Komatsu Dump Truck HD785-8 Shop Manual SEN06772-19 PDF

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Komatsu Dump Truck HD785-8 Shop Manual SEN06772-19 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu Dump Truck HD785-8 Shop Manual SEN06772-19 – PDF DOWNLOAD 

Language : English
Pages :6800
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu Dump Truck HD785-8 Shop Manual SEN06772-19 – PDF DOWNLOAD 

SERIAL NUMBERS 50001 and up

TABLE OF CONTENTS:

Komatsu Dump Truck HD785-8 Shop Manual SEN06772-19 – PDF DOWNLOAD 

SERIAL NUMBERS 50001 and up

Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 28
How to Read the Shop Manual 28
Safety Notice for Operation 30
Precautions to Prevent Fire 38
Procedures If Fire Occurs 40
Precautions for Disposing of Waste Materials 41
Engine Technology to Conform Exhaust Gas Emission 42
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 53
Precautions When You Handle Fuel System Equipment 55
Precautions When You Handle Intake System Equipment 56
Practical Use of KOMTRAX 57
Disconnect and Connect Push-Pull Type Coupler 58
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 60
Precautions for Disconnection and Connection of Connectors 62
How to Disconnect and Connect Deutsch Connector 66
How to Disconnect and Connect Slide Lock Type Connector 67
How to Disconnect and Connect Connector with Lock to Pull 69
How to Disconnect and Connect Connector with Lock to Push 70
How to Disconnect and Connect Connector with Housing to Rotate 72
Standard Tightening Torque Table 73
Conversion Table 80
Abbreviation List 85
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing HD785-8 91
Specifications 93
Specifications HD785-8 93
Weight Table 98
Weight Table HD785-8 98
Fuel, Coolant, Lubricant 100
How to Use Fuel, Coolant and Lubricant to Meet Ambient Temperature (Applicable Machine: 50001 to 50052) 100
How to Use Fuel, Coolant and Lubricant to Meet Ambient Temperature (Applicable Machine: 50053 and up) 102
10 Structure and Function 105
Table of Contents 106
Boot-up System 111
Layout Drawing of Boot-up System 111
Pre-lubrication System 114
Pre-lubrication System Diagram 114
Function of Pre-lubrication System 114
Operation of Pre-lubrication System 115
System Operating Lamp System 117
System Diagram of System Operating Lamp System 117
Function of Operation Lamp System 117
Operation of System Operating Lamp System 117
Battery Disconnect Switch 118
Function of Battery Disconnect Switch 118
Operation of Battery Disconnect Switch 118
Starting Motor Disconnect Switch 119
Function of Starting Motor Disconnect Switch 119
Operation of Starting Motor Disconnect Switch 119
Preheating System 120
System Diagram of Preheating System 120
Function of Automatic Preheating System 120
Operation of Automatic Preheating System 121
Function of Manual Preheating System 121
Operation of Manual Preheating System 121
Engine Shutdown Secondary Switch 122
Function of Engine Shutdown Secondary Switch 122
Operation of Engine Shutdown Secondary Switch 122
Emergency Engine Stop Switch 123
Function of Emergency Engine Stop Switch 123
Operation of Emergency Engine Stop Switch 123
Engine System 124
Layout Drawing of Engine System 124
Engine Control System 126
System Diagram of Engine Control 126
Operation of Engine Control System 127
Engine Power Mode Selector System 128
Engine Power Mode Selector System Diagram 128
Function of Engine Power Mode Selector System 128
Operation of Engine Power Mode Selector System 128
Automatic Idle Stop System 129
Function of Automatic Idle Stop System 129
Operation of Automatic Idle Stop System 129
Component Parts of Engine System 131
Damper 131
VGT 133
EGR System 137
EGR Valve 141
EGR Cooler 143
KCCV System 144
KCCV 146
KDPF 148
Cooling System 152
Layout Drawing of Cooling System 152
Specifications of Cooling System 153
Cooling Fan Control System 154
System Diagram of Cooling Fan Control System 154
Component Parts of Cooling System 159
Cooling Fan, Hoist Pump 159
Cooling Fan Motor 167
Control System 172
Layout Drawing of Control System 172
Layout Drawing of Control System (Machine with Mobile Communication Terminal) 174
Machine Monitor System 176
System Diagram of Machine Monitor System 176
Function of Machine Monitor System 177
Rearview Monitor System 178
System Diagram of Rearview Monitor System 178
Function of Rearview Monitor System 178
KOMTRAX Plus System 179
System Diagram of KOMTRAX Plus System 179
System Diagram of KOMTRAX Plus System (Machine with Mobile Communication Terminal) 181
Function of KOMTRAX Plus System 182
Payload Meter System 186
Layout Drawing of Payload Meter System 186
Payload Meter System Diagram 188
Function of Payload Meter System 189
Measurement Principle of Loading Mass 190
Make Download Function 191
Communication Function with External Device Other Than Data Download 192
Machine Lock-out System 194
Layout Drawing of Machine Lock-out System 194
Machine Lock-out System Drawing 195
Function of Machine Lock-out System 196
Operation of Machine Lock-out System 197
Automatic Suspension System 198
Layout Drawing of Automatic Suspension System 198
Function of Automatic Suspension System 198
Drowsiness Detection System 201
Layout Drawing of Drowsiness Detection System 201
System Diagram of Drowsiness Detection System 202
Function of Drowsiness Detection System 204
Operation of Drowsiness Detection System 205
Component Parts of Control System 206
Machine Monitor 206
Switch Panel 225
Rearview Monitor 226
Rearview Camera 228
KOMTRAX Terminal 229
KOMTRAX Plus Controller 231
Communication Terminal 237
Wireless LAN Unit 238
Transmission Controller 239
Retarder and Hoist Controller 243
Monitor Controller 247
CAN Terminating Resistor 252
Engine Controller 253
ABS Controller 266
Translator Controller 271
Drowsiness Detection Camera 275
Driver Status Monitor 276
Solenoid Valve (Automatic Suspension) 278
Accelerator Pedal 279
Gear Shift Lever 281
Retarder Control Lever 283
Fuel Feed Pump 285
Fuel Feed Pump Switch 286
Hydraulic System 287
Layout Drawing of Hydraulic System 287
Component Parts of Hydraulic System 288
Hydraulic Tank 288
Pump Assembly (Steering, Hoist) 289
Pump Assembly (Power Train) 301
Pump Assembly (Rear Brake Cooling, Brake Charge) 302
Steering, Hoist Filter 304
Hoist Valve 305
Power Train System 311
Layout Drawing of Power Train System 311
Operation of Power Train System 314
Transmission Control System 315
Transmission Control System Diagram 315
Transmission Gear Shift Control System 317
Electric Modulation Function System Diagram 317
Electric Modulation Function 318
Gear Shift Display Function 318
Hunting Prevention Function 318
Transmission Initial Learning and ECMV Current Adjustment Function 318
Transmission Protection Function 319
Gear Shift Lever Positions and Automatic Gear Shift Range 319
Safe Travel Function of Transmission Control System 322
Protection Function of Transmission Control System 322
Self-Diagnosis Function of Transmission Control System 322
Gear Shift Control System 323
Automatic Gear Shift Control of Gear Shift Control System 323
How to Shift in Each Shift Lever Positions of Gear Shift Control System 324
Gear Shift Disabled Time Control of Gear Shift Control System 324
Throttle Limit Function at F1 Start at D Position Setting of Direction Control System 325
Komatsu Traction Control System (KTCS) 326
Komatsu Traction Control System (KTCS) Diagram 326
Function of Komatsu Traction Control System (KTCS) 326
Operation of Komatsu Traction Control System (KTCS) 327
Travel Speed Limitation System 328
System Diagram of Travel Speed Limitation System 328
Function of Travel Speed Limitation System 329
Operation of Travel Speed Limitation System 329
Component Parts of Power Train System 332
Drive Shaft 332
Torque Converter and PTO 333
Transmission 337
Transmission Control Valve 360
Lockup Clutch ECMV 363
H, L, R, 1st, 2nd, 3rd, 4th Clutch ECMV 366
Valve Assembly (Main Pressure Variable, Torque Converter Relief, Main Flow Rate Select) 370
Transmission Lubricating Oil Level Selector Valve 377
Axle 379
Differential 381
Final Drive 383
Work Equipment System 384
Layout Drawing of Work Equipment System 384
Hoist Control System 386
Hoist Control System Diagram 386
Function of Hoist Control System 386
Buddy System 388
Structure of Buddy System 388
Function of Buddy System 389
Operation of Buddy System 389
Component Parts of Work Equipment System 390
Solenoid Valve (Cooling Fan, Hoist Selector) 390
Dump Lever 391
Hoist EPC Valve 395
Steering System 396
Layout Drawing of Steering System 396
Secondary Steering System 397
Secondary Steering System Diagram 397
Function of Secondary Steering System 397
Steering Column 398
Structure of Steering Column 398
Steering Linkage 399
Structure of Steering Linkage 399
Component Parts of Steering System 400
Demand Valve 400
Steering Relief Valve 405
Steering Unit 406
Solenoid Valve (Steering Pump Selector) 411
Cross over Relief Valve 412
Secondary Steering Pump 413
Secondary Steering Motor 414
Brake System 415
Layout Drawing of Brake System 415
Retarder Control 418
Retarder Control System Diagram 418
Function of Retarder Control 419
ARSC System 420
ARSC System Diagram 420
Function of ARSC System 420
ABS 422
Layout Drawing of ABS 422
ABS System Diagram 423
Function of ABS 424
Operation of ABS 425
Component Parts of Brake System 427
Solenoid Valve (Parking Brake) 427
Accumulator Charge Valve 428
Accumulator (Brake Circuit) 432
Brake Valve 433
Secondary Brake Valve 436
Solenoid Valve (Retarder Shut-off) 437
Proportional Pressure Reducing Valve 438
Slack Adjuster 439
Brake Cooling Oil Control Valve 443
Brake 444
Parking Brake 448
Brake Sub-Tank 449
ABS Control Valve 450
ABS Cut Valve 451
Undercarriage and Frame 452
Suspension 452
Structure of Suspension 452
Function of Suspension 453
Front Suspension 454
Function of Front Suspension 454
Rear Suspension 455
Function of Rear Suspension 455
Front Suspension Cylinder 456
Structure of Front Suspension Cylinder 456
Function of Front Suspension Cylinder 459
Operation of Front Suspension Cylinder 459
Rear Suspension Cylinder 462
Structure of Rear Suspension Cylinder 462
Function of Rear Suspension Cylinder 463
Operation of Rear Suspension Cylinder 463
Tires 464
Structure of Radial Tire 464
Function of Radial Tire 464
Work Equipment 465
Structure of Work Equipment 465
Function of Work Equipment 466
CAB Related Parts 467
ROPS CAB 467
Structure of ROPS CAB 467
Function of ROPS CAB 467
CAB Mount 468
Structure of CAB Mount 468
Function of CAB Mount 468
Lifting System 469
Power Ladder System 469
Layout Drawing of Power Ladder System 469
Power Ladder System Diagram 470
Function of Power Ladder System 470
Operation of Power Ladder System 471
Power Ladder System 472
Power Ladder Pump 472
Power Ladder Relief Valve 474
Solenoid Valve (Power Ladder Shock Reduction) 476
Solenoid Valve (Power Ladder Raise and Lower Switch) 477
20 Standard Value Table 479
Table of Contents 480
Standard Value Table for Engine 481
Standard Value Table for Engine HD785-8 481
Standard Value Table for Machine 486
Standard Value Table for Machine HD785-8 486
Machine Posture and Procedures to Measure Performance 506
30 Testing and Adjusting 507
Table of Contents 508
Precautions Before Work 513
Related Information on Testing and Adjusting 514
Tools for Testing and Adjusting 514
Sketch of Tools for Testing and Adjusting 526
Engine and Cooling System 527
Examine Engine Speed 527
How to Examine Engine Speed 527
Examine Boost Pressure 531
How to Examine Boost Pressure on Machine Monitor 531
How to Examine Boost Pressure by Testing Tool 532
Examine Exhaust Gas Temperature 537
How to Examine Exhaust Gas Temperature 537
Examine Exhaust Gas Color 539
How to Examine Exhaust Gas Color with the Handy Smoke Checker 539
How to Examine Exhaust Gas Color with Smoke Meter 542
Examine Mass Air Flow and Temperature Sensor 546
How to Examine Mass Air Flow and Temperature Sensor 546
Examine and Adjust Valve Clearance 552
How to Examine Valve Clearance 552
How to Adjust Valve Clearance 554
Examine Compression Pressure 555
How to Examine Compression Pressure 555
Examine Blowby Pressure 559
How to Examine Blowby Pressure 559
Examine Engine Oil Pressure 564
How to Examine Engine Oil Pressure on Machine Monitor 564
How to Examine Engine Oil Pressure by Testing Tool 564
Examine EGR Valve and VGT Oil Pressure 566
How to Examine EGR Valve and VGT Oil Pressure 566
Examine Fuel Pressure 568
How to Examine Fuel Pressure 568
Examine Fuel Return Rate and Leakage 571
How to Examine Fuel Return Rate and Leakage 572
Bleed Air from Fuel System 578
How to Bleed Air from Fuel System 578
Examine Fuel Circuit for Leakage 580
How to Examine Fuel System for Leakage 580
Examine Low Pressure Circuit Devices 581
How to Examine Low Pressure Circuit Devices 581
Handle Cylinder Cut-out Mode Operation 586
Handle No-Injection Cranking Operation 587
Examine KDPF and Muffler for Looseness and Damage 588
How to Examine KDPF and Muffler for Looseness and Damage 588
Examine Installation of Cylinder Head Cover and Manifolds 589
How to Examine Installed Condition of Cylinder Head covers and Manifolds 589
Examine Engine Piping for Damage and Looseness 590
How to Examine Engine Piping for Damage and Looseness 590
Clean Fuel Doser 591
How to Clean Fuel Doser 591
Write Injector Compensation Value to Engine Controller 594
How to Write Injector Compensation Value 594
Write Correction for Ash in Soot Accumulation to Engine Controller 600
How to Write Correction for Ash in Soot Accumulation to Engine Controller 600
Examine and Adjust Alternator Belt 601
How to Examine Alternator Belt 601
How to Adjust Tension of Alternator Belt 602
Examine and Adjust Air Conditioner Compressor Belt 603
How to Examine Air Conditioner Compressor Belt 603
How to Adjust Air Conditioner Compressor Belt Tension 604
Examine Cooling Fan Speed 605
How to Examine Cooling Fan Speed 605
Power Train 607
Examine Power Train Oil Pressure 607
How to Examine Power Train Oil Pressure 610
Adjust Speed Sensor (Transmission) 627
How to Adjust Speed Sensor (Transmission) 627
Examine After You Adjust Speed Sensor (Transmission) 629
How to Examine After You Adjust Speed Sensor (Transmission) 629
Flush Torque Converter and Transmission Hydraulic Circuit 630
How to Flush Torque Converter and Transmission Hydraulic Circuit 630
Clean Magnet of Final Drive Case 632
How to Clean Final Drive Case Magnet 632
Move Machine Which Has a Trouble in Electrical System 633
How to Move Machine Which Has a Trouble in Engine Control System 633
How to Move Machine Which Has a Trouble in Transmission Control System 635
Steering System 640
Examine Steering Wheel 640
How to Examine Play of Steering Wheel 640
How to Examine Operating Force of Steering Wheel 640
Examine and Adjust Steering Circuit Oil Pressure 642
How to Examine Steering Circuit Oil Pressure 642
How to Adjust Steering Circuit Oil Pressure 642
Examine Outlet Pressure of Demand Valve 644
How to Examine Outlet Pressure of Demand Valve 644
Examine Outlet Pressure of Steering Valve 646
How to Examine Outlet Pressure of Steering Valve 646
Bleed Air from Steering Cylinder Circuit 649
How to Bleed Air from Steering Cylinder Circuit 649
Brake System 651
Release Remained Pressure in Brake Accumulator Circuit 651
How to Release Remained Pressure in Brake Accumulator Circuit 651
Examine Wheel Brake Oil Pressure 652
How to Examine Operating Pressure of Front Brake 652
How to Examine Operating Pressure of Rear Brake 653
How to Examine Operating Pressure of Retarder Brake by Machine Monitor 655
How to Examine Operating Pressure of Retarder Brake by Testing Tool 655
Examine and Adjust Brake Accumulator Charge Pressure 658
How to Examine Brake Accumulator Charge Pressure on Machine Monitor 658
How to Examine Brake Accumulator Charge Pressure by Testing Tool 658
How to Adjust Brake Accumulator Charge Pressure 660
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 661
How to Examine Accumulator Nitrogen Gas Pressure for Brake 662
How to Charge Accumulator Nitrogen Gas for Brake 665
How to Release Nitrogen Gas When You Discard Accumulator 670
Examine Brake Performance 671
How to Examine Foot Brake Performance 671
How to Examine Retarder Brake Performance 671
How to Examine Parking Brake Performance 672
Bleed Air from Brake Circuit 674
How to Bleed Air from Front Brake Circuit 674
How to Bleed Air from Front Brake Circuit (Machine with ABS) 675
How to Bleed Air from Rear Brake Circuit 678
How to Bleed Air from Rear Brake Circuit (Machine with ABS) 679
How to Bleed Air from Parking Brake Circuit 682
Examine Releasing Pressure of Parking Brake 686
How to Examine Releasing Pressure of Parking Brake by Machine Monitor 686
How to Examine Releasing Pressure of Parking Brake on Front Brake Side 686
How to Examine Releasing Pressure of Parking Brake on Rear Brake Side 688
Examine Operating Pressure of Secondary Brake 690
How to Examine Operating Pressure of Secondary Brake 690
Release Parking Brake Manually 691
How to Release Front Parking Brake Manually 691
How to Release Rear Parking Brake Manually 692
Examine Wear of Wheel Brake Disc 694
How to Examine Front Brake Disc Wear Volume 694
How to Examine Rear Brake Disc Wear Volume 695
Hydraulic System 696
Examine and Adjust Hoist Circuit Oil Pressure 696
How to Examine Hoist Circuit Oil Pressure 696
How to Adjust Hoist Circuit Oil Pressure 697
Examine Hoist Cylinder Source Pressure 698
How to Examine Source Pressure of Hoist Cylinder 698
Examine Oil Pressure of Hoist EPC Valve Circuit 700
How to Examine Source Pressure of Hoist EPC Valve 700
How to Examine Outlet Pressure of Hoist EPC Valve 701
Examine Cooling Fan Circuit Oil Pressure 704
How to Examine Cooling Fan Circuit Oil Pressure 704
Examine and Adjust Front Suspension Cylinder 706
How to Examine Front Suspension Cylinder 706
How to Adjust Front Suspension Cylinder 707
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification) 711
How to Examine Front Suspension Cylinder (Automatic Suspension Specification) 711
How to Adjust Front Suspension Cylinder (Automatic Suspension Specification) 712
Examine and Adjust Rear Suspension Cylinder 713
How to Examine Rear Suspension Cylinder 713
How to Adjust Rear Suspension Cylinder 714
Examine Oil Pressure of KTCS Circuit 719
How to Examine Oil Pressure of KTCS Circuit 719
Bleed Air from Hydraulic System 721
How to Bleed Air from Piston Pump 721
How to Bleed Air from Hoist Cylinder 722
Device to Get on or Off Machine 725
Bleed Air from Power Ladder Cylinder 725
How to Bleed Air in Power Ladder Cylinder 725
Calibrate Ladder Position 726
How to Calibrate Ladder Store Position 726
How to Calibrate Ladder Lower Position 726
Work Equipment 728
Examine and Adjust Dump Body Positioner Sensor 728
How to Examine Dump Body Positioner Sensor 728
How to Adjust Dump Body Positioner Sensor 728
Lower Dump Body Manually 730
How to Lower Dump Body Manually 730
How to Lower Dump Body Manually (Machine with 2 Pieces of Forced Lower Valves) 730
Lift Dump Body Manually 732
How to Lift Dump Body Manually 732
Lift Dump Body by Buddy System 733
How to Lift Dump Body by Buddy System 733
CAB Related Parts 737
Adjust Tilt Lock Lever of Steering Wheel 737
How to Adjust Tilt Lock Lever of Steering Wheel 737
Adjust Play of Operator Seat 739
How to Adjust Play of Operator Seat 739
Adjust Door Lock Link 740
How to Adjust Door Lock Link 740
Examine and Adjust Clearance of Escape Door 742
How to Examine Clearance of Escape Door 742
How to Adjust Clearance of Escape Door 742
Electrical System 743
Set and Adjust Each Equipment 743
Set and Operate Machine Monitor 746
Operator Mode 750
Function to Show Operator Identification Input Screen 750
Examine Function by LCD (Liquid Crystal Display) 752
Examine Function of Service Meter and Odometer 752
How to Set Usage Limitation Setting and Change Password 753
Travel Speed Limit Function 756
Service Mode 765
How to Operate Service Mode 765
How to See Pre-defined Monitoring Information 767
How to Examine Monitoring Information 777
Abnormality Record Menu 795
How to See Maintenance Record 801
Maintenance Mode Setting 802
How to Set Phone Number Entry 809
Default Setting Menu 811
Testing Menu 833
Adjustment Menu 848
No-Injection Cranking Operation 870
Set Payload Meter 873
Communication with External Device Specification of Payload Meter System 895
KOMTRAX Settings Menu 903
How to Show Service Message 907
How to Operate Snap Shot Manually 908
How to Start Up KOMTRAX Terminal 913
How to Stop Use of KOMTRAX Terminal 918
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal) 920
Default Setting of KOMTRAX Plus Controller 922
Default Setting of KOMTRAX Plus Controller 922
Default Setting of Wireless LAN Modem 925
Default Setting of Wireless LAN Modem 925
How to Examine Wireless LAN Modem Communication 926
Download Data from KOMTRAX Plus Controller 927
How to Download Data from KOMTRAX Plus Controller 927
How to Download Data from Service Connector in Cab 927
How to Download Data Through the Service Connector Outside Cab (Ground Level Download Specification) 929
How to Download Data from Wireless LAN (Wireless LAN Spec) 930
Adjust After Replacement of KOMTRAX Plus Controller 932
How to Adjust After Replacement of KOMTRAX Plus Controller 932
Adjust After Replacement of Wireless LAN Modem 935
How to Adjust After Replacement of Wireless LAN Modem 935
Setting of Mobile Communication Terminal 938
How to Set Mobile Communication Terminal 938
Set Driver Status Monitor 948
Preparation for Driver Status Monitor Setting 948
How to Set Driver Status Monitor 955
How to Do Operation Check of Driver Status Monitor 957
How to Adjust Drowsiness Detection Camera Angle 958
Adjust Rearview Camera Angle 959
How to Adjust Rearview Camera Angle 959
Set Region of Bluetooth(R) Compatible Radio 960
How to Set Region of Bluetooth(R) Compatible Radio 960
Handle Voltage Circuit of Engine Controller 962
Handle Battery Disconnect Switch 963
Battery Disconnect Switch (Machine with Mobile Communication Terminal) 965
Examine Diodes 967
How to Examine Diodes by Digital Tester 967
How to Examine Diodes by Analog Tester 967
Pm Clinic 968
Pm Clinic Service 968
Pm Clinic Check Sheet HD785-8 971
Perform Quick Pm 982
How to Perform Quick Pm 982
40 Troubleshooting 987
Table of Contents 988
Precautions Before Work1006
Related Information for Troubleshooting1007
General Troubleshooting Points1007
Troubleshooting Points for Aftertreatment System1008
Sequence of Events in Troubleshooting1014
Checks Before Troubleshooting1016
Inspection Procedure Before Troubleshooting1018
Walk-Around Check1018
Test in Accordance with Testing Procedure1020
Examine Fuel Level1020
Examine for Impure Ingredient in Fuel1021
Examine Fuel Prefilter1021
Examine Fuel Main Filter1023
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1025
Examine Coolant Level (Sub-Tank)1026
Examine Air Cleaner Clogging1027
Clean Outer Element1028
Replace Element1030
Examine Hydraulic Oil Level1032
Examine Hydraulic Oil Filter or Hydraulic Oil Strainer1032
Examine Oil Level in Transmission Case1033
Examine Oil Level in Differential Case1034
Examine Oil Level in Final Drive Case1034
Bleed Air from Fuel System1034
Bleed Air from Hydraulic System1034
How to Examine Electric Equipment1034
Preparation for Troubleshooting of Electrical System1041
How to Connect Adapter for Troubleshooting Machine Monitor1041
How to Connect Adapter to Troubleshoot Transmission Controller1041
How to Connect Adapter to Troubleshoot Retarder and Hoist Controller1042
How to Connect Adapter to Troubleshoot Monitor Controller1042
How to Connect Adapter to Troubleshoot KOMTRAX Terminal1045
How to Connect Adapter to Troubleshoot KOMTRAX Plus Controller1045
How to Connect Adapter to Troubleshoot KomVision Controller1046
How to Connect Adapter to Troubleshoot ABS Controller1046
How to Connect Adapter for Troubleshooting Engine Controller1047
How to Connect Connectors for Engine Related Parts1048
How to Disconnect KomVision Radar Connector1052
Procedure for Troubleshooting1054
Symptom and Troubleshooting Numbers1057
Information Shown in Troubleshooting1067
Connectors List1070
Connector List (Machine with KomVision)1091
Connector List (Machine with Mobile Communication Terminal)1094
Connector List (Machine with Power Ladder)1095
Connector List (Machine with Drowsiness Detection System)1097
Connector Layout1098
Connector Contact Connection Table1117
T-Branch Box and T-Branch Adapter Table1164
Fuse Location Table1170
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1175
Prepare Troubleshoot Machine Monitor1179
Procedure to Make Harness Checker on Machine Monitor LCD Unit1181
Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1186
Failure Code Table1188
Troubleshooting by Failure Code (Display of Code)1222
Failure Code [1500L0]1222
Failure Code [15B0NX]1223
Failure Code [15F0KM]1227
Failure Code [15F0MB]1228
Failure Code [15F7KM]1229
Failure Code [15G0MW]1230
List of Number of Gear Shift When Failure is Found1231
Failure Code [15G7KM]1232
Failure Code [15H0MW]1233
List of Number of Gear Shift When Failure is Found1234
Failure Code [15J0MW]1235
List of Number of Gear Shift When Failure is Found1236
Failure Code [15K0MW]1237
List of Number of Gear Shift When Failure is Found1238
Failure Code [15L0MW]1239
List of Number of Gear Shift When Failure is Found1240
Failure Code [15M0MW]1241
List of Number of Gear Shift When Failure is Found1242
Failure Code [15N0MW]1243
List of Number of Gear Shift When Failure is Found1244
Failure Code [15SBL1]1245
List of Number of Gear Shift When Failure is Found1247
Failure Code [15SBMA]1249
List of Number of Gear Shift When Failure is Found1250
Failure Code [15SCL1]1251
List of Number of Gear Shift When Failure is Found1253
Failure Code [15SCMA]1255
List of Number of Gear Shift When Failure is Found1256
Failure Code [15SDL1]1257
List of Number of Gear Shift When Failure is Found1259
Failure Code [15SDMA]1261
List of Number of Gear Shift When Failure is Found1262
Failure Code [15SEL1]1263
List of Number of Gear Shift When Failure is Found1265
Failure Code [15SEMA]1267
List of Number of Gear Shift When Failure is Found1268
Failure Code [15SFL1]1270
List of Number of Gear Shift When Failure is Found1272
Failure Code [15SFMA]1274
List of Number of Gear Shift When Failure is Found1275
Failure Code [15SGL1]1277
List of Number of Gear Shift When Failure is Found1279
Failure Code [15SGMA]1281
List of Number of Gear Shift When Failure is Found1282
Failure Code [15SHL1]1284
List of Number of Gear Shift When Failure is Found1286
Failure Code [15SHMA]1288
List of Number of Gear Shift When Failure is Found1289
Failure Code [15SJMA]1290
Failure Code [2C4MNX]1292
Failure Code [2F00KM]1296
Failure Code [2G42ZG]1300
Failure Code [2G43ZG]1302
Failure Code [6014NX]1304
Failure Code [879AKA]1307
Failure Code [879AKB]1308
Failure Code [879BKA]1309
Failure Code [879BKB]1312
Failure Code [879CKA]1315
Failure Code [879CKB]1316
Failure Code [879EMC]1317
Failure Code [879FMC]1318
Failure Code [879GKX]1319
Failure Code [989D00]1322
Failure Code [989L00]1324
Failure Code [989M00]1325
Failure Code [989N00]1326
Failure Code [989X00]1327
Failure Code [989Y00]1328
Failure Code [98A000]1330
Failure Code [98A100]1331
Failure Code [98A200]1332
Failure Code [98A300]1333
Failure Code [98A400]1334
Failure Code [98A500]1335
Failure Code [98A600]1336
Failure Code [A1U0N3]1337
Failure Code [A1U0N4]1341
Failure Code [AA10NX]1345
Failure Code [AB00KE]1348
Failure Code [AB00KY]1352
Failure Code [AQ10N3]1354
Failure Code [B@BAZG]1357
Failure Code [B@BAZK]1360
Failure Code [B@BCNS]1363
Failure Code [B@BCQA]1366
Failure Code [B@BCZK]1369
Failure Code [B@C6NS]1372
Failure Code [B@C7NS]1375
Failure Code [B@CENS]1378
Failure Code [B@JANS]1381
Failure Code [CA115]1384
Failure Code [CA122]1389
Failure Code [CA123]1392
Failure Code [CA131]1396
Failure Code [CA132]1399
Failure Code [CA135]1402
Failure Code [CA141]1405
Failure Code [CA144]1408
Failure Code [CA145]1411
Failure Code [CA153]1414
Failure Code [CA154]1418
Failure Code [CA187]1422
Failure Code [CA212]1426
Failure Code [CA213]1429
Failure Code [CA221]1432
Failure Code [CA222]1435
Failure Code [CA227]1439
Failure Code [CA234]1442
Failure Code [CA238]1444
Failure Code [CA239]1447
Failure Code [CA271]1450
Failure Code [CA272]1453
Failure Code [CA273]1455
Failure Code [CA274]1458
Failure Code [CA322]1460
Failure Code [CA323]1463
Failure Code [CA324]1466
Failure Code [CA325]1469
Failure Code [CA331]1472
Failure Code [CA332]1475
Failure Code [CA343]1478
Failure Code [CA351]1484
Failure Code [CA352]1490
Failure Code [CA356]1494
Failure Code [CA357]1498
Failure Code [CA386]1502
Failure Code [CA431]1506
Failure Code [CA432]1511
Failure Code [CA441]1516
Failure Code [CA442]1519
Failure Code [CA449]1522
Failure Code [CA451]1525
Failure Code [CA452]1528
Failure Code [CA515]1531
Failure Code [CA516]1533
Failure Code [CA553]1536
Failure Code [CA555]1539
Failure Code [CA556]1542
Failure Code [CA559]1545
Failure Code [CA595]1551
Failure Code [CA687]1554
Failure Code [CA689]1558
Failure Code [CA691]1563
Failure Code [CA692]1566
Failure Code [CA697]1569
Failure Code [CA698]1571
Failure Code [CA731]1573
Failure Code [CA778]1582
Failure Code [CA1117]1587
Failure Code [CA1135]1591
Failure Code [CA1257]1602
Failure Code [CA1664]1604
Loaded Diagnostics Operation to Clear Failure Code1606
Failure Code [CA1691]1608
Failure Code [CA1695]1613
Failure Code [CA1696]1616
Failure Code [CA1843]1619
Failure Code [CA1844]1622
Failure Code [CA1879]1625
Failure Code [CA1881]1628
Failure Code [CA1883]1632
Loaded Diagnostics Operation to Clear Failure Code1635
Failure Code [CA1921]1637
Failure Code [CA1922]1645
Failure Code [CA1923]1652
Failure Code [CA1924]1655
Diagram Related to Fuel Doser1658
Failure Code [CA1925]1660
Diagram Related to Fuel Doser1662
Failure Code [CA1927]1664
Failure Code [CA1928]1667
Failure Code [CA1942]1670
Failure Code [CA1963]1673
Diagram Related to Fuel Doser1679
Failure Code [CA1977]1681
Loaded Diagnostics Operation to Clear Failure Code1684
Failure Code [CA1993]1685
Loaded Diagnostics Operation to Clear Failure Code1687
Failure Code [CA2185]1689
Failure Code [CA2186]1691
Failure Code [CA2249]1694
Failure Code [CA2265]1701
Failure Code [CA2266]1704
Failure Code [CA2271]1707
Failure Code [CA2272]1710
Failure Code [CA2349]1714
Failure Code [CA2353]1717
Failure Code [CA2357]1719
Failure Code [CA2381]1724
Failure Code [CA2382]1727
Failure Code [CA2383]1731
Failure Code [CA2386]1735
Failure Code [CA2387]1737
Failure Code [CA2555]1747
Failure Code [CA2556]1751
Failure Code [CA2637]1754
Failure Code [CA2639]1761
Failure Code [CA2732]1769
Failure Code [CA2733]1772
Failure Code [CA2741]1775
Diagram Related to Fuel Doser1776
Failure Code [CA2765]1778
Failure Code [CA2777]1780
Failure Code [CA2878]1783
Diagram Related to Fuel Doser1787
Failure Code [CA2881]1789
Loaded Diagnostics Operation to Clear Failure Code1793
Failure Code [CA3133]1796
Failure Code [CA3134]1799
Failure Code [CA3135]1802
Loaded Diagnostics Operation to Clear Failure Code1804
Failure Code [CA3167]1807
How to Reset Fuel Doser Information1810
Failure Code [CA3251]1813
Loaded Diagnostics Operation to Clear Failure Code1820
Failure Code [CA3253]1821
Loaded Diagnostics Operation to Clear Failure Code1829
Failure Code [CA3254]1831
Loaded Diagnostics Operation to Clear Failure Code1838
Failure Code [CA3255]1839
Loaded Diagnostics Operation to Clear Failure Code1846
Failure Code [CA3256]1848
Loaded Diagnostics Operation to Clear Failure Code1855
Failure Code [CA3311]1856
Loaded Diagnostics Operation to Confirm Failure Correction1863
Failure Code [CA3312]1865
Loaded Diagnostics Operation to Confirm Failure Correction1872
Failure Code [CA3313]1874
Failure Code [CA3314]1877
Failure Code [CA3315]1880
Loaded Diagnostics Operation to Confirm Failure Correction1885
Failure Code [CA3316]1887
Failure Code [CA3317]1890
Failure Code [CA3318]1893
Loaded Diagnostics Operation to Confirm Failure Correction1898
Failure Code [CA3319]1900
Failure Code [CA3321]1903
Failure Code [CA3322]1906
Loaded Diagnostics Operation to Confirm Failure Correction1911
Failure Code [CA3419]1913
Failure Code [CA3421]1915
Failure Code [CA4151]1918
Failure Code [CA4158]1925
Failure Code [CA4161]1928
Failure Code [CA4162]1931
Failure Code [CA4163]1934
Loaded Diagnostics Operation to Confirm Failure Correction1936
Failure Code [CA4259]1937
Failure Code [CA4952]1940
Failure Code [CA5383]1943
Failure Code [CB115]1945
Failure Code [CB122]1950
Failure Code [CB123]1953
Failure Code [CB153]1957
Failure Code [CB154]1961
Failure Code [CB187]1965
Failure Code [CB227]1969
Failure Code [CB238]1972
Failure Code [CB239]1975
Failure Code [CB271]1978
Failure Code [CB272]1981
Failure Code [CB273]1983
Failure Code [CB274]1986
Failure Code [CB343]1988
Failure Code [CB351]1994
Failure Code [CB352]2000
Failure Code [CB356]2004
Failure Code [CB357]2008
Failure Code [CB386]2012
Failure Code [CB441]2015
Failure Code [CB442]2018
Failure Code [CB449]2021
Failure Code [CB451]2024
Failure Code [CB452]2027
Failure Code [CB515]2030
Failure Code [CB516]2032
Failure Code [CB553]2035
Failure Code [CB555]2038
Failure Code [CB556]2041
Failure Code [CB559]2044
Failure Code [CB595]2050
Failure Code [CB687]2053
Failure Code [CB689]2057
Failure Code [CB691]2062
Failure Code [CB692]2065
Failure Code [CB697]2068
Failure Code [CB698]2070
Failure Code [CB731]2072
Failure Code [CB778]2081
Failure Code [CB1117]2086
Failure Code [CB1257]2090
Failure Code [CB1548]2092
Failure Code [CB1549]2095
Failure Code [CB1551]2098
Failure Code [CB1552]2101
Failure Code [CB1553]2104
Failure Code [CB1622]2107
Failure Code [CB1664]2110
Loaded Diagnostics Operation to Clear Failure Code2112
Failure Code [CB1691]2114
Failure Code [CB1695]2119
Failure Code [CB1696]2122
Failure Code [CB1843]2125
Failure Code [CB1844]2128
Failure Code [CB1879]2131
Failure Code [CB1881]2134
Failure Code [CB1883]2138
Loaded Diagnostics Operation to Clear Failure Code2141
Failure Code [CB1921]2143
Failure Code [CB1922]2151
Failure Code [CB1923]2158
Failure Code [CB1924]2161
Diagram Related to Fuel Doser2164
Failure Code [CB1925]2166
Diagram Related to Fuel Doser2168
Failure Code [CB1927]2170
Failure Code [CB1928]2173
Failure Code [CB1942]2177
Failure Code [CB1963]2180
Diagram Related to Fuel Doser2186
Failure Code [CB1977]2188
Loaded Diagnostics Operation to Clear Failure Code2191
Failure Code [CB1993]2192
Loaded Diagnostics Operation to Clear Failure Code2194
Failure Code [CB2249]2196
Failure Code [CB2265]2202
Failure Code [CB2266]2205
Failure Code [CB2271]2208
Failure Code [CB2272]2211
Failure Code [CB2349]2215
Failure Code [CB2353]2218
Failure Code [CB2357]2220
Failure Code [CB2381]2225
Failure Code [CB2382]2228
Failure Code [CB2383]2232
Failure Code [CB2386]2236
Failure Code [CB2387]2238
Failure Code [CB2637]2248
Failure Code [CB2639]2255
Failure Code [CB2732]2264
Failure Code [CB2733]2267
Failure Code [CB2741]2270
Diagram Related to Fuel Doser2271
Failure Code [CB2765]2273
Failure Code [CB2777]2275
Failure Code [CB2878]2278
Diagram Related to Fuel Doser2282
Failure Code [CB2881]2284
Loaded Diagnostics Operation to Clear Failure Code2288
Failure Code [CB3133]2291
Failure Code [CB3134]2294
Failure Code [CB3135]2297
Loaded Diagnostics Operation to Clear Failure Code2299
Failure Code [CB3167]2301
How to Reset Fuel Doser Information2304
Failure Code [CB3251]2307
Loaded Diagnostics Operation to Clear Failure Code2314
Failure Code [CB3253]2315
Loaded Diagnostics Operation to Clear Failure Code2323
Failure Code [CB3254]2325
Loaded Diagnostics Operation to Clear Failure Code2332
Failure Code [CB3255]2333
Loaded Diagnostics Operation to Clear Failure Code2340
Failure Code [CB3256]2342
Loaded Diagnostics Operation to Clear Failure Code2349
Failure Code [CB3311]2350
Loaded Diagnostics Operation to Confirm Failure Correction2357
Failure Code [CB3312]2359
Loaded Diagnostics Operation to Confirm Failure Correction2366
Failure Code [CB3313]2368
Failure Code [CB3314]2371
Failure Code [CB3315]2374
Loaded Diagnostics Operation to Confirm Failure Correction2378
Failure Code [CB3316]2380
Failure Code [CB3317]2383
Failure Code [CB3318]2386
Loaded Diagnostics Operation to Confirm Failure Correction2391
Failure Code [CB3319]2393
Failure Code [CB3321]2396
Failure Code [CB3322]2399
Loaded Diagnostics Operation to Confirm Failure Correction2404
Failure Code [CB3419]2406
Failure Code [CB3421]2408
Failure Code [CB4151]2411
Failure Code [CB4158]2418
Failure Code [CB4161]2421
Failure Code [CB4162]2424
Failure Code [CB4163]2427
Loaded Diagnostics Operation to Confirm Failure Correction2429
Failure Code [CB4259]2430
Failure Code [CB4952]2433
Failure Code [CB5383]2436
Failure Code [D018KB]2438
Failure Code [D018KY]2440
Failure Code [D019KB]2442
Failure Code [D019KY]2444
Failure Code [D150KB]2446
Failure Code [D150KZ]2449
Failure Code [D164KY]2452
Failure Code [D180KA]2455
Failure Code [D180KB]2458
Failure Code [D180KY]2461
Failure Code [D19HKZ]2463
Failure Code [D19JKZ]2466
Failure Code [D19QKZ]2469
Failure Code [D1EFKA]2472
Failure Code [D1EFKB]2475
Failure Code [D1EFKY]2478
Failure Code [D1EHKA]2480
Failure Code [D1EHKB]2483
Failure Code [D1EHKY]2486
Failure Code [D1EMKA]2488
Failure Code [D1EMKB]2491
Failure Code [D1EMKY]2494
Failure Code [D1ENKZ]2496
Failure Code [D1EPKA]2499
Failure Code [D1EPKB]2502
Failure Code [D1EPKY]2505
Failure Code [D1EQKA]2507
Failure Code [D1EQKB]2510
Failure Code [D1EQKY]2513
Failure Code [D1ERKA]2515
Failure Code [D1ERKB]2518
Failure Code [D1ERKY]2521
Failure Code [D1ESKA]2523
Failure Code [D1ESKB]2526
Failure Code [D1ESKY]2529
Failure Code [D1EWKA]2531
Failure Code [D1EWKB]2534
Failure Code [D1EWKY]2537
Failure Code [D1FBKB]2539
Failure Code [D1J0KB]2542
Failure Code [D5WNKZ]2545
Failure Code [D5ZHL6]2547
Failure Code [D862KA]2550
Failure Code [DAF0KT]2553
Failure Code [DAF0MB]2554
Failure Code [DAF0MC]2555
Failure Code [DAF3KK]2556
Failure Code [DAF8KB]2561
Failure Code [DAFDKB]2564
Failure Code [DAFGMC]2567
Failure Code [DAFLKA]2568
Failure Code [DAFLKB]2572
Failure Code [DAFQKR]2575
Failure Code [DAQ0KK]2589
Failure Code [DAQ0KT]2593
Failure Code [DAQ0MC]2595
Failure Code [DAQ1KA]2596
Failure Code [DAQ2KK]2599
Failure Code [DAQ9KQ]2603
Failure Code [DAQLKA]2605
Failure Code [DAQLKB]2609
Failure Code [DAQQKR]2612
Failure Code [DAQRKR]2627
Failure Code [DAQRMA]2641
Failure Code [DAQV00]2643
Failure Code [DAQW00]2645
Failure Code [DAZ9KQ]2646
Failure Code [DAZQKR]2648
Failure Code [DB10KT]2662
Failure Code [DB10MC]2663
Failure Code [DB11KA]2664
Failure Code [DB12KK]2667
Failure Code [DB13KK]2671
Failure Code [DB19KQ]2675
Failure Code [DB1LKA]2677
Failure Code [DB1LKB]2681
Failure Code [DB1QKR]2684
Failure Code [DB1QMA]2699
Failure Code [DB1RKR]2701
Failure Code [DB2QKR]2715
Failure Code [DB2RKR]2733
Failure Code [DBC0KT]2748
Failure Code [DBC0MC]2749
Failure Code [DBC1KA]2750
Failure Code [DBC2KK]2753
Failure Code [DBC3KK]2757
Failure Code [DBC9KQ]2761
Failure Code [DBCLKA]2763
Failure Code [DBCLKB]2767
Failure Code [DBCQKR]2770
Failure Code [DBCQMA]2784
Failure Code [DBCRKR]2785
Failure Code [DBP0KM]2797
Failure Code [DBP0KT]2799
Failure Code [DBP0NR]2802
Failure Code [DBP5KP]2803
Failure Code [DBPLKA]2807
Failure Code [DBPLKB]2811
Failure Code [DBPQKR]2814
Failure Code [DBPRKR]2828
Failure Code [DBPRMA]2841
Failure Code [DBPUKR]2843
Failure Code [DBPVKR]2853
Failure Code [DBPWKR]2863
Failure Code [DBPXKR]2865
Failure Code [DBV0MC]2868
Failure Code [DBV1KK]2869
Failure Code [DBV6KB]2873
Failure Code [DBV7KB]2878
Failure Code [DBV8KB]2881
Failure Code [DBVLKA]2884
Failure Code [DBVLKB]2888
Failure Code [DBVQKR]2891
Failure Code [DBVRKR]2906
Failure Code [DBVVKR]2920
Failure Code [DBVWKR]2922
Failure Code [DCR0MC]2924
Failure Code [DCR2KK]2925
Failure Code [DCR8L4]2929
Failure Code [DCR9KQ]2933
Failure Code [DCRLKA]2935
Failure Code [DCRLKB]2939
Failure Code [DCRQKR]2941
Failure Code [DCRRKR]2956
Failure Code [DDAAL6]2970
Failure Code [DDACL4]2974
Failure Code [DDADKA]2979
Failure Code [DDADKY]2982
Failure Code [DDD7KX]2985
Failure Code [DDDGL4]2989
Failure Code [DDDHL4]2992
Failure Code [DDE2KB]2995
Failure Code [DDE2L6]2998
Failure Code [DDP6L4]3001
Failure Code [DDTHKA]3005
Failure Code [DDTJKA]3008
Failure Code [DDTKKA]3011
Failure Code [DDTLKA]3014
Failure Code [DDTMKA]3017
Failure Code [DDTNKA]3020
Failure Code [DDTPKA]3023
Failure Code [DDU1KA]3026
Failure Code [DF10KA]3029
Failure Code [DF10KB]3035
Failure Code [DGE5KX]3040
Failure Code [DGF1KX]3044
Failure Code [DGR2KB]3048
Failure Code [DGR2L8]3051
Failure Code [DGR4KB]3054
Failure Code [DGR4L8]3057
Failure Code [DGR6KB]3060
Failure Code [DGR6L8]3063
Failure Code [DGT1KX]3066
Failure Code [DGT5KY]3070
Failure Code [DGT5KZ]3074
Failure Code [DGT6KY]3079
Failure Code [DGT6KZ]3083
Failure Code [DHAAMA]3088
Failure Code [DHABMA]3090
Failure Code [DHACMA]3092
Failure Code [DHADMA]3094
Failure Code [DHP4KY]3096
Failure Code [DHP4KZ]3099
Failure Code [DHP5KY]3103
Failure Code [DHP5KZ]3106
Failure Code [DHP6KA]3110
Failure Code [DHP6KX]3115
Failure Code [DHP6KY]3119
Failure Code [DHP6KZ]3122
Failure Code [DHP7KA]3126
Failure Code [DHP7KX]3131
Failure Code [DHP7KY]3136
Failure Code [DHP7KZ]3139
Failure Code [DHQ2KX]3143
Failure Code [DHQ4KX]3147
Failure Code [DHQ6KX]3151
Failure Code [DHT5KX]3155
Failure Code [DHT5L6]3158
Failure Code [DHT8KX]3160
Failure Code [DHT8ZG]3164
Failure Code [DHU2KX]3167
Failure Code [DHU3KX]3171
Failure Code [DHU6KX]3175
Failure Code [DHU7KX]3179
Failure Code [DHU8KX]3183
Failure Code [DHU9KX]3187
Failure Code [DHUBKX]3191
Failure Code [DHUCKX]3195
Failure Code [DHUDKX]3199
Failure Code [DHUHKX]3203
Failure Code [DHULKX]3207
Failure Code [DHUMKX]3211
Failure Code [DHUQKX]3215
Failure Code [DHUTKX]3219
Failure Code [DHY9KX]3223
Failure Code [DJF1KA]3226
Failure Code [DK30KX]3229
Failure Code [DK51L5]3233
Failure Code [DK52KX]3241
Failure Code [DK53L8]3245
Failure Code [DK54KX]3248
Failure Code [DK5VKX]3252
Failure Code [DK5VMA]3255
Failure Code [DK60KX]3257
Failure Code [DKD0L6]3261
Failure Code [DKH0KX]3265
Failure Code [DKH1KX]3268
Failure Code [DKR2KY]3272
Failure Code [DKR2KZ]3275
Failure Code [DLF1KA]3278
Failure Code [DLF1LC]3281
Failure Code [DLF2KA]3285
Failure Code [DLF2LC]3288
Failure Code [DLF6L3]3292
Failure Code [DLF7L3]3296
Failure Code [DLF8L3]3300
Failure Code [DLF8LC]3305
Failure Code [DLF9L3]3309
Failure Code [DLF9LC]3314
Failure Code [DLM3KA]3318
Failure Code [DLM3LC]3320
Failure Code [DLM3MB]3323
Failure Code [DLT3KA]3325
Failure Code [DLT3LC]3327
Failure Code [DPQ1KR]3330
Failure Code [DPQ1LD]3336
Failure Code [DPQ2KR]3342
Failure Code [DPQ3KR]3348
Failure Code [DPQ4KB]3354
Failure Code [DQ11KQ]3357
Sensor Addresses List3361
Failure Code [DQ11KR]3362
Failure Code [DQ11KT]3365
Failure Code [DQ11MA]3368
Failure Code [DQ11NR]3373
Failure Code [DQ12KQ]3376
Sensor Addresses List3380
Failure Code [DQ12KR]3381
Failure Code [DQ12KT]3384
Failure Code [DQ12MA]3387
Failure Code [DQ12NR]3392
Failure Code [DQ13KQ]3395
Sensor Addresses List3399
Failure Code [DQ13KR]3400
Failure Code [DQ13KT]3403
Failure Code [DQ13MA]3406
Failure Code [DQ13NR]3411
Failure Code [DQ14KQ]3414
Sensor Addresses List3418
Failure Code [DQ14KR]3419
Failure Code [DQ14KT]3422
Failure Code [DQ14MA]3425
Failure Code [DQ14NR]3430
Failure Code [DQ15KQ]3433
Sensor Addresses List3437
Failure Code [DQ15KR]3438
Failure Code [DQ15KT]3441
Failure Code [DQ15MA]3444
Failure Code [DQ15NR]3449
Failure Code [DQ16KQ]3452
Sensor Addresses List3456
Failure Code [DQ16KR]3457
Failure Code [DQ16KT]3460
Failure Code [DQ16MA]3463
Failure Code [DQ16NR]3468
Failure Code [DQ17KQ]3471
Sensor Addresses List3475
Failure Code [DQ17KR]3476
Failure Code [DQ17KT]3479
Failure Code [DQ17MA]3482
Failure Code [DQ17NR]3487
Failure Code [DQ18KQ]3490
Sensor Addresses List3494
Failure Code [DQ18KR]3495
Failure Code [DQ18KT]3498
Failure Code [DQ18MA]3501
Failure Code [DQ18NR]3506
Failure Code [DR10KA]3509
Failure Code [DR20KA]3513
Failure Code [DR30KA]3517
Failure Code [DR40KA]3521
Failure Code [DR50KA]3525
Failure Code [DR60KA]3529
Failure Code [DR81KR]3533
Failure Code [DR81MA]3543
Failure Code [DSJ0KR]3544
Failure Code [DUMBKB]3557
Failure Code [DV00KB]3560
Failure Code [DV01KB]3563
Failure Code [DV03KB]3566
Failure Code [DV03KY]3569
Failure Code [DW2AKA]3571
Failure Code [DW2AKB]3574
Failure Code [DW2AKY]3577
Failure Code [DW2AL1]3579
Failure Code [DW2ALH]3582
Failure Code [DW2BKA]3585
Failure Code [DW2BKB]3588
Failure Code [DW2BKY]3591
Failure Code [DW2BL1]3593
Failure Code [DW2BLH]3596
Failure Code [DW2CKA]3599
Failure Code [DW2CKB]3601
Failure Code [DW2CKY]3604
Failure Code [DW2CL1]3606
Failure Code [DW2CLH]3609
Failure Code [DW35KZ]3612
Failure Code [DW36KZ]3615
Failure Code [DW4BK4]3618
Failure Code [DW4BMA]3622
Failure Code [DW72KZ]3626
Failure Code [DW73KA]3629
Failure Code [DW73KB]3631
Failure Code [DW73KY]3634
Failure Code [DW78KZ]3636
Failure Code [DW7BKB]3640
Failure Code [DW7BKY]3643
Failure Code [DW7BKZ]3645
Failure Code [DW7MKB]3647
Failure Code [DW7MKY]3650
Failure Code [DW7MKZ]3652
Failure Code [DW7NKZ]3654
Failure Code [DWD6KA]3657
Failure Code [DWD6KB]3659
Failure Code [DWD6KY]3662
Failure Code [DWD6MA]3664
Failure Code [DWD7K4]3668
Failure Code [DWD7KA]3671
Failure Code [DWD7KB]3673
Failure Code [DWD7KY]3676
Failure Code [DWD7MA]3678
Failure Code [DWNJKZ]3681
Failure Code [DWNLKA]3684
Failure Code [DWNLKB]3686
Failure Code [DWNLKY]3689
Failure Code [DWNMKZ]3691
Failure Code [DWPQKZ]3694
Failure Code [DWPQMA]3697
Failure Code [DWPRKZ]3702
Failure Code [DWPRMