Komatsu Dump Truck HD465-8E0 HD605-8E0 Shop Manual SEN06768-00

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Komatsu Dump Truck HD465-8E0 HD605-8E0 Shop Manual SEN06768-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Dump Truck HD465-8E0 HD605-8E0 Shop Manual SEN06768-00 – PDF DOWNLOAD

Language : English
Pages :3104
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Dump Truck HD465-8E0 HD605-8E0 Shop Manual SEN06768-00 – PDF DOWNLOAD

SERIAL NUMBERS HD465-35001 and up
HD605-35001 and up

TABLE OF CONTENTS:

Komatsu Dump Truck HD465-8E0 HD605-8E0 Shop Manual SEN06768-00 – PDF DOWNLOAD

SERIAL NUMBERS HD465-35001 and up
HD605-35001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATIONS 26
FOREWORD, SAFETY, BASIC INFORMATION 31
HOW TO READ THE SHOP MANUAL 31
Configuration of the shop manual 31
Symbols 31
Signal word 32
Unit 32
SAFETY NOTICE FOR OPERATION 33
Safety matters 33
General precautions 33
Preliminary work precautions 34
Precautions during work 34
Hand signals and use of sling precautions 36
Precautions when using a mobile crane 37
Precautions when using an overhead crane 37
Select wire ropes 38
Precautions when you disconnect air conditioner piping 39
Precautions for air conditioner piping 39
PRECAUTIONS TO PREVENT FIRE 41
Fire caused by fuel, oil, coolant or window washer fluid 41
Fire caused by accumulation or flammable material 41
Fire caused from electrical wires 41
Fire caused by piping 41
Fire around the machine because of hot exhaust gas 41
Explosion caused by lighting equipment 41
ACTIONS IF FIRE OCCURS 42
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS 42
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT 44
Select an appropriate workplace 44
Disassemble and maintenance work outdoors 44
Seal openings and prevent oil flow 44
Prevent unwanted materials during fill 44
Change hydraulic oil while its temperature is high 45
Flush operation 45
Clean operation 45
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES 46
Precautions for removal and disassemble work 46
Parts for disassemble of the face type seals on hoses and piping 46
Parts for the removal of hoses and piping with taper seals 47
Parts to disconnect split flange type on hoses and piping 47
Parts to remove an o-ring boss type joint 48
Parts to remove taper pipe thread type joint 49
Precautions for installation and assembly work 49
Precaution at the time work is done 50
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 52
Handle wire harness and connectors 52
Primary causes of failure in wiring harness 52
PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT 54
Select an appropriate workplace 54
Seal opening 54
How to clean parts when dirt is stuck 54
Precautions when you replace fuel filter cartridge 54
PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIPMENT 55
Select an appropriate workplace 55
Seal opening 55
PRACTICAL USEAGE OF KOMTRAX 56
Value of using KOMTRAX 56
How to use KOMTRAX 56
How to operate KOMTRAX 56
DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT 57
PROCEDURE TO DISCONNECT AND CONNECT TYPE 1 PUSH PULL TYPE QUICK DISCONNECT 57
PROCEDURE TO DISCONNECT AND CONNECT TYPE 2 PUSH PULL TYPE QUICK DISCONNECT 58
PROCEDURE TO DISCONNECT AND CONNECT TYPE 3 PUSH PULL TYPE QUICK DISCONNECT 59
PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS 61
Disconnect connectors 61
Connect connectors 62
Blow dry wiring harness 63
Handle controller 64
Precautions for when you troubleshoot electrical circuits 64
PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH CONNECTOR 65
Procedure to disconnect Deutsch connector 65
Procedure to connect Deutsch connector 65
PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR 66
Procedure to disconnect slide lock connector (FRAMATOME-3, FRAMATOME-2) 66
Procedure to connect slide lock connector (FRAMATOME-3, FRAMATOME- 2) 66
Procedure to disconnect slide lock connector (FRAMATOME-24) 66
Procedure to connect slide lock connector (FRAMATOME-24) 67
PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK TYPE CONNECTOR 68
Procedure to disconnect pull to lock type connector 68
Procedure to connect pull to lock type connector 68
PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CONNECTOR 69
Procedure to disconnect push to lock type connector (BOSCH-3) 69
Procedure to connect push to lock type connector (BOSCH-3) 69
Procedure to disconnect push to lock type connector (AMP-3) 70
Procedure to connect push to lock type connector (AMP-3) 70
Procedure to disconnect push to lock type connector (SUMITOMO-3) 70
Procedure to connect push to lock type connector (SUMITOMO-3) 70
Procedure to disconnect push to lock type connector (SUMITOMO-4) 70
Procedure to connect push to lock type connector (SUMITOMO-4) 70
PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE CONNECTORS 71
Procedure to disconnect twist type connector 71
Procedure to connect twist type connector 71
HOW TO READ ELECTRICAL WIRE CODES 72
Type, symbol, and material 72
Dimensions 72
Color codes table 74
Types of circuits and color codes 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 76
Standard dimension and tolerance 76
Standard clearance and standard value 77
Standard interference 77
Repair limit and approved value or permitted dimension 77
Permitted clearance 77
Permitted interference 77
STANDARD VAULE TIGHTEN TABLE 78
Table of tighten values for bolts and nuts 78
Table of tighten value for o-ring boss piping joints 81
Table of tighten value for o-ring boss plugs 81
Table of tighten value for hoses (Taper seal and face seal type) 82
Table of tighten value for face seal joints 83
Tighten value table for bolts and nuts on 102,107 and 114 engines 83
Tighten value table for 102, 107, and 114 engines (joint bolts) 84
Tighten value table for tapered screws on 102, 107, and 114 engines (NPT) 84
CONVERSION TABLE 85
Procedure for using the conversion table 85
Examples of using the conversion table to convert a unit from mm to in 85
mm to in 85
mm to in 85
kg to lb 86
l to USGal 86
l to UKGal 86
kgm to lbft 87
kg/cm2 to lb/in2 87
Temperature 88
01 SPECIFICATIONS 91
CONTENTS 92
ABBREVIATIONS 93
SPECIFICATIONS 98
DIAGRAM SPECIFICATION 98
DIAGRAM SPECIFICATION: HD465-8E0 98
DIAGRAM SPECIFICATION: HD605-8E0 100
SPECIFICATIONS 102
SPECIFICATIONS: HD465-8E0 102
SPECIFICATIONS: HD605-8E0 107
WEIGHT TABLE 112
WEIGHT TABLE: HD465-8E0 112
WEIGHT TABLE: HD605-8E0 113
FUEL, COOLANT, AND LUBRICATING OIL 114
10 STRUCTURE AND FUNCTION 117
CONTENTS 118
ABBREVIATIONS 123
NOx CONTROL SYSTEM 128
FUNCTION OF NOx CONTROL SYSTEM 128
INDUCEMENT STRATEGY 128
BOOT UP SYSTEM 131
BOOT UP SYSTEM DIAGRAM 131
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) 132
SYSTEM IN OPERATION LAMP 134
OPERATION LAMP SYSTEM DIAGRAM 134
FUNCTION OF OPERATION LAMP SYSTEM 134
BATTERY DISCONNECT SWITCH 135
BATTERY DISCONNECT SWITCH DIAGRAM 135
FUNCTION OF BATTERY DISCONNECT SWITCH 136
ENGINE SYSTEM 139
ENGINE SYSTEM DIAGRAM 139
FUNCTION OF ENGINE SYSTEM 140
ENGINE CONTROL SYSTEM 141
ENGINE CONTROL SYSTEM DIAGRAM 141
AUTOMATIC IDLE STOP SYSTEM 145
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 145
ENGINE COMPONENTS 147
OUTPUT SHAFT 147
VGT 148
EGR SYSTEM 152
EGR VALVE 154
EGR COOLER 156
KCCV SYSTEM 157
KCCV VENTILATOR 159
KDPF 161
COOLING SYSTEM 165
COOLING SYSTEM DIAGRAM 165
SPECIFICATIONS OF COOLING SYSTEM 166
RADIATOR FAN CONTROL SYSTEM 167
RADIATOR FAN CONTROL SYSTEM DIAGRAM 167
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 167
COOLING SYSTEM COMPONENTS 169
COOLING FAN PUMP 169
CONTROL SYSTEM 183
CONTROL SYSTEM DIAGRAM 183
RETARDER AND HOIST CONTROL SYSTEM 184
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 184
MACHINE MONITOR SYSTEM 186
MACHINE MONITOR SYSTEM DIAGRAM 186
FUNCTION OF MACHINE MONITOR SYSTEM 187
REARVIEW MONITOR SYSTEM 188
REARVIEW MONITOR SYSTEM DIAGRAM 188
FUNCTION OF REARVIEW MONITOR SYSTEM 188
KOMTRAX PLUS SYSTEM 189
KOMTRAX PLUS SYSTEM DIAGRAM 189
FUNCTION OF KOMTRAX PLUS SYSTEM 191
PAYLOAD METER SYSTEM 194
PAYLOAD METER SYSTEM DIAGRAM 194
PAYLOAD METER SYSTEM DIAGRAM 195
FUNCTION OF PAYLOAD METER SYSTEM 195
MEASUREMENT PRINCIPLE OF LOADING MASS 196
MACHINE LOCK-OUT SYSTEM 205
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM 205
FUNCTION OF MACHINE LOCK-OUT SYSTEM 206
OPERATION OF MACHINE LOCK-OUT SYSTEM 206
CONTROL SYSTEM COMPONENTS 207
MACHINE MONITOR 207
SWITCH PANEL 224
REARVIEW MONITOR 225
REARVIEW CAMERA 226
KOMTRAX TERMINAL 227
KOMTRAX PLUS CONTROLLER 229
STRUCTURE OF KOMTRAX PLUS CONTROLLER 229
INPUT AND OUTPUT SIGNALS OF KOMTRAX PLUS CONTROLLER 229
WIRELESS LAN UNIT 233
STRUCTURE OF WIRELESS LAN UNIT 233
FUNCTION OF WIRELESS LAN UNIT 233
INPUT AND OUTPUT SIGNALS OF WIRELESS LAN UNIT 233
TRANSMISSION CONTROLLER 234
RETARDER AND HOIST CONTROLLER 238
MONITOR CONTROLLER 242
ENGINE CONTROLLER 247
ABS CONTROLLER 259
ACCELERATOR PEDAL 263
GEAR SHIFT LEVER 264
RETARDER CONTROL LEVER 265
HYDRAULIC SYSTEM 266
HYDRAULIC SYSTEM DIAGRAM 266
HYDRAULIC SYSTEM COMPONENTS 267
HYDRAULIC TANK 267
STEERING AND HOIST PUMP 268
LS VALVE 274
CO VALVE 275
POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 278
BRAKE COOLING, CONTROL TRIPLE PUMP 279
HOIST VALVE 281
POWER TRAIN SYSTEM 287
POWER TRAIN DIAGRAM 287
TRANSMISSION CONTROL SYSTEM 288
TRANSMISSION CONTROL SYSTEM DIAGRAM 288
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 290
GEAR SHIFT CONTROL SYSTEM 294
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 294
DIRECTION CONTROL SYSTEM 296
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 296
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 296
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 297
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 297
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 297
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 298
TRAVEL SPEED LIMITATION SYSTEM 299
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 299
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 300
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 301
POWER TRAIN COMPONENTS 303
DRIVE SHAFT 303
TORQUE CONVERTER AND PTO 305
LOCKUP CLUTCH ECMV 309
TRANSMISSION 312
TRANSMISSION CONTROL VALVE 329
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 331
AXLE 340
DIFFERENTIAL 342
FINAL DRIVE 344
WORK EQUIPMENT SYSTEM 345
WORK EQUIPMENT CONTROL 345
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 345
FUNCTION OF WORK EQUIPMENT CONTROL 345
HOIST CONTROL 346
HOIST CONTROL SYSTEM DIAGRAM 346
FUNCTION OF HOIST CONTROL 346
WORK EQUIPMENT SYSTEM COMPONENTS 348
DUMP LEVER 348
HOIST EPC VALVE 353
STEERING SYSTEM 354
STEERING SYSTEM DIAGRAM 354
STEERING SYSTEM FUNCTION 355
STEERING COLUMN 356
STRUCTURE OF STEERING COLUMN 356
STEERING LINKAGE 357
STRUCTURE OF STEERING LINKAGE 357
STEERING SYSTEM COMPONENTS 358
DEMAND VALVE 358
STEERING RELIEF VALVE 365
STRUCTURE OF STEERING RELIEF VALVE 365
FUNCTION OF STEERING RELIEF VALVE 365
OPERATION OF STEERING RELIEF VALVE 365
ORBITROL VALVE 366
STEERING PUMP SELECTOR SOLENOID VALVE 372
CROSS-OVER RELIEF VALVE 373
SECONDARY STEERING PUMP 374
SECONDARY STEERING MOTOR 375
BRAKE SYSTEM 376
BRAKE SYSTEM DIAGRAM 376
RETARDER CONTROL 378
RETARDER CONTROL SYSTEM DIAGRAM 378
FUNCTION OF RETARDER CONTROL 378
ARSC SYSTEM 379
ARCS SYSTEM DIAGRAM 379
FUNCTION OF ARSC SYSTEM 379
BRAKE SYSTEM COMPONENTS 380
BRAKE CHARGE PUMP 380
PARKING BRAKE SOLENOID VALVE 381
ACCUMULATOR CHARGE VALVE 382
BRAKE CIRCUIT ACCUMULATOR 386
BRAKE VALVE 387
SECONDARY BRAKE VALVE 390
SECONDARY BRAKE RELAY VALVE 391
PROPORTION PRESSURE REDUCING VALVE 392
SLACK ADJUSTER 393
BRAKE 395
PARKING BRAKE 398
BRAKE SUB-TANK 400
ABS 401
ABS SYSTEM DIAGRAM 401
ABS SYSTEM DIAGRAM 402
FUNCTION OF ABS 403
OPERATION OF ABS 403
COMPONENT PARTS OF ABS 406
AUTO-GREASING SYSTEM 409
AUTO-GREASING SYSTEM DIAGRAM 409
AUTO-GREASING SYSTEM DIAGRAM 412
FUNCTION OF AUTO-GREASING SYSTEM 412
COMPONENT PARTS OF AUTO-GREASING SYSTEM 413
AUTO-GREASING PUMP 413
AUTO-GREASING INJECTOR 414
UNDERCARRIAGE AND FRAME 419
SUSPENSION 419
STRUCTURE OF SUSPENSION 419
FUNCTION OF SUSPENSION 419
FRONT SUSPENSION 420
STRUCTURE OF FRONT SUSPENSION 420
FUNCTION OF FRONT SUSPENSION 421
REAR SUSPENSION 422
STRUCTURE OF REAR SUSPENSION 422
FUNCTION OF REAR SUSPENSION 423
SUSPENSION CYLINDER 424
STRUCTURE OF SUSPENSION CYLINDER 424
FUNCTION OF SUSPENSION CYLINDER 424
OPERATION OF SUSPENSION CYLINDER 424
WORK EQUIPMENT 425
STRUCTURE OF WORK EQUIPMENT 425
FUNCTION OF WORK EQUIPMENT 425
CAB AND ATTACHMENTS 426
ROPS CAB 426
STRUCTURE OF ROPS CAB 426
FUNCTION OF ROPS CAB 426
CAB MOUNT 427
STRUCTURE OF CAB MOUNT 427
FUNCTION OF CAB MOUNT 427
20 STANDARD VALUE TABLE 429
CONTENTS 430
ABBREVIATIONS 431
STANDARD VALUE TABLE FOR ENGINE 436
STANDARD VALUE TABLE FOR ENGINE: HD465-8E0 436
STANDARD VALUE TABLE FOR ENGINE: HD605-8E0 439
STANDARD VALUE TABLE FOR MACHINE 442
STANDARD VALUE TABLE FOR MACHINE: HD465-8E0 442
STANDARD VALUE TABLE FOR MACHINE: HD605-8E0 455
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE 468
30 TEST AND ADJUST 469
CONTENTS 470
ABBREVIATIONS 474
RELATED INFORMATION TO TEST AND ADJUST 479
TOOLS TO TEST AND ADJUST 479
DIAGRAM FOR TEST AND ADJUST TOOLS 489
ENGINE AND COOLING SYSTEM 490
TEST ENGINE SPEED 490
PROCEDURE TO TEST ENGINE SPEED 490
TEST BOOST PRESSURE 492
BOOST PRESSURE TEST BY MACHINE MONITOR 492
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 494
TESTING EXHAUST GAS TEMPERATURE 496
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR 496
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 498
TEST EXHAUST GAS COLOR 500
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER 500
TEST EXHAUST GAS COLOR WITH SMOKE METER 501
TEST AND ADJUST VALVE CLEARANCE 503
TEST VALVE CLEARANCE 503
ADJUST VALVE CLEARANCE 504
COMPRESSION TEST 506
COMPRESSION PRESSURE TEST 506
BLOWBY PRESSURE TEST 510
BLOWBY PRESSURE TEST 510
TEST ENGINE OIL PRESSURE 512
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR 512
TEST ENGINE OIL PRESSURE 512
EGR VALVE AND VGT OIL PRESSURE TEST 514
EGR VALVE AND VGT OIL PRESSURE TEST 514
FUEL PRESSURE TEST 515
FUEL PRESSURE TEST 515
FUEL RETURN RATE AND LEAKAGE TEST 517
FUEL RETURN RATE AND LEAKAGE TEST 518
BLEEDING AIR FROM FUEL SYSTEM 521
BLEED AIR FROM FUEL SYSTEM 521
FUEL CIRCUIT LEAK TEST 523
FUEL CIRCUIT LEAK TEST 523
SUPPLY PUMP TEST 525
SUPPLY PUMP TEST 525
CYLINDER CUT-OUT MODE 528
NO-INJECTION CRANKING 529
CLEAN FUEL DOSER 530
CLEAN FUEL DOSER 530
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 532
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 532
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 538
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 538
TEST TORQUE CONVERTER STALL SPEED 539
TEST TORQUE CONVERTER STALL SPEED 539
RADIATOR FAN SPEED TEST 541
RADIATOR FAN SPEED TEST 541
POWER TRAIN 543
TEST POWER TRAIN OIL PRESSURE 543
POWER TRAIN OIL PRESSURE TEST 546
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 558
ADJUST TRANSMISSION INPUT SPEED SENSOR 558
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR 559
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR 559
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 560
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 560
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS 561
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SENSORS 561
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 562
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 562
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEM 562
STEERING SYSTEM 567
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 567
TEST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR 567
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS 567
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 569
TEST SUPPLY PRESSURE OF ORBITROL VALVE 570
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 570
TEST STEERING CYLINDER PRESSURE 572
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 572
BLEED AIR FROM STEERING CYLINDER CIRCUIT 574
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 574
BRAKE SYSTEM 575
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 575
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 575
TEST WHEEL BRAKE OIL PRESSURE 576
FRONT BRAKE ACTUATION PRESSURE TEST 576
REAR BRAKE ACTUATION PRESSURE TEST 577
RETARDER BRAKE PRESSURE TEST 578
RETARDER BRAKE ACTUATION PRESSURE TEST (FOR MACHINE WITH KTCS) 579
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 580
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR 580
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 580
ADJUST BRAKE ACCUMULATOR PRESSURE 582
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 583
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 584
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 588
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 592
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 598
TEST BRAKE PERFORMANCE 599
TEST FOOT BRAKE PERFORMANCE 599
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 600
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 601
BLEED AIR FROM BRAKE CIRCUIT 602
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 602
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT (FOR MACHINE WITH ABS) 603
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT 604
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/WITHOUT KTCS) 606
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 608
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/KTCS) 610
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 612
TEST PARKING BRAKE OIL PRESSURE 614
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 614
RELEASE PARKING BRAKE MANUALLY 615
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY 615
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 616
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 616
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE 616
TEST THE QUANTITY OF REAR BRAKE DISC WEAR 617
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR 617
HYDRAULIC SYSTEM 618
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 618
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 618
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 619
TEST HOIST CYLINDER SUPPLY PRESSURE 620
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 620
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 622
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 622
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 623
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 624
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 624
TEST AND ADJUST FRONT SUSPENSION CYLINDER 626
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 626
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 627
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 631
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 631
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 632
TEST AND ADJUST REAR SUSPENSION CYLINDER 633
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 633
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 634
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 638
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 638
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 638
WORK EQUIPMENT 640
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 640
PROCEDURE TO TEST THE BODY POSITION SENSOR 640
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR 640
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR 640
LOWER THE BODY MANUALLY 642
PROCEDURE TO LOWER THE BODY MANUALLY 642
LIFT THE BODY MANUALLY 643
PROCEDURE TO RAISE THE BODY MANUALLY 643
CAB AND ITS ATTACHMENTS 644
ADJUST STEERING WHEEL TILT LOCK LEVER 644
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 644
ADJUST RATTLING OPERATOR’S SEAT 646
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 646
ELECTRICAL SYSTEM 647
SET AND ADJUST EACH EQUIPMENT 647
SET AND OPERATE OF MACHINE MONITOR 650
OPERATOR MODE 654
SERVICE MODE 667
ABNORMALITY RECORD MENU 694
DEFAULT MENU 709
DIAGNOSTIC TESTS 725
ADJUSTMENT MENU 736
PROCEDURE TO CRANK WITH NO-INJECTION 763
PAYLOAD METER SETTING 765
PROCEDURE FOR MANUAL SNAP SHOT 784
KOMTRAX SETTINGS MENU 787
PROCEDURE TO DISPLAY SERVICE MESSAGE 789
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL 791
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 796
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 796
SETTING DEFAULT OF WIRELESS LAN MODEM 798
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM 798
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION 799
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 800
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 800
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 804
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED 804
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 807
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED 807
ADJUST REARVIEW CAMERA ANGLE 809
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 809
ADJUST OPTICAL AXIS OF HEAD LAMP 810
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 810
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK 813
BATTERY DISCONNECT SWITCH WORK 814
TEST DIODES 815
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 815
PROCEDURE TO TEST DIODE USING ANALOG TESTER 815
Pm CLINIC 816
Pm CLINIC SERVICE 816
Pm CLINIC CHECK SHEET: HD465-8E0 819
Pm CLINIC CHECK SHEET: HD605-8E0 825
PERFORMING QUICK Pm 831
PROCEDURE TO PERFORM QUICK Pm 831
40 TROUBLESHOOTING 835
CONTENTS 836
ABBREVIATIONS 851
RELATED INFORMATION ON TROUBLESHOOTING 856
GENERAL TROUBLESHOOTING POINTS 856
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS 857
SEQUENCE OF EVENTS IN TROUBLESHOOTING 865
CHECKS BEFORE TROUBLESHOOTING 867
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 870
WALK-AROUND CHECK 870
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 871
CHECK FUEL LEVEL AND TYPE 871
CHECK IMPURE INGREDIENT IN FUEL 871
CHECK FUEL PREFILTER 871
CHECK MAIN FILTER 873
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 875
CHECK COOLANT LEVEL (RESERVOIR TANK) 875
CHECK CLOGGING OF AIR CLEANER 877
OUTER ELEMENT – CLEAN 878
REPLACE ELEMENT 880
CHECK HYDRAULIC OIL LEVEL 881
CHECK HYDRAULIC OIL STRAINER 881
CHECK HYDRAULIC FILTER 882
CHECK OIL LEVEL IN TRANSMISSION CASE 883
CHECK OIL LEVEL IN DIFFERENTIAL CASE 883
CHECK OIL LEVEL IN FINAL DRIVE CASE 883
BLEED AIR FROM FUEL SYSTEM 883
BLEED AIR FROM HYDRAULIC SYSTEM 884
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 884
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 890
PROCEDURE FOR TESTING AND TROUBLESHOOTING 901
SYMPTOM AND TROUBLESHOOTING NUMBERS 903
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 907
CONNECTORS LIST AND LAYOUT 910
CONNECTOR CONTACT IDENTIFICATION 938
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 978
FUSE LOCATION TABLE 984
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 990
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 994
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 996
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND [CB3135])1002
FAILURE CODES TABLE1004
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1029
FAILURE CODE [1500L0]1029
FAILURE CODE [15B0NX]1030
FAILURE CODE [15F0KM]1032
FAILURE CODE [15F0MB]1033
FAILURE CODE [15F7KM]1034
FAILURE CODE [15G0MW]1035
FAILURE CODE [15G7KM]1036
FAILURE CODE [15H0MW]1037
FAILURE CODE [15J0MW]1038
FAILURE CODE [15K0MW]1039
FAILURE CODE [15L0MW]1041
FAILURE CODE [15M0MW]1043
FAILURE CODE [15N0MW]1045
FAILURE CODE [15SBL1]1047
FAILURE CODE [15SBMA]1050
FAILURE CODE [15SCL1]1051
FAILURE CODE [15SCMA]1054
FAILURE CODE [15SDL1]1055
FAILURE CODE [15SDMA]1058
FAILURE CODE [15SEL1]1059
FAILURE CODE [15SEMA]1062
FAILURE CODE [15SFL1]1063
FAILURE CODE [15SFMA]1066
FAILURE CODE [15SGL1]1067
FAILURE CODE [15SGMA]1070
FAILURE CODE [15SHL1]1071
FAILURE CODE [15SHMA]1074
FAILURE CODE [15SJMA]1075
FAILURE CODE [2C4MNX]1076
FAILURE CODE [2F00KM]1077
FAILURE CODE [2G42ZG]1081
FAILURE CODE [2G43ZG]1082
FAILURE CODE [6014NX]1083
FAILURE CODE [879AKA]1084
FAILURE CODE [879AKB]1085
FAILURE CODE [879BKA]1086
FAILURE CODE [879BKB]1087
FAILURE CODE [879CKA]1089
FAILURE CODE [879CKB]1090
FAILURE CODE [879EMC]1091
FAILURE CODE [879FMC]1092
FAILURE CODE [879GKX]1093
FAILURE CODE [989D00]1094
FAILURE CODE [989L00]1095
FAILURE CODE [989M00]1096
FAILURE CODE [989N00]1097
FAILURE CODE [989X00]1098
FAILURE CODE [989Y00]1099
FAILURE CODE [A1U0N3]1100
FAILURE CODE [A1U0N4]1101
FAILURE CODE [AA10NX]1103
FAILURE CODE [AB00KE]1105
FAILURE CODE [AB00KY]1107
FAILURE CODE [AQ00N3]1108
FAILURE CODE [AQ00N4]1109
FAILURE CODE [AQ10N3]1110
FAILURE CODE [AS00R2]1111
FAILURE CODE [AS00R3]1112
FAILURE CODE [AS00R4]1113
FAILURE CODE [AS00R6]1114
FAILURE CODE [B@BAZG]1115
FAILURE CODE [B@BAZK]1116
FAILURE CODE [B@BCNS]1117
FAILURE CODE [B@BCZK]1118
FAILURE CODE [B@C7NS]1120
FAILURE CODE [B@CENS]1122
FAILURE CODE [B@JANS]1123
FAILURE CODE [CA115]1124
FAILURE CODE [CA122]1128
FAILURE CODE [CA123]1130
FAILURE CODE [CA131]1132
FAILURE CODE [CA132]1134
FAILURE CODE [CA135]1136
FAILURE CODE [CA141]1138
FAILURE CODE [CA144]1140
FAILURE CODE [CA145]1142
FAILURE CODE [CA153]1144
FAILURE CODE [CA154]1146
FAILURE CODE [CA187]1148
FAILURE CODE [CA212]1150
FAILURE CODE [CA213]1152
FAILURE CODE [CA221]1154
FAILURE CODE [CA222]1156
FAILURE CODE [CA227]1158
FAILURE CODE [CA234]1160
FAILURE CODE [CA238]1161
FAILURE CODE [CA239]1162
FAILURE CODE [CA271]1163
FAILURE CODE [CA272]1165
FAILURE CODE [CA273]1166
FAILURE CODE [CA274]1168
FAILURE CODE [CA322]1169
FAILURE CODE [CA323]1171
FAILURE CODE [CA324]1173
FAILURE CODE [CA325]1175
FAILURE CODE [CA331]1177
FAILURE CODE [CA332]1179
FAILURE CODE [CA343]1181
FAILURE CODE [CA351]1184
FAILURE CODE [CA352]1187
FAILURE CODE [CA356]1189
FAILURE CODE [CA357]1191
FAILURE CODE [CA386]1193
FAILURE CODE [CA431]1195
FAILURE CODE [CA432]1198
FAILURE CODE [CA441]1201
FAILURE CODE [CA442]1204
FAILURE CODE [CA449]1207
FAILURE CODE [CA451]1208
FAILURE CODE [CA452]1210
FAILURE CODE [CA515]1212
FAILURE CODE [CA516]1214
FAILURE CODE [CA553]1216
FAILURE CODE [CA555]1217
FAILURE CODE [CA556]1219
FAILURE CODE [CA559]1221
FAILURE CODE [CA595]1226
FAILURE CODE [CA687]1228
FAILURE CODE [CA689]1230
FAILURE CODE [CA691]1232
FAILURE CODE [CA692]1234
FAILURE CODE [CA697]1236
FAILURE CODE [CA698]1237
FAILURE CODE [CA731]1238
FAILURE CODE [CA778]1241
FAILURE CODE [CA1117]1243
FAILURE CODE [CA1135]1246
FAILURE CODE [CA1257]1249
FAILURE CODE [CA1664]1250
FAILURE CODE [CA1691]1252
FAILURE CODE [CA1695]1254
FAILURE CODE [CA1696]1256
FAILURE CODE [CA1843]1258
FAILURE CODE [CA1844]1260
FAILURE CODE [CA1879]1262
FAILURE CODE [CA1881]1264
FAILURE CODE [CA1883]1266
FAILURE CODE [CA1921]1269
FAILURE CODE [CA1922]1271
FAILURE CODE [CA1923]1274
FAILURE CODE [CA1924]1276
FAILURE CODE [CA1925]1278
FAILURE CODE [CA1927]1280
FAILURE CODE [CA1928]1282
FAILURE CODE [CA1942]1284
FAILURE CODE [CA1963]1286
FAILURE CODE [CA1977]1290
FAILURE CODE [CA1993]1292
FAILURE CODE [CA2185]1294
FAILURE CODE [CA2186]1296
FAILURE CODE [CA2249]1298
FAILURE CODE [CA2265]1303
FAILURE CODE [CA2266]1305
FAILURE CODE [CA2271]1307
FAILURE CODE [CA2272]1309
FAILURE CODE [CA2349]1311
FAILURE CODE [CA2353]1313
FAILURE CODE [CA2357]1315
FAILURE CODE [CA2381]1317
FAILURE CODE [CA2382]1319
FAILURE CODE [CA2383]1321
FAILURE CODE [CA2386]1323
FAILURE CODE [CA2387]1325
FAILURE CODE [CA2555]1327
FAILURE CODE [CA2556]1329
FAILURE CODE [CA2637]1331
FAILURE CODE [CA2639]1333
FAILURE CODE [CA2732]1335
FAILURE CODE [CA2733]1337
FAILURE CODE [CA2741]1339
FAILURE CODE [CA2765]1340
FAILURE CODE [CA2777]1341
FAILURE CODE [CA2878]1342
FAILURE CODE [CA2881]1344
FAILURE CODE [CA3133]1347
FAILURE CODE [CA3134]1349
FAILURE CODE [CA3135]1351
FAILURE CODE [CA3167]1354
FAILURE CODE [CA3251]1356
FAILURE CODE [CA3253]1358
FAILURE CODE [CA3254]1361
FAILURE CODE [CA3255]1363
FAILURE CODE [CA3256]1365
FAILURE CODE [CA3311]1367
FAILURE CODE [CA3312]1369
FAILURE CODE [CA3313]1371
FAILURE CODE [CA3314]1372
FAILURE CODE [CA3315]1373
FAILURE CODE [CA3316]1376
FAILURE CODE [CA3317]1377
FAILURE CODE [CA3318]1378
FAILURE CODE [CA3319]1381
FAILURE CODE [CA3321]1382
FAILURE CODE [CA3322]1383
FAILURE CODE [CA3419]1386
FAILURE CODE [CA3421]1388
FAILURE CODE [CA4151]1390
FAILURE CODE [CA4158]1393
FAILURE CODE [CA4161]1395
FAILURE CODE [CA4162]1397
FAILURE CODE [CA4163]1399
FAILURE CODE [CA4259]1401
FAILURE CODE [CA4952]1403
FAILURE CODE [CA5383]1406
FAILURE CODE [CB115]1407
FAILURE CODE [CB187]1411
FAILURE CODE [CB227]1412
FAILURE CODE [CB238]1413
FAILURE CODE [CB239]1415
FAILURE CODE [CB271]1416
FAILURE CODE [CB272]1418
FAILURE CODE [CB273]1419
FAILURE CODE [CB274]1421
FAILURE CODE [CB343]1422
FAILURE CODE [CB352]1425
FAILURE CODE [CB386]1427
FAILURE CODE [CB441]1429
FAILURE CODE [CB442]1432
FAILURE CODE [CB689]1435
FAILURE CODE [CB697]1437
FAILURE CODE [CB698]1438
FAILURE CODE [CB731]1439
FAILURE CODE [CB778]1442
FAILURE CODE [CB1117]1444
FAILURE CODE [CB1257]1447
FAILURE CODE [CB1664]1448
FAILURE CODE [CB1691]1450
FAILURE CODE [CB1695]1452
FAILURE CODE [CB1696]1454
FAILURE CODE [CB1879]1456
FAILURE CODE [CB1881]1458
FAILURE CODE [CB1883]1460
FAILURE CODE [CB1921]1463
FAILURE CODE [CB1922]1465
FAILURE CODE [CB1923]1468
FAILURE CODE [CB1924]1470
FAILURE CODE [CB1925]1472
FAILURE CODE [CB1927]1474
FAILURE CODE [CB1928]1476
FAILURE CODE [CB1963]1478
FAILURE CODE [CB1977]1482
FAILURE CODE [CB1993]1484
FAILURE CODE [CB2265]1487
FAILURE CODE [CB2266]1489
FAILURE CODE [CB2637]1491
FAILURE CODE [CB2639]1493
FAILURE CODE [CB2732]1495
FAILURE CODE [CB2733]1497
FAILURE CODE [CB2741]1499
FAILURE CODE [CB2777]1500
FAILURE CODE [CB2878]1501
FAILURE CODE [CB2881]1503
FAILURE CODE [CB3133]1506
FAILURE CODE [CB3134]1508
FAILURE CODE [CB3135]1510
FAILURE CODE [CB3167]1513
FAILURE CODE [CB3251]1515
FAILURE CODE [CB3253]1517
FAILURE CODE [CB3254]1520
FAILURE CODE [CB3255]1522
FAILURE CODE [CB3256]1524
FAILURE CODE [CB3311]1526
FAILURE CODE [CB3312]1528
FAILURE CODE [CB3313]1530
FAILURE CODE [CB3314]1531
FAILURE CODE [CB3315]1532
FAILURE CODE [CB3316]1535
FAILURE CODE [CB3317]1536
FAILURE CODE [CB3318]1537
FAILURE CODE [CB3319]1540
FAILURE CODE [CB3321]1541
FAILURE CODE [CB3322]1542
FAILURE CODE [CB4151]1545
FAILURE CODE [CB4158]1548
FAILURE CODE [CB4161]1549
FAILURE CODE [CB4162]1551
FAILURE CODE [CB4163]1553
FAILURE CODE [CB4259]1555
FAILURE CODE [CB4952]1557
FAILURE CODE [CB5383]1560
FAILURE CODE [D150KB]1561
FAILURE CODE [D150KZ]1562
FAILURE CODE [D164KY]1563
FAILURE CODE [D19HKZ]1564
FAILURE CODE [D19JKZ]1566
FAILURE CODE [D19QKZ]1567
FAILURE CODE [D1EHKA]1569
FAILURE CODE [D1EHKB]1571
FAILURE CODE [D1EHKY]1573
FAILURE CODE [D1EMKA]1574
FAILURE CODE [D1EMKB]1575
FAILURE CODE [D1EMKY]1576
FAILURE CODE [D1FBKB]1577
FAILURE CODE [D5ZHL6]1579
FAILURE CODE [D5ZKKZ]1581
FAILURE CODE [D862KA]1583
FAILURE CODE [DAF0KT]1584
FAILURE CODE [DAF0MB]1585
FAILURE CODE [DAF0MC]1586
FAILURE CODE [DAF3KK]1587
FAILURE CODE [DAF8KB]1589
FAILURE CODE [DAFDKB]1590
FAILURE CODE [DAFGMC]1592
FAILURE CODE [DAFLKA]1593
FAILURE CODE [DAFLKB]1596
FAILURE CODE [DAFQKR]1599
FAILURE CODE [DAQ0KK]1600
FAILURE CODE [DAQ0KT]1603
FAILURE CODE [DAQ0MC]1604
FAILURE CODE [DAQ1KA]1605
FAILURE CODE [DAQ2KK]1608
FAILURE CODE [DAQ9KQ]1611
FAILURE CODE [DAQLKA]1612
FAILURE CODE [DAQLKB]1615
FAILURE CODE [DAQQKR]1618
FAILURE CODE [DAQRKR]1619
FAILURE CODE [DAQRMA]1620
FAILURE CODE [DAQV00]1621
FAILURE CODE [DAQW00]1622
FAILURE CODE [DAZ9KQ]1623
FAILURE CODE [DAZQKR]1624
FAILURE CODE [DB10KT]1625
FAILURE CODE [DB10MC]1626
FAILURE CODE [DB11KA]1627
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch)1630
FAILURE CODE [DB12KK]1633
FAILURE CODE [DB13KK]1636
FAILURE CODE [DB19KQ]1639
FAILURE CODE [DB1LKA]1640
FAILURE CODE [DB1LKB]1643
FAILURE CODE [DB1QKR]1646
FAILURE CODE [DB1QMA]1647
FAILURE CODE [DB1RKR]1648
FAILURE CODE [DB2QKR]1649
FAILURE CODE [DB2QKR]1655
FAILURE CODE [DB2RKR]1662
FAILURE CODE [DB2RKR]1668
FAILURE CODE [DBC0KT]1675
FAILURE CODE [DBC0MC]1676
FAILURE CODE [DBC1KA]1677
FAILURE CODE [DBC2KK]1680
FAILURE CODE [DBC3KK]1682
FAILURE CODE [DBC9KQ]1685
FAILURE CODE [DBCLKA]1686
FAILURE CODE [DBCLKB]1688
FAILURE CODE [DBCQKR]1690
FAILURE CODE [DBCQMA]1691
FAILURE CODE [DBCRKR]1692
FAILURE CODE [DBV0MC]1693
FAILURE CODE [DBV1KK]1694
FAILURE CODE [DBV6KB]1696
FAILURE CODE [DBV7KB]1698
FAILURE CODE [DBVLKA]1699
FAILURE CODE [DBVLKB]1702
FAILURE CODE [DBVQKR]1705
FAILURE CODE [DBVRKR]1706
FAILURE CODE [DBVVKR]1707
FAILURE CODE [DBVWKR]1708
FAILURE CODE [DDAAL6]1709
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch)1711
FAILURE CODE [DDACL4]1713
FAILURE CODE [DDADKA]1715
FAILURE CODE [DDADKY]1717
FAILURE CODE [DDD7KX]1718
FAILURE CODE [DDP6L4]1720
FAILURE CODE [DDTHKA]1722
FAILURE CODE [DDTJKA]1724
FAILURE CODE [DDTKKA]1726
FAILURE CODE [DDTLKA]1728
FAILURE CODE [DDTMKA]1730
FAILURE CODE [DDTNKA]1732
FAILURE CODE [DDTPKA]1734
FAILURE CODE [DF10KA]1736
FAILURE CODE [DF10KB]1740
FAILURE CODE [DGE5KX]1745
FAILURE CODE [DGF1KX]1747
FAILURE CODE [DGR2KB]1749
FAILURE CODE [DGR6KB]1751
FAILURE CODE [DGR6L8]1752
FAILURE CODE [DGT1KX]1754
FAILURE CODE [DGT4KA]1756
FAILURE CODE [DGT4KB]1758
FAILURE CODE [DGT4KY]1760
FAILURE CODE [DHA4KA]1762
FAILURE CODE [DHAAMA]1764
FAILURE CODE [DHABMA]1765
FAILURE CODE [DHACMA]1766
FAILURE CODE [DHADMA]1767
FAILURE CODE [DHP4KY]1768
FAILURE CODE [DHP4KZ]1770
FAILURE CODE [DHP5KY]1772
FAILURE CODE [DHP5KZ]1774
FAILURE CODE [DHP6KA]1776
FAILURE CODE [DHP6KX]1778
FAILURE CODE [DHP6KY]1780
FAILURE CODE [DHP6KZ]1782
FAILURE CODE [DHP7KA]1784
FAILURE CODE [DHP7KX]1786
FAILURE CODE [DHP7KY]1788
FAILURE CODE [DHP7KZ]1790
FAILURE CODE [DHQ2KX]1792
FAILURE CODE [DHQ4KX]1794
FAILURE CODE [DHT5KX]1796
FAILURE CODE [DHT5L6]1798
FAILURE CODE [DHT8KX]1800
FAILURE CODE [DHT8ZG]1802
FAILURE CODE [DHU2KX]1803
FAILURE CODE [DHU3KX]1805
FAILURE CODE [DHU6KX]1807
FAILURE CODE [DHU7KX]1809
FAILURE CODE [DHU8KX]1811
FAILURE CODE [DHU9KX]1813
FAILURE CODE [DHUCKX]1815
FAILURE CODE [DHUDKX]1818
FAILURE CODE [DHUHKX]1820
FAILURE CODE [DHULKX]1822
FAILURE CODE [DHUMKX]1824
FAILURE CODE [DHUPKX]1826
FAILURE CODE [DHUTKX]1828
FAILURE CODE [DHY9KX]1830
FAILURE CODE [DJF1KA]1832
FAILURE CODE [DK30KX]1834
FAILURE CODE [DK51L5]1836
FAILURE CODE [DK52KX]1839
FAILURE CODE [DK53L8]1841
FAILURE CODE [DK54KX]1843
FAILURE CODE [DK60KX]1845
FAILURE CODE [DKD0L6]1847
FAILURE CODE [DKH0KX]1849
FAILURE CODE [DKH1KX]1851
FAILURE CODE [DLF1KA]1853
FAILURE CODE [DLF1LC]1854
FAILURE CODE [DLF2KA]1856
FAILURE CODE [DLF2LC]1857
FAILURE CODE [DLF6KA]1859
FAILURE CODE [DLF6L3]1860
FAILURE CODE [DLF7KA]1862
FAILURE CODE [DLF7L3]1863
FAILURE CODE [DLF8KA]1865
FAILURE CODE [DLF8L3]1866
FAILURE CODE [DLF8LC]1867
FAILURE CODE [DLF8MA]1869
FAILURE CODE [DLF9KA]1870
FAILURE CODE [DLF9L3]1871
FAILURE CODE [DLF9LC]1872
FAILURE CODE [DLF9MA]1874
FAILURE CODE [DLM3KA]1875
FAILURE CODE [DLM3LC]1876
FAILURE CODE [DLM3MB]1878
FAILURE CODE [DLT3KA]1879
FAILURE CODE [DLT3LC]1880
FAILURE CODE [DPQ1KR]1882
FAILURE CODE [DPQ2KR]1885
FAILURE CODE [DPQ3KR]1888
FAILURE CODE [DSJ0KR]1892
FAILURE CODE [DV00KB]1893
FAILURE CODE [DW2AKA]1895
FAILURE CODE [DW2AKB]1896
FAILURE CODE [DW2AKY]1897
FAILURE CODE [DW2AL1]1898
FAILURE CODE [DW2ALH]1899
FAILURE CODE [DW2BKA]1900
FAILURE CODE [DW2BKB]1901
FAILURE CODE [DW2BKY]1902
FAILURE CODE [DW2BL1]1903
FAILURE CODE [DW2BLH]1904
FAILURE CODE [DW35KZ]1905
FAILURE CODE [DW36KZ]1907
FAILURE CODE [DW4BK4]1909
FAILURE CODE [DW4BMA]1911
FAILURE CODE [DW72KZ]1913
FAILURE CODE [DW73KA]1915
FAILURE CODE [DW73KB]1917
FAILURE CODE [DW73KY]1919
FAILURE CODE [DW78KZ]1920
FAILURE CODE [DW7BKB]1922
FAILURE CODE [DW7BKY]1923
FAILURE CODE [DW7BKZ]1924
FAILURE CODE [DW7NKZ]1925
FAILURE CODE [DWD6KA]1927
FAILURE CODE [DWD6KB]1928
FAILURE CODE [DWD6KY]1930
FAILURE CODE [DWD6MA]1931
FAILURE CODE [DWD7K4]1932
FAILURE CODE [DWD7KA]1933
FAILURE CODE [DWD7KB]1934
FAILURE CODE [DWD7KY]1936
FAILURE CODE [DWD7MA]1937
FAILURE CODE [DWNDKZ]1938
FAILURE CODE [DWNDMA]1940
FAILURE CODE [DWNEKZ]1942
FAILURE CODE [DWNEMA]1944
FAILURE CODE [DWNMKZ]1946
FAILURE CODE [DX11K4]1948
FAILURE CODE [DX11KA]1950
FAILURE CODE [DX11KB]1952
FAILURE CODE [DX11KY]1954
FAILURE CODE [DX11MA]1955
FAILURE CODE [DX13KA]1957
FAILURE CODE [DX13KB]1959
FAILURE CODE [DX13KY]1961
FAILURE CODE [DX16KA]1962
FAILURE CODE [DX16KB]1963
FAILURE CODE [DX16KY]1965
FAILURE CODE [DX21KA]1966
FAILURE CODE [DX21KB]1967
FAILURE CODE [DX21KY]1969
FAILURE CODE [DX21MA]1970
FAILURE CODE [DX22KA]1972
FAILURE CODE [DX22KB]1973
FAILURE CODE [DX22KY]1975
FAILURE CODE [DX22MA]1976
FAILURE CODE [DX23KA]1978
FAILURE CODE [DX23KB]1979
FAILURE CODE [DX23KY]1981
FAILURE CODE [DX23MA]1982
FAILURE CODE [DX24KA]1984
FAILURE CODE [DX24KB]1985
FAILURE CODE [DX24KY]1987
FAILURE CODE [DX24MA]1988
FAILURE CODE [DX25MA]1990
FAILURE CODE [DX26MA]1991
FAILURE CODE [DX37K4]1992
FAILURE CODE [DX37KA]1994
FAILURE CODE [DX37KB]1996
FAILURE CODE [DX37KY]1998
FAILURE CODE [DX37MA]1999
FAILURE CODE [DX38K4]2001
FAILURE CODE [DX38KA]2003
FAILURE CODE [DX38KB]2005
FAILURE CODE [DX38KY]2007
FAILURE CODE [DX38MA]2008
FAILURE CODE [DXH1KA]2010
FAILURE CODE [DXH1KB]2012
FAILURE CODE [DXH1KY]2014
FAILURE CODE [DXH2KA]2015
FAILURE CODE [DXH2KB]2017
FAILURE CODE [DXH2KY]2019
FAILURE CODE [DXH3KA]2022
FAILURE CODE [DXH3KB]2024
FAILURE CODE [DXH3KY]2026
FAILURE CODE [DXH4KA]2029
FAILURE CODE [DXH4KB]2031
FAILURE CODE [DXH4KY]2033
FAILURE CODE [DXH5KA]2036
FAILURE CODE [DXH5KB]2038
FAILURE CODE [DXH5KY]2040
FAILURE CODE [DXH6KA]2043
FAILURE CODE [DXH6KB]2045
FAILURE CODE [DXH6KY]2047
FAILURE CODE [DXH7KA]2050
FAILURE CODE [DXH7KB]2052
FAILURE CODE [DXH7KY]2054
FAILURE CODE [DXHHKA]2056
FAILURE CODE [DXHHKB]2058
FAILURE CODE [DXHHKY]2060
FAILURE CODE [DY30MA]2062
FAILURE CODE [DY30MC]2064
FAILURE CODE [DY30ME]2067
FAILURE CODE [F@BYNR]2069
FAILURE CODE [F@BYNS]2070
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2071
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2071
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2079
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2082
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2084
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2086
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch)2089
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2092
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2094
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2096
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2098
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2101
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2105
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2108
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2110
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2112
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2114
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2115
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2119
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2123
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2126
E-21 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED2128
E-22 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET2131
E-23 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2133
E-24 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2135
E-25 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION2137
E-26 ALARM BUZZER DOES NOT SOUND2138
E-27 ALARM BUZZER DOES NOT STOP SOUNDING2140
E-28 AISS FUNCTION DOES NOT OPERATE PROPERLY2142
E-29 HOIST LEVER DOES NOT OPERATE PROPERLY2144
E-30 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY2146
E-31 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY2149
E-32 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2153
E-33 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP2156
E-34 TAIL LAMP DOES NOT LIGHT UP2159
E-35 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP2162
E-36 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP2164
E-37 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP2166
E-38 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED2168
E-39 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2170
E-40 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED2172
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2173
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2173
FAILURE MODE AND CAUSE TABLE2174
H-1 MACHINE DOES NOT START2183
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)2186
H-3 LOCKUP IS NOT RELEASED2187
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING2188
H-5 GEAR IS NOT SHIFTED UP2190
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS2193
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE2194
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED2195
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2197
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2200
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW2201
H-12 STEERING WHEEL IS HEAVY TO OPERATE2202
H-13 STEERING WHEEL CANNOT BE OPERATED2203
H-14 STEERING WHEEL WAGGLES2204
H-15 FRONT BRAKE DOES NOT WORK ENOUGH2205
H-16 REAR BRAKE DOES NOT WORK ENOUGH2206
H-17 DUMP BODY RISING SPEED IS LOW2208
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE2210
H-19 DUMP BODY DOES NOT MOVE2211
H-20 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2213
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN2214
TROUBLESHOOTING OF ENGINE (S-MODE)2215
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2215
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2216
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2217
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2218
S-4 ENGINE STARTABILITY IS POOR2219
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2221
S-6 ENGINE STOPS DURING OPERATION2223
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2225
S-8 ENGINE LACKS POWER2226
S-9 KDPF GETS CLOGGED IN A SHORT TIME2228
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2230
S-11 OIL BECOMES CONTAMINATED QUICKLY2231
S-12 FUEL CONSUMPTION IS EXCESSIVE2232
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2233
S-14 OIL PRESSURE DROPS2234
S-15 FUEL MIXES INTO ENGINE OIL2235
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2236
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2237
S-18 UNUSUAL NOISE IS HEARD2238
S-19 VIBRATION IS EXCESSIVE2239
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2240
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2241
S-22 ACTIVE REGENERATION TAKES TIME2242
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2243
50 DISASSEMBLY AND ASSEMBLY2245
CONTENTS2246
ABBREVIATIONS2250
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION2255
HOW TO READ THIS MANUAL2255
COATING MATERIALS LIST2257
SPECIAL TOOL LIST2260
DIAGRAMS OF SPECIAL TOOLS2272
ENGINE AND COOLING SYSTEM2277
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2277
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY2277
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY2288
REMOVE AND INSTALL INJECTOR ASSEMBLY2301
PROCEDURE TO REMOVE INJECTOR ASSEMBLY2302
PROCEDURE TO INSTALL INJECTOR ASSEMBLY2324
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2350
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY2350
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY2352
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2354
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY2355
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY2398
REMOVE AND INSTALL EGR VALVE ASSEMBLY2451
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY2451
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY2454
REMOVE AND INSTALL EGR COOLER ASSEMBLY2457
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY2457
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY2466
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2473
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY2473
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY2474
REMOVE AND INSTALL ALTERNATOR BELT2475
PROCEDURE TO REMOVE ALTERNATOR BELT2475
PROCEDURE TO INSTALL ALTERNATOR BELT2476
REMOVE AND INSTALL COOLER ASSEMBLY2478
PROCEDURE TO REMOVE COOLER ASSEMBLY2479
PROCEDURE TO INSTALL COOLER ASSEMBLY2494
REMOVE AND INSTALL RADIATOR2506
PROCEDURE TO REMOVE RADIATOR2506
PROCEDURE TO INSTALL RADIATOR2512
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2519
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2519
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2521
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2524
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY2524
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY2531
REMOVE AND INSTALL ENGINE ASSEMBLY2537
PROCEDURE TO REMOVE ENGINE ASSEMBLY2538
PROCEDURE TO INSTALL ENGINE ASSEMBLY2551
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2564
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL2564
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL2566
REMOVE AND INSTALL ENGINE REAR OIL SEAL2568
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL2568
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL2569
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY2574
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY2574
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY2576
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY2579
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY2579
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY2580
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET)2582
PROCEDURE TO REMOVE KDPF ASSEMBLY2582
PROCEDURE TO INSTALL KDPF ASSEMBLY2586
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET)2591
PROCEDURE TO REMOVE KDPF ASSEMBLY2592
PROCEDURE TO INSTALL KDPF ASSEMBLY2598
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2605
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY2606
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY2611
REMOVE AND INSTALL KCCV ASSEMBLY2619
PROCEDURE TO REMOVE KCCV ASSEMBLY2619
PROCEDURE TO INSTALL KCCV ASSEMBLY2621
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2623
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY2623
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY2625
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2627
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2627
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2628
POWER TRAIN2630
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2630
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2631
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2634
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2638
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2638
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2644
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY2658
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY2660
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY2666
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY2677
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY2678
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY2698
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY2726
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY2726
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY2728
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY2730
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY2730
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY2737
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD2747
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD2747
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD2747
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY2748
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY2748
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY2748
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY2750
DISASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY2750
ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY2750
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2752
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY2752
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2756
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2760
PROCEDURE TO REMOVE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2760
PROCEDURE TO INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2763
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2767
PROCEDURE TO DISASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2767
PROCEDURE TO ASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY2774
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY2783
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY2783
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY2784
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY2786
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2786
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2786
STEERING SYSTEM2787
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY2787
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY2787
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY2789
UNDERCARRIAGE AND FRAME2792
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY2792
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY2792
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY2793
REMOVE AND INSTALL REAR WHEEL ASSEMBLY2795
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY2795
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY2797
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2799
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY2799
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2800
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2801
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2801
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2803
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2805
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY2805
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2805
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2806
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY2806
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY2807
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY2810
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY2810
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY2812
HYDRAULIC SYSTEM2817
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY2817
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY2818
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY2821
WORK EQUIPMENT2827
REMOVE AND INSTALL DUMP BODY ASSEMBLY2827
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY2827
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY2828
CAB AND ITS ATTACHMENTS2831
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY2831
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY2832
PROCEDURE TO INSTALL AIR CONDITIONER ASSEMBLY2838
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY2845
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY2845
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY2847
REMOVE AND INSTALL SEAT BELT2850
PROCEDURE TO REMOVE SEAT BELT2850
PROCEDURE TO INSTALL SEAT BELT2851
ELECTRICAL SYSTEM2852
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2852
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY2852
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY2854
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY2857
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY2857
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY2858
REMOVE AND INSTALL ABS CONTROLLER ASSEMBLY2859
PROCEDURE TO REMOVE ABS CONTROLLER ASSEMBLY2859
PROCEDURE TO INSTALL ABS CONTROLLER ASSEMBLY2860
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY2861
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY2861
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY2862
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2863
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY2863
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY2865
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY2868
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY2868
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY2869
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2870
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR2870
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2871
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2873
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR2873
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR2874
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY2876
PROCEDURE TO REMOVE KOMTRAX PLUS CONTROLLER ASSEMBLY2876
PROCEDURE TO INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY2877
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY2879
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY2879
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY2880
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY2881
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY2881
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY2882
60 MAINTENANCE STANDARD2887
CONTENTS2888
ABBREVIATIONS2889
ENGINE AND COOLING SYSTEM2894
MAINTENANCE STANDARD FOR ENGINE MOUNT2894
MAINTENANCE STANDARD FOR OUTPUT SHAFT2895
MAINTENANCE STANDARD FOR COOLING FAN PUMP2897
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP2899
MAINTENANCE STANDARD FOR COOLING FAN MOTOR2900
POWER TRAIN2902
MAINTENANCE STANDARD FOR DRIVE SHAFT2902
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT2903
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO2904
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE2908
MAINTENANCE STANDARD FOR TRANSMISSION2910
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE2916
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV2917
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV2918
MAINTENANCE STANDARD FOR FRONT AXLE2919
MAINTENANCE STANDARD FOR REAR AXLE2920
MAINTENANCE STANDARD FOR DIFFERENTIAL2921
MAINTENANCE STANDARD FOR FINAL DRIVE2922
STEERING SYSTEM2923
MAINTENANCE STANDARD FOR STEERING COLUMN2923
MAINTENANCE STANDARD FOR STEERING LINKAGE2924
MAINTENANCE STANDARD FOR DEMAND VALVE2927
MAINTENANCE STANDARD FOR STEERING CYLINDER2930
BRAKE SYSTEM2931
MAINTENANCE STANDARD FOR SLACK ADJUSTER2931
MAINTENANCE STANDARD FOR FRONT BRAKE2932
MAINTENANCE STANDARD FOR REAR BRAKE2933
UNDERCARRIAGE AND FRAME2935
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER2935
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER2937
HYDRAULIC SYSTEM2939
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP2939
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP2940
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP2942
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP2943
MAINTENANCE STANDARD FOR HOIST VALVE2945
WORK EQUIPMENT2947
MAINTENANCE STANDARD FOR HOIST CYLINDER2947
CAB AND ITS ATTACHMENTS2948
MAINTENANCE STANDARD FOR CAB MOUNT2948
80 THE OTHER INFORMATION2949
CONTENTS2950
ABBREVIATIONS2952
AIR CONDITIONER SYSTEM2957
PRECAUTIONS FOR REFRIGERANT2957
AIR CONDITIONER COMPONENT2958
SPECIFICATIONS OF AIR CONDITIONER2960
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2961
OUTLINE OF REFRIGERATION CYCLE2962
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2964
AIR CONDITIONER UNIT2964
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2964
FUNCTION OF AIR CONDITIONER UNIT2965
COMPONENT PARTS OF AIR CONDITIONER UNIT2967
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2967
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2968
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2968
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2968
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2969
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2969
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2969
FUNCTION OF DUAL PRESSURE SWITCH2970
AIR CONDITIONER CONTROLLER2971
STRUCTURE OF AIR CONDITIONER CONTROLLER2971
COMPRESSOR2972
STRUCTURE OF COMPRESSOR2972
SPECIFICATIONS OF COMPRESSOR2972
FUNCTION OF COMPRESSOR2972
CONDENSER2973
STRUCTURE OF CONDENSER2973
SPECIFICATIONS OF CONDENSER2973
FUNCTION OF CONDENSER2973
SENSORS FOR AIR CONDITIONER SYSTEM2975
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2975
FUNCTION OF AMBIENT TEMPERATURE SENSOR2975
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2976
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2978
AIR CONDITIONER SYSTEM DIAGRAM2980
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2981
FUNCTION OF AIR CONDITIONER CONTROLLER2982
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2983
TESTING AIR LEAKAGE (DUCT)2986
METHOD FOR TESTING AIR LEAKAGE (DUCT)2986
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2989
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2990
TEST VENT (MODE) CHANGEOVER2992
METHOD FOR TESTING VENT (MODE) CHANGEOVER2992
TESTING FRESH/RECIRC AIR CHANGEOVER2993
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2993
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2994
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2994
TEST RELAYS2995
METHOD FOR TESTING RELAYS2995
AIR CONDITIONER TROUBLESHOOTING CHART 12996
AIR CONDITIONER TROUBLESHOOTING CHART 22997
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3000
FAILURE CODE [879AKA]3001
FAILURE CODE [879AKB]3002
FAILURE CODE [879BKA]3003
FAILURE CODE [879BKB]3004
FAILURE CODE [879CKA]3006
FAILURE CODE [879CKB]3007
FAILURE CODE [879EMC]3008
FAILURE CODE [879FMC]3009
FAILURE CODE [879GKX]3010
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3011
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3013
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3016
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3018
TROUBLESHOOTING USING GAUGE PRESSURE3020
CONNECTION OF SERVICE TOOL3022
METHOD FOR CONNECTING SERVICE TOOL3022
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3023
HANDLE COMPRESSOR OIL3025
METHOD FOR REPLACING DESICCANT3027
90 CIRCUIT DIAGRAMS3029
CONTENTS3030
ABBREVIATIONS3031
HYDRAULIC CIRCUIT DIAGRAM3036
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3036
HYDRAULIC CIRCUIT DIAGRAM (1/3)3041
HYDRAULIC CIRCUIT DIAGRAM (2/3)3043
HYDRAULIC CIRCUIT DIAGRAM (3/3)3045
POWER TRAIN HYDRAULIC DIAGRAM3047
ELECTRICAL CIRCUIT DIAGRAM3049
ELECTRICAL DIAGRAMS SYMBOLS3049
INTERNAL CAB ELECTRICAL DIAGRAM (1/10)3053
INTERNAL CAB ELECTRICAL DIAGRAM (2/10)3055
INTERNAL CAB ELECTRICAL DIAGRAM (3/10)3057
INTERNAL CAB ELECTRICAL DIAGRAM (4/10)3059
INTERNAL CAB ELECTRICAL DIAGRAM (5/10)3061
INTERNAL CAB ELECTRICAL DIAGRAM (6/10)3063
INTERNAL CAB ELECTRICAL DIAGRAM (7/10)3065
INTERNAL CAB ELECTRICAL DIAGRAM (8/10)3067
INTERNAL CAB ELECTRICAL DIAGRAM (9/10)3069
INTERNAL CAB ELECTRICAL DIAGRAM (10/10)3071
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8)3073
EXTERNAL CAB ELECTRICAL DIAGRAM (2/8)3075
EXTERNAL CAB ELECTRICAL DIAGRAM (3/8)3077
EXTERNAL CAB ELECTRICAL DIAGRAM (4/8)3079
EXTERNAL CAB ELECTRICAL DIAGRAM (5/8)3081
EXTERNAL CAB ELECTRICAL DIAGRAM (6/8)3083
EXTERNAL CAB ELECTRICAL DIAGRAM (7/8)3085
EXTERNAL CAB ELECTRICAL DIAGRAM (8/8)3087
INDEX3089

S.M 30/12/24