]1053
FAILURE CODE [15SEMA]1056
FAILURE CODE [15SFL1]1057
FAILURE CODE [15SFMA]1060
FAILURE CODE [15SGL1]1061
FAILURE CODE [15SGMA]1064
FAILURE CODE [15SJMA]1065
FAILURE CODE [15SKMA]1067
FAILURE CODE [2F00KM]1069
FAILURE CODE [2G42ZG]1072
FAILURE CODE [2G43ZG]1073
FAILURE CODE [879AKA]1074
FAILURE CODE [879AKB]1075
FAILURE CODE [879BKA]1076
FAILURE CODE [879BKB]1078
FAILURE CODE [879CKA]1080
FAILURE CODE [879CKB]1081
FAILURE CODE [879EMC]1082
FAILURE CODE [879FMC]1083
FAILURE CODE [879GKX]1084
FAILURE CODE [989D00]1086
FAILURE CODE [989L00]1087
FAILURE CODE [989M00]1088
FAILURE CODE [989N00]1089
FAILURE CODE [A1U0N3]1090
FAILURE CODE [A1U0N4]1092
FAILURE CODE [AA10NX]1094
FAILURE CODE [AB00KE]1096
FAILURE CODE [AB00KY]1098
FAILURE CODE [AQ10N3]1100
FAILURE CODE [AS00N3]1102
FAILURE CODE [AS00R2]1104
FAILURE CODE [AS00R3]1105
FAILURE CODE [AS00R4]1106
FAILURE CODE [AS00R5]1107
FAILURE CODE [AS00R6]1108
FAILURE CODE [AS00ZK]1109
FAILURE CODE [AS10KM]1110
FAILURE CODE [AS10NR]1111
FAILURE CODE [AS10NT]1112
FAILURE CODE [B@BAZG]1113
FAILURE CODE [B@BAZK]1114
FAILURE CODE [B@BCNS]1115
FAILURE CODE [B@BCZK]1116
FAILURE CODE [B@C6NS]1118
FAILURE CODE [B@C8NS]1119
FAILURE CODE [B@CENS]1120
FAILURE CODE [B@JANS]1121
FAILURE CODE [CA115]1122
FAILURE CODE [CA122]1123
FAILURE CODE [CA123]1125
FAILURE CODE [CA131]1127
FAILURE CODE [CA132]1129
FAILURE CODE [CA135]1132
FAILURE CODE [CA141]1134
FAILURE CODE [CA144]1136
FAILURE CODE [CA145]1138
FAILURE CODE [CA153]1140
FAILURE CODE [CA154]1143
FAILURE CODE [CA187]1146
FAILURE CODE [CA221]1148
FAILURE CODE [CA222]1150
FAILURE CODE [CA227]1152
FAILURE CODE [CA234]1153
FAILURE CODE [CA238]1154
FAILURE CODE [CA239]1156
FAILURE CODE [CA249]1158
FAILURE CODE [CA256]1160
FAILURE CODE [CA271]1162
FAILURE CODE [CA272]1164
FAILURE CODE [CA273]1165
FAILURE CODE [CA274]1167
FAILURE CODE [CA322]1168
FAILURE CODE [CA323]1170
FAILURE CODE [CA324]1172
FAILURE CODE [CA325]1174
FAILURE CODE [CA331]1176
FAILURE CODE [CA332]1178
FAILURE CODE [CA343]1180
FAILURE CODE [CA351]1181
FAILURE CODE [CA352]1182
FAILURE CODE [CA356]1185
FAILURE CODE [CA357]1187
FAILURE CODE [CA386]1189
FAILURE CODE [CA431]1190
FAILURE CODE [CA432]1193
FAILURE CODE [CA441]1196
FAILURE CODE [CA442]1199
FAILURE CODE [CA449]1200
FAILURE CODE [CA451]1201
FAILURE CODE [CA452]1203
FAILURE CODE [CA515]1205
FAILURE CODE [CA516]1207
FAILURE CODE [CA553]1209
FAILURE CODE [CA555]1210
FAILURE CODE [CA556]1211
FAILURE CODE [CA559]1212
FAILURE CODE [CA595]1217
FAILURE CODE [CA687]1218
FAILURE CODE [CA689]1220
FAILURE CODE [CA691]1222
FAILURE CODE [CA692]1224
FAILURE CODE [CA697]1226
FAILURE CODE [CA698]1227
FAILURE CODE [CA731]1228
FAILURE CODE [CA778]1229
FAILURE CODE [CA1117]1232
FAILURE CODE [CA1664]1233
FAILURE CODE [CA1669]1236
FAILURE CODE [CA1673]1237
FAILURE CODE [CA1677]1238
FAILURE CODE [CA1678]1239
FAILURE CODE [CA1682]1240
FAILURE CODE [CA1683]1242
FAILURE CODE [CA1684]1244
FAILURE CODE [CA1686]1246
FAILURE CODE [CA1691]1247
FAILURE CODE [CA1694]1250
FAILURE CODE [CA1695]1252
FAILURE CODE [CA1696]1253
FAILURE CODE [CA1712]1255
FAILURE CODE [CA1713]1258
FAILURE CODE [CA1714]1260
FAILURE CODE [CA1715]1261
FAILURE CODE [CA1776]1262
FAILURE CODE [CA1777]1265
FAILURE CODE [CA1843]1268
FAILURE CODE [CA1844]1270
FAILURE CODE [CA1879]1273
FAILURE CODE [CA1881]1276
FAILURE CODE [CA1883]1278
FAILURE CODE [CA1885]1282
FAILURE CODE [CA1887]1284
FAILURE CODE [CA1921]1286
FAILURE CODE [CA1922]1289
FAILURE CODE [CA1923]1294
FAILURE CODE [CA1924]1296
FAILURE CODE [CA1925]1298
FAILURE CODE [CA1927]1300
FAILURE CODE [CA1928]1302
FAILURE CODE [CA1942]1304
FAILURE CODE [CA1963]1305
FAILURE CODE [CA1977]1309
FAILURE CODE [CA1993]1312
FAILURE CODE [CA2185]1315
FAILURE CODE [CA2186]1317
FAILURE CODE [CA2249]1319
FAILURE CODE [CA2265]1320
FAILURE CODE [CA2266]1322
FAILURE CODE [CA2271]1325
FAILURE CODE [CA2272]1327
FAILURE CODE [CA2349]1329
FAILURE CODE [CA2353]1331
FAILURE CODE [CA2357]1333
FAILURE CODE [CA2381]1334
FAILURE CODE [CA2382]1336
FAILURE CODE [CA2383]1338
FAILURE CODE [CA2386]1340
FAILURE CODE [CA2387]1342
FAILURE CODE [CA2555]1343
FAILURE CODE [CA2556]1345
FAILURE CODE [CA2637]1347
FAILURE CODE [CA2639]1349
FAILURE CODE [CA2732]1352
FAILURE CODE [CA2733]1354
FAILURE CODE [CA2741]1356
FAILURE CODE [CA2765]1357
FAILURE CODE [CA2771]1358
FAILURE CODE [CA2777]1364
FAILURE CODE [CA2878]1367
FAILURE CODE [CA2881]1370
FAILURE CODE [CA2976]1373
FAILURE CODE [CA3133]1375
FAILURE CODE [CA3134]1377
FAILURE CODE [CA3135]1379
FAILURE CODE [CA3142]1383
FAILURE CODE [CA3143]1384
FAILURE CODE [CA3144]1385
FAILURE CODE [CA3146]1388
FAILURE CODE [CA3147]1389
FAILURE CODE [CA3148]1390
FAILURE CODE [CA3151]1392
FAILURE CODE [CA3165]1398
FAILURE CODE [CA3167]1400
FAILURE CODE [CA3229]1403
FAILURE CODE [CA3231]1405
FAILURE CODE [CA3232]1407
FAILURE CODE [CA3235]1411
FAILURE CODE [CA3239]1413
FAILURE CODE [CA3241]1416
FAILURE CODE [CA3242]1419
FAILURE CODE [CA3251]1422
FAILURE CODE [CA3253]1424
FAILURE CODE [CA3254]1428
FAILURE CODE [CA3255]1431
FAILURE CODE [CA3256]1435
FAILURE CODE [CA3311]1437
FAILURE CODE [CA3312]1439
FAILURE CODE [CA3313]1442
FAILURE CODE [CA3314]1443
FAILURE CODE [CA3315]1444
FAILURE CODE [CA3316]1447
FAILURE CODE [CA3317]1448
FAILURE CODE [CA3318]1449
FAILURE CODE [CA3319]1452
FAILURE CODE [CA3321]1453
FAILURE CODE [CA3322]1455
FAILURE CODE [CA3419]1458
FAILURE CODE [CA3421]1460
FAILURE CODE [CA3497]1462
FAILURE CODE [CA3498]1463
FAILURE CODE [CA3543]1464
FAILURE CODE [CA3545]1471
FAILURE CODE [CA3547]1473
FAILURE CODE [CA3558]1474
FAILURE CODE [CA3559]1476
FAILURE CODE [CA3562]1478
FAILURE CODE [CA3563]1480
FAILURE CODE [CA3567]1483
FAILURE CODE [CA3568]1486
FAILURE CODE [CA3571]1490
FAILURE CODE [CA3572]1492
FAILURE CODE [CA3574]1494
FAILURE CODE [CA3575]1496
FAILURE CODE [CA3577]1498
FAILURE CODE [CA3578]1500
FAILURE CODE [CA3582]1502
FAILURE CODE [CA3583]1508
FAILURE CODE [CA3596]1510
FAILURE CODE [CA3649]1512
FAILURE CODE [CA3681]1514
FAILURE CODE [CA3682]1519
FAILURE CODE [CA3713]1525
FAILURE CODE [CA3717]1528
FAILURE CODE [CA3718]1529
FAILURE CODE [CA3725]1530
FAILURE CODE [CA3748]1533
FAILURE CODE [CA3751]1536
FAILURE CODE [CA3755]1538
FAILURE CODE [CA3866]1540
FAILURE CODE [CA3867]1544
FAILURE CODE [CA3868]1547
FAILURE CODE [CA3899]1551
FAILURE CODE [CA3911]1553
FAILURE CODE [CA3912]1557
FAILURE CODE [CA3932]1559
FAILURE CODE [CA3933]1561
FAILURE CODE [CA3934]1563
FAILURE CODE [CA3935]1566
FAILURE CODE [CA3936]1568
FAILURE CODE [CA4151]1570
FAILURE CODE [CA4152]1574
FAILURE CODE [CA4155]1578
FAILURE CODE [CA4156]1581
FAILURE CODE [CA4157]1584
FAILURE CODE [CA4158]1586
FAILURE CODE [CA4159]1587
FAILURE CODE [CA4161]1588
FAILURE CODE [CA4162]1591
FAILURE CODE [CA4163]1594
FAILURE CODE [CA4164]1596
FAILURE CODE [CA4165]1598
FAILURE CODE [CA4166]1600
FAILURE CODE [CA4168]1602
FAILURE CODE [CA4169]1605
FAILURE CODE [CA4171]1607
FAILURE CODE [CA4249]1610
FAILURE CODE [CA4251]1612
FAILURE CODE [CA4259]1614
FAILURE CODE [CA4261]1617
FAILURE CODE [CA4277]1619
FAILURE CODE [CA4281]1623
FAILURE CODE [CA4459]1626
FAILURE CODE [CA4461]1629
FAILURE CODE [CA4658]1632
FAILURE CODE [CA4731]1636
FAILURE CODE [CA4732]1637
FAILURE CODE [CA4739]1638
FAILURE CODE [CA4768]1639
FAILURE CODE [CA4769]1641
FAILURE CODE [CA4842]1644
FAILURE CODE [CA4952]1648
FAILURE CODE [CA5115]1650
FAILURE CODE [CA5179]1653
FAILURE CODE [CA5181]1655
FAILURE CODE [CA5383]1657
FAILURE CODE [D150KB]1659
FAILURE CODE [D150KZ]1660
FAILURE CODE [D151KB]1661
FAILURE CODE [D151KZ]1662
FAILURE CODE [D164KY]1663
FAILURE CODE [D19HKZ]1665
FAILURE CODE [D19JKZ]1667
FAILURE CODE [D1EHKA]1669
FAILURE CODE [D1EHKB]1670
FAILURE CODE [D1EHKY]1671
FAILURE CODE [D1EMKA]1672
FAILURE CODE [D1EMKB]1673
FAILURE CODE [D1EMKY]1674
FAILURE CODE [D1FBKB]1675
FAILURE CODE [D5ZHL6]1677
FAILURE CODE [D811MC]1679
FAILURE CODE [D862KA]1680
FAILURE CODE [D8ALKA]1681
FAILURE CODE [D8ALKB]1683
FAILURE CODE [D8AQK4]1685
FAILURE CODE [D8AQKR]1686
FAILURE CODE [DAF0KT]1688
FAILURE CODE [DAF0MB]1689
FAILURE CODE [DAF0MC]1690
FAILURE CODE [DAF3KK]1691
FAILURE CODE [DAF8KB]1693
FAILURE CODE [DAFDKB]1695
FAILURE CODE [DAFGMC]1697
FAILURE CODE [DAFLKA]1698
FAILURE CODE [DAFLKB]1700
FAILURE CODE [DAFQKR]1702
FAILURE CODE [DAQ0KK]1703
FAILURE CODE [DAQ0KT]1705
FAILURE CODE [DAQ0MC]1706
FAILURE CODE [DAQ1KA]1707
FAILURE CODE [DAQ2KK]1710
FAILURE CODE [DAQ9KQ]1712
FAILURE CODE [DAQLKA]1713
FAILURE CODE [DAQLKB]1715
FAILURE CODE [DAQQKR]1717
FAILURE CODE [DAQRKR]1718
FAILURE CODE [DAQRMA]1719
FAILURE CODE [DAQV00]1720
FAILURE CODE [DAQW00]1721
FAILURE CODE [DAZ9KQ]1722
FAILURE CODE [DAZQKR]1723
FAILURE CODE [DB10KT]1724
FAILURE CODE [DB10MC]1725
FAILURE CODE [DB11KA]1726
FAILURE CODE [DB11KA]1728
FAILURE CODE [DB12KK]1731
FAILURE CODE [DB13KK]1733
FAILURE CODE [DB19KQ]1735
FAILURE CODE [DB1LKA]1736
FAILURE CODE [DB1LKB]1738
FAILURE CODE [DB1QKR]1740
FAILURE CODE [DB1QMA]1741
FAILURE CODE [DB1RKR]1742
FAILURE CODE [DB2QKR]1743
FAILURE CODE [DB2RKR]1749
FAILURE CODE [DBS6KP]1755
FAILURE CODE [DBSQKQ]1758
FAILURE CODE [DBSQKR]1759
FAILURE CODE [DD1ML4]1764
FAILURE CODE [DDAAL6]1767
FAILURE CODE [DDAAL6]1769
FAILURE CODE [DDTHKA]1772
FAILURE CODE [DDTJKA]1774
FAILURE CODE [DDTKKA]1776
FAILURE CODE [DDTLKA]1778
FAILURE CODE [DDTMKA]1780
FAILURE CODE [DDTNKA]1782
FAILURE CODE [DF10KA]1784
FAILURE CODE [DF10KB]1788
FAILURE CODE [DGF1KX]1793
FAILURE CODE [DGR3KB]1795
FAILURE CODE [DGR3L8]1796
FAILURE CODE [DGR4KB]1798
FAILURE CODE [DGR4L8]1799
FAILURE CODE [DGR6KB]1801
FAILURE CODE [DGR6L8]1802
FAILURE CODE [DGR7KX]1804
FAILURE CODE [DGT1KX]1806
FAILURE CODE [DHAAMA]1808
FAILURE CODE [DHACMA]1810
FAILURE CODE [DHP4KY]1812
FAILURE CODE [DHP4KZ]1814
FAILURE CODE [DHP5KY]1816
FAILURE CODE [DHP5KZ]1818
FAILURE CODE [DHP6KY]1820
FAILURE CODE [DHP6KZ]1822
FAILURE CODE [DHP7KY]1824
FAILURE CODE [DHP7KZ]1826
FAILURE CODE [DHQ2KX]1828
FAILURE CODE [DHT5KX]1830
FAILURE CODE [DHT5L6]1832
FAILURE CODE [DHT8KX]1834
FAILURE CODE [DHT8ZG]1836
FAILURE CODE [DHU2KX]1838
FAILURE CODE [DHU3KX]1840
FAILURE CODE [DHUAKX]1842
FAILURE CODE [DHUBKX]1844
FAILURE CODE [DHUCKX]1846
FAILURE CODE [DHUDKX]1848
FAILURE CODE [DHUEKX]1850
FAILURE CODE [DHUQKX]1852
FAILURE CODE [DHURKX]1854
FAILURE CODE [DJF1KA]1856
FAILURE CODE [DK30KX]1858
FAILURE CODE [DK51L5]1860
FAILURE CODE [DK52KX]1863
FAILURE CODE [DK53L8]1865
FAILURE CODE [DK54KX]1867
FAILURE CODE [DK60KX]1869
FAILURE CODE [DKH0KX]1871
FAILURE CODE [DKH1KX]1873
FAILURE CODE [DLF1KA]1875
FAILURE CODE [DLF1LC]1877
FAILURE CODE [DLF2KA]1879
FAILURE CODE [DLF2LC]1881
FAILURE CODE [DLF400]1883
FAILURE CODE [DLF4KA]1884
FAILURE CODE [DLF4LC]1886
FAILURE CODE [DLF6LC]1888
FAILURE CODE [DLF7LC]1890
FAILURE CODE [DLFDLC]1892
FAILURE CODE [DLFELC]1894
FAILURE CODE [DLFFLC]1896
FAILURE CODE [DLFGLC]1897
FAILURE CODE [DLM3KA]1898
FAILURE CODE [DLM3LC]1900
FAILURE CODE [DLM3MB]1902
FAILURE CODE [DLM4KA]1903
FAILURE CODE [DLM4LC]1905
FAILURE CODE [DLM4MB]1907
FAILURE CODE [DLT3KA]1909
FAILURE CODE [DLT3LC]1911
FAILURE CODE [DPQ1KR]1913
FAILURE CODE [DPQ2KR]1916
FAILURE CODE [DPQ3KR]1919
FAILURE CODE [DSJ0KR]1923
FAILURE CODE [DV00KB]1924
FAILURE CODE [DW2BKA]1926
FAILURE CODE [DW2BKB]1927
FAILURE CODE [DW2BKY]1928
FAILURE CODE [DW2BL1]1929
FAILURE CODE [DW2BLH]1931
FAILURE CODE [DW4BK4]1932
FAILURE CODE [DW4BMA]1934
FAILURE CODE [DW72KZ]1935
FAILURE CODE [DW73KA]1937
FAILURE CODE [DW73KB]1939
FAILURE CODE [DW73KY]1941
FAILURE CODE [DW7BKB]1943
FAILURE CODE [DW7BKY]1945
FAILURE CODE [DW7BKZ]1946
FAILURE CODE [DW7LKB]1948
FAILURE CODE [DW7LKY]1949
FAILURE CODE [DW7LKZ]1950
FAILURE CODE [DW7NKZ]1951
FAILURE CODE [DWNJKZ]1953
FAILURE CODE [DWNKKZ]1955
FAILURE CODE [DX13KA]1957
FAILURE CODE [DX13KB]1959
FAILURE CODE [DX13KY]1961
FAILURE CODE [DX16KA]1963
FAILURE CODE [DX16KB]1964
FAILURE CODE [DX16KY]1966
FAILURE CODE [DX29KA]1967
FAILURE CODE [DX29KB]1969
FAILURE CODE [DX29KY]1971
FAILURE CODE [DX30K4]1972
FAILURE CODE [DX30KA]1974
FAILURE CODE [DX30KB]1976
FAILURE CODE [DX30KY]1978
FAILURE CODE [DX30MA]1980
FAILURE CODE [DX31K4]1982
FAILURE CODE [DX31KA]1984
FAILURE CODE [DX31KB]1986
FAILURE CODE [DX31KY]1988
FAILURE CODE [DX31MA]1990
FAILURE CODE [DX32K4]1992
FAILURE CODE [DX32KA]1994
FAILURE CODE [DX32KB]1996
FAILURE CODE [DX32KY]1998
FAILURE CODE [DX32MA]2000
FAILURE CODE [DX33K4]2002
FAILURE CODE [DX33KA]2004
FAILURE CODE [DX33KB]2006
FAILURE CODE [DX33KY]2008
FAILURE CODE [DX33MA]2010
FAILURE CODE [DX34KA]2012
FAILURE CODE [DX34KB]2013
FAILURE CODE [DX34KY]2015
FAILURE CODE [DXH0KA]2016
FAILURE CODE [DXH0KB]2018
FAILURE CODE [DXH0KY]2020
FAILURE CODE [DXH1KA]2022
FAILURE CODE [DXH1KB]2024
FAILURE CODE [DXH1KY]2026
FAILURE CODE [DXH2KA]2028
FAILURE CODE [DXH2KB]2031
FAILURE CODE [DXH2KY]2034
FAILURE CODE [DXH3KA]2037
FAILURE CODE [DXH3KB]2040
FAILURE CODE [DXH3KY]2043
FAILURE CODE [DXH4KA]2046
FAILURE CODE [DXH4KB]2048
FAILURE CODE [DXH4KY]2050
FAILURE CODE [DXH5KA]2053
FAILURE CODE [DXH5KB]2055
FAILURE CODE [DXH5KY]2057
FAILURE CODE [DXH6KA]2060
FAILURE CODE [DXH6KB]2062
FAILURE CODE [DXH6KY]2064
FAILURE CODE [DXH7KA]2067
FAILURE CODE [DXH7KB]2069
FAILURE CODE [DXH7KY]2071
FAILURE CODE [DY30MA]2074
FAILURE CODE [DY30MC]2077
FAILURE CODE [DY30ME]2080
FAILURE CODE [DY32MC]2082
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2085
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2085
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2091
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2094
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2096
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2098
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (FOR MACHINES EQUIPPED WITH EMERGENCY ENGINE STOP SWITCH)2101
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2104
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2107
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2110
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2113
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2116
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2120
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2122
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2125
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2128
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2131
E-17 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY2132
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2135
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2138
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2142
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2145
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED2147
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET2150
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2152
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2154
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION2155
E-27 ALARM BUZZER DOES NOT SOUND2156
E-28 ALARM BUZZER DOES NOT STOP SOUNDING2157
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY2159
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY2161
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY2163
E-32 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY2165
E-33 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2169
E-34 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP2171
E-35 TAIL LAMP DOES NOT LIGHT UP2173
E-36 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP2175
E-37 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP2177
E-38 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP2179
E-39 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED2181
E-40 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2183
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2184
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2184
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS2185
FAILURE MODE AND CAUSE TABLE2187
H-1 MACHINE DOES NOT START2197
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)2200
H-3 LOCKUP IS NOT RELEASED2201
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING2202
H-5 GEAR IS NOT SHIFTED UP2204
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS2207
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE2209
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED2210
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2212
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2215
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW2217
H-12 STEERING WHEEL IS HEAVY TO OPERATE2219
H-13 STEERING WHEEL CANNOT BE OPERATED2220
H-14 STEERING WHEEL WAGGLES2221
H-15 FRONT BRAKE DOES NOT WORK ENOUGH2222
H-16 CENTER BRAKE DOES NOT WORK ENOUGH2223
H-17 DUMP BODY RISING SPEED IS LOW2224
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE2226
H-19 DUMP BODY DOES NOT MOVE2227
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)2229
H-21 AFTERCOOLER FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)2230
H-22 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN2231
H-23 UNUSUAL NOISE IS HEARD FROM AROUND AFTERCOOLER FAN2232
TROUBLESHOOTING OF ENGINE (S-MODE)2233
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2233
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2234
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2235
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2236
S-4 ENGINE STARTABILITY IS POOR2237
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2239
S-6 ENGINE STOPS DURING OPERATION2241
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2243
S-8 ENGINE LACKS POWER2244
S-9 KDPF GETS CLOGGED IN A SHORT TIME2246
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2248
S-11 OIL BECOMES CONTAMINATED QUICKLY2249
S-12 FUEL CONSUMPTION IS EXCESSIVE2250
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2251
S-14 OIL PRESSURE DROPS2252
S-15 FUEL MIXES INTO ENGINE OIL2254
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2255
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2256
S-18 UNUSUAL NOISE IS HEARD2257
S-19 VIBRATION IS EXCESSIVE2258
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2259
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2260
S-22 ACTIVE REGENERATION TAKES TIME2262
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2264
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2265
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2267
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2268
50 DISASSEMBLY AND ASSEMBLY2269
CONTENTS2270
ABBREVIATION LIST2275
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2281
HOW TO READ THIS MANUAL2281
COATING MATERIALS LIST2283
SPECIAL TOOLS LIST2287
SKETCHES OF SPECIAL TOOLS2304
ENGINE AND COOLING SYSTEM2323
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2323
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2323
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2324
REMOVE AND INSTALL INJECTOR ASSEMBLY2328
METHOD FOR REMOVING INJECTOR ASSEMBLY2328
METHOD FOR INSTALLING INJECTOR ASSEMBLY2341
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2359
METHOD FOR REMOVING FUEL DOSER ASSEMBLY2359
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY2360
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2362
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2363
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2377
REMOVE AND INSTALL EGR VALVE ASSEMBLY2401
METHOD FOR REMOVING EGR VALVE ASSEMBLY2401
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2403
REMOVE AND INSTALL EGR COOLER ASSEMBLY2405
METHOD FOR REMOVING EGR COOLER ASSEMBLY2405
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2409
REMOVE AND INSTALL STARTER ASSEMBLY2413
METHOD FOR REMOVING STARTER ASSEMBLY2413
METHOD FOR INSTALLING STARTER ASSEMBLY2414
REMOVE AND INSTALL ALTERNATOR BELT2417
METHOD FOR REMOVING ALTERNATOR BELT2417
METHOD FOR INSTALLING ALTERNATOR BELT2418
REMOVE AND INSTALL RADIATOR ASSEMBLY2420
METHOD FOR REMOVING RADIATOR ASSEMBLY2420
METHOD FOR INSTALLING RADIATOR ASSEMBLY2425
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2432
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2432
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2438
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2445
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2445
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2447
REMOVE AND INSTALL AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY2451
METHOD FOR REMOVING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY2451
METHOD FOR INSTALLING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY2452
REMOVE AND INSTALL ENGINE ASSEMBLY2455
METHOD FOR REMOVING ENGINE ASSEMBLY2456
METHOD FOR INSTALLING ENGINE ASSEMBLY2464
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2474
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2474
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2475
REMOVE AND INSTALL ENGINE REAR OIL SEAL2478
METHOD FOR REMOVING ENGINE REAR OIL SEAL2478
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2479
REMOVE AND INSTALL OUTPUT SHAFT2486
METHOD FOR REMOVING OUTPUT SHAFT2487
METHOD FOR INSTALLING OUTPUT SHAFT2490
DISASSEMBLE AND ASSEMBLE OUTPUT SHAFT2494
METHOD FOR DISASSEMBLING OUTPUT SHAFT2494
METHOD FOR ASSEMBLING OUTPUT SHAFT2495
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2497
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2497
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2502
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2506
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2506
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2511
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2516
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2516
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2516
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2518
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2518
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2518
REMOVE AND INSTALL KDPF ASSEMBLY2519
METHOD FOR REMOVING KDPF ASSEMBLY2519
METHOD FOR INSTALLING KDPF ASSEMBLY2522
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2527
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2527
METHOD FOR ASSEMBLING KDPF ASSEMBLY2531
REMOVE AND INSTALL SCR ASSEMBLY2536
METHOD FOR REMOVING SCR ASSEMBLY2536
METHOD FOR INSTALLING SCR ASSEMBLY2540
REMOVE AND INSTALL KCCV ASSEMBLY2545
METHOD FOR REMOVING KCCV ASSEMBLY2545
METHOD FOR INSTALLING KCCV ASSEMBLY2547
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2550
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2550
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2557
REMOVE AND INSTALL AdBlue/DEF INJECTOR2565
METHOD FOR REMOVING AdBlue/DEF INJECTOR2565
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2568
REMOVE AND INSTALL AdBlue/DEF PUMP2571
METHOD FOR REMOVING AdBlue/DEF PUMP2571
METHOD FOR INSTALLING AdBlue/DEF PUMP2575
REMOVE AND INSTALL AdBlue/DEF HOSE2579
METHOD FOR REMOVING AdBlue/DEF HOSE2579
METHOD FOR INSTALLING AdBlue/DEF HOSE2583
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2588
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2588
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2591
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2594
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2595
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2596
POWER TRAIN2599
REMOVE AND INSTALL TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2599
METHOD FOR REMOVING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2599
METHOD FOR INSTALLING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2612
DISCONNECT AND CONNECT TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2626
METHOD FOR DISCONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2626
METHOD FOR CONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY2627
DISASSEMBLE AND ASSEMBLE FRONT DIFFERENTIAL ASSEMBLY2630
METHOD FOR DISASSEMBLING FRONT DIFFERENTIAL ASSEMBLY2631
METHOD FOR ASSEMBLING FRONT DIFFERENTIAL ASSEMBLY2638
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY2650
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY2651
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY2655
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY2661
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY2662
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY2692
REMOVE AND INSTALL CENTER DIFFERENTIAL ASSEMBLY2727
METHOD FOR REMOVING CENTER DIFFERENTIAL ASSEMBLY2727
METHOD FOR INSTALLING CENTER DIFFERENTIAL ASSEMBLY2730
DISASSEMBLE AND ASSEMBLE CENTER DIFFERENTIAL ASSEMBLY2734
METHOD FOR DISASSEMBLING CENTER DIFFERENTIAL ASSEMBLY2735
METHOD FOR ASSEMBLING CENTER DIFFERENTIAL ASSEMBLY2742
REMOVE AND INSTALL REAR DIFFERENTIAL ASSEMBLY2755
METHOD FOR REMOVING REAR DIFFERENTIAL ASSEMBLY2755
METHOD FOR INSTALLING REAR DIFFERENTIAL ASSEMBLY2757
DISASSEMBLE AND ASSEMBLE REAR DIFFERENTIAL ASSEMBLY2759
METHOD FOR DISASSEMBLING REAR DIFFERENTIAL ASSEMBLY2760
METHOD FOR ASSEMBLING REAR DIFFERENTIAL ASSEMBLY2764
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY2773
METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY2773
METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY2774
DISASSEMBLE AND ASSEMBLE FRONT FINAL DRIVE AND BRAKE ASSEMBLY2776
METHOD FOR DISASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY2777
METHOD FOR ASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY2785
REMOVE AND INSTALL CENTER FINAL DRIVE AND BRAKE ASSEMBLY2796
METHOD FOR REMOVING CENTER FINAL DRIVE AND BRAKE ASSEMBLY2796
METHOD FOR INSTALLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY2798
DISASSEMBLE AND ASSEMBLE CENTER FINAL DRIVE AND BRAKE ASSEMBLY2800
METHOD FOR DISASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY2800
METHOD FOR ASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY2807
REMOVE AND INSTALL REAR FINAL DRIVE ASSEMBLY2816
METHOD FOR REMOVING REAR FINAL DRIVE ASSEMBLY2816
METHOD FOR INSTALLING REAR FINAL DRIVE ASSEMBLY2817
DISASSEMBLE AND ASSEMBLE REAR FINAL DRIVE ASSEMBLY2818
METHOD FOR DISASSEMBLING REAR FINAL DRIVE ASSEMBLY2818
METHOD FOR ASSEMBLING REAR FINAL DRIVE ASSEMBLY2821
REMOVE AND INSTALL CENTER AXLE ASSEMBLY2826
METHOD FOR REMOVING CENTER AXLE ASSEMBLY2826
METHOD FOR INSTALLING CENTER AXLE ASSEMBLY2829
REMOVE AND INSTALL REAR AXLE ASSEMBLY2833
METHOD FOR REMOVING REAR AXLE ASSEMBLY2833
METHOD FOR INSTALLING REAR AXLE ASSEMBLY2836
STEERING SYSTEM2839
DISASSEMBLE AND ASSEMBLE STEERING VALVE2839
METHOD FOR DISASSEMBLING STEERING VALVE2839
METHOD FOR ASSEMBLING STEERING VALVE2842
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY2849
METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY2849
METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY2853
UNDERCARRIAGE AND FRAME2858
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2858
METHOD FOR REMOVING FRONT SUSPENSION CYLINDER ASSEMBLY2858
METHOD FOR INSTALLING FRONT SUSPENSION CYLINDER ASSEMBLY2859
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2861
METHOD FOR REMOVING REAR SUSPENSION CYLINDER ASSEMBLY2861
METHOD FOR INSTALLING REAR SUSPENSION CYLINDER ASSEMBLY2862
DISASSEMBLE AND ASSEMBLE SUSPENSION CYLINDER ASSEMBLY2864
METHOD FOR DISASSEMBLING SUSPENSION CYLINDER ASSEMBLY2864
METHOD FOR ASSEMBLING SUSPENSION CYLINDER ASSEMBLY2865
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY2867
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY2867
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY2869
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY2872
METHOD FOR REMOVING FRONT WHEEL ASSEMBLY2873
METHOD FOR INSTALLING FRONT WHEEL ASSEMBLY2878
REMOVE AND INSTALL REAR(FRONT SIDE) WHEEL ASSEMBLY2883
METHOD FOR REMOVING REAR(FRONT SIDE) WHEEL ASSEMBLY2883
METHOD FOR INSTALLING REAR(FRONT SIDE) WHEEL ASSEMBLY2883
REMOVE AND INSTALL REAR(BACK SIDE) WHEEL ASSEMBLY2884
METHOD FOR REMOVING REAR(BACK SIDE) WHEEL ASSEMBLY2884
METHOD FOR INSTALLING REAR(BACK SIDE) WHEEL ASSEMBLY2884
REMOVE AND INSTALL HITCH FRAME ASSEMBLY2885
METHOD FOR REMOVING HITCH FRAME ASSEMBLY2886
METHOD FOR INSTALLING HITCH FRAME ASSEMBLY2894
DISASSEMBLE AND ASSEMBLE HITCH FRAME ASSEMBLY2903
METHOD FOR DISASSEMBLING HITCH FRAME ASSEMBLY2903
METHOD FOR ASSEMBLING HITCH FRAME ASSEMBLY2905
HYDRAULIC SYSTEM2910
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2910
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2910
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2915
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY2919
METHOD FOR REMOVING FLOW AMPLIFIER VALVE ASSEMBLY2919
METHOD FOR INSTALLING FLOW AMPLIFIER VALVE ASSEMBLY2922
REMOVE AND INSTALL HOIST VALVE ASSEMBLY2925
METHOD FOR REMOVING HOIST VALVE ASSEMBLY2925
METHOD FOR INSTALLING HOIST VALVE ASSEMBLY2930
DISASSEMBLE AND ASSEMBLE HOIST VALVE ASSEMBLY2934
METHOD FOR DISASSEMBLING HOIST VALVE ASSEMBLY2934
METHOD FOR ASSEMBLING HOIST VALVE ASSEMBLY2935
DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY2938
METHOD FOR DISASSEMBLING HOIST CYLINDER ASSEMBLY2938
METHOD FOR ASSEMBLING HOIST CYLINDER ASSEMBLY2941
WORK EQUIPMENT2947
REMOVE AND INSTALL DUMP BODY ASSEMBLY2947
METHOD FOR REMOVING DUMP BODY ASSEMBLY2947
METHOD FOR INSTALLING DUMP BODY ASSEMBLY2949
CAB AND ITS ATTACHMENTS2952
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2952
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY2953
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY2956
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2960
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)2961
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)2961
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2966
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2967
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2973
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY GRAMMER)2979
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY2979
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY2980
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY SEARS)2982
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY2982
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY2984
REMOVE AND INSTALL SEAT BELT2987
METHOD FOR REMOVING SEAT BELT2987
METHOD FOR INSTALLING SEAT BELT2988
ELECTRICAL SYSTEM2989
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2989
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2989
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2991
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY2995
METHOD FOR REMOVING RETARDER AND HOIST CONTROLLER ASSEMBLY2995
METHOD FOR INSTALLING RETARDER AND HOIST CONTROLLER ASSEMBLY2996
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY2997
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY2997
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY2998
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2999
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2999
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3001
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3004
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3004
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3006
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3008
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3008
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3010
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3012
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3012
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3013
60 MAINTENANCE STANDARD3015
CONTENTS3016
ABBREVIATION LIST3018
ENGINE AND COOLING SYSTEM3024
MAINTENANCE STANDARD OF ENGINE MOUNT3024
MAINTENANCE STANDARD OF OUTPUT SHAFT3025
MAINTENANCE STANDARD OF RADIATOR FAN PUMP3026
MAINTENANCE STANDARD OF SERVO VALVE OF RADIATOR FAN PUMP3027
MAINTENANCE STANDARD OF RADIATOR FAN MOTOR3028
MAINTENANCE STANDARD OF AFTERCOOLER FAN MOTOR3029
POWER TRAIN3032
MAINTENANCE STANDARD OF DRIVE SHAFT3032
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT3034
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO3035
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV3038
MAINTENANCE STANDARD OF TRANSMISSION3039
MAINTENANCE STANDARD OF FL, R CLUTCH3044
MAINTENANCE STANDARD OF FH, 1ST CLUTCH3045
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH3046
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH3047
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE3049
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV3050
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH ECMV3051
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE3052
MAINTENANCE STANDARD OF FRONT AXLE3054
MAINTENANCE STANDARD OF CENTER AXLE3055
MAINTENANCE STANDARD OF REAR AXLE3056
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL3057
MAINTENANCE STANDARD OF CENTER DIFFERENTIAL3058
MAINTENANCE STANDARD OF REAR DIFFERENTIAL3059
MAINTENANCE STANDARD OF FRONT FINAL DRIVE3060
MAINTENANCE STANDARD OF CENTER FINAL DRIVE3062
MAINTENANCE STANDARD OF REAR FINAL DRIVE3063
STEERING SYSTEM3065
MAINTENANCE STANDARD OF STEERING COLUMN3065
MAINTENANCE STANDARD OF STEERING CYLINDER3066
BRAKE SYSTEM3067
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER3067
MAINTENANCE STANDARD OF CENTER SLACK ADJUSTER3068
MAINTENANCE STANDARD OF FRONT BRAKE3069
MAINTENANCE STANDARD OF CENTER BRAKE3071
MAINTENANCE STANDARD OF PARKING BRAKE3072
UNDERCARRIAGE AND FRAME3074
MAINTENANCE STANDARD OF FRONT SUSPENSION3074
MAINTENANCE STANDARD OF CENTER AND REAR SUSPENSIONS3076
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER3079
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER3080
MAINTENANCE STANDARD OF OSCILLATION HITCH3081
HYDRAULIC SYSTEM3083
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP3083
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP3084
MAINTENANCE STANDARD OF POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP, AFTERCOOLER FAN PUMP, AND CENTER BRAKE COOLING REMOTE MOTOR DRIVE PUMP3086
MAINTENANCE STANDARD OF CENTER BRAKE COOLING PUMP3088
MAINTENANCE STANDARD OF CENTER BRAKE COOLING REMOTE PUMP3089
MAINTENANCE STANDARD OF CENTER BRAKE COOLING REMOTE MOTOR3090
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP3093
MAINTENANCE STANDARD OF HOIST VALVE3094
WORK EQUIPMENT3096
MAINTENANCE STANDARD OF HOIST CYLINDER3096
80 APPENDIX3097
CONTENTS3098
ABBREVIATION LIST3100
AIR CONDITIONER SYSTEM3106
PRECAUTIONS FOR REFRIGERANT3106
AIR CONDITIONER COMPONENT3107
SPECIFICATIONS OF AIR CONDITIONER3109
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3110
OUTLINE OF REFRIGERATION CYCLE3111
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3113
AIR CONDITIONER UNIT3113
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3113
FUNCTION OF AIR CONDITIONER UNIT3115
COMPONENT PARTS OF AIR CONDITIONER UNIT3117
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3118
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3118
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3118
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3118
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3119
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3119
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3119
FUNCTION OF DUAL PRESSURE SWITCH3120
AIR CONDITIONER CONTROLLER3121
STRUCTURE OF AIR CONDITIONER CONTROLLER3121
COMPRESSOR3122
STRUCTURE OF COMPRESSOR3122
SPECIFICATIONS OF COMPRESSOR3122
FUNCTION OF COMPRESSOR3122
CONDENSER3123
STRUCTURE OF CONDENSER3123
SPECIFICATIONS OF CONDENSER3123
FUNCTION OF CONDENSER3123
RECEIVER DRIER3124
STRUCTURE OF RECEIVER DRIER3124
SPECIFICATIONS OF RECEIVER DRIER3124
FUNCTION OF RECEIVER DRIER3124
SENSORS FOR AIR CONDITIONER SYSTEM3125
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3125
FUNCTION OF AMBIENT TEMPERATURE SENSOR3125
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3126
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3128
AIR CONDITIONER SYSTEM DIAGRAM3130
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3131
FUNCTION OF AIR CONDITIONER CONTROLLER3132
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3133
TESTING AIR LEAKAGE (DUCT)3136
METHOD FOR TESTING AIR LEAKAGE (DUCT)3136
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3140
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3141
TEST VENT (MODE) CHANGEOVER3143
METHOD FOR TESTING VENT (MODE) CHANGEOVER3143
TESTING FRESH/RECIRC AIR CHANGEOVER3144
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3144
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3145
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3145
TEST RELAYS3146
METHOD FOR TESTING RELAYS3146
AIR CONDITIONER TROUBLESHOOTING CHART 13148
AIR CONDITIONER TROUBLESHOOTING CHART 23149
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3152
FAILURE CODE [879AKA]3154
FAILURE CODE [879AKB]3155
FAILURE CODE [879BKA]3156
FAILURE CODE [879BKB]3158
FAILURE CODE [879CKA]3160
FAILURE CODE [879CKB]3161
FAILURE CODE [879EMC]3162
FAILURE CODE [879FMC]3163
FAILURE CODE [879GKX]3164
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3166
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3168
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3171
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3173
TROUBLESHOOTING USING GAUGE PRESSURE3175
CONNECTION OF SERVICE TOOL3178
METHOD FOR CONNECTING SERVICE TOOL3178
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3180
HANDLE COMPRESSOR OIL3182
90 CIRCUIT DIAGRAMS3185
CONTENTS3186
ABBREVIATION LIST3187
HYDRAULIC CIRCUIT DIAGRAM3193
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3193
HYDRAULIC CIRCUIT DIAGRAM3197
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM3199
ELECTRICAL CIRCUIT DIAGRAM3201
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3201
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/8)3205
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/8)3207
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/8)3209
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/8)3211
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/8)3213
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/8)3215
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/8)3217
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/8)3219
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/8)3221
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/8)3223
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/8)3225
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/8)3227
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/8)3229
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/8)3231
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/8)3233
OUTSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/8)3235
INDEX3237

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24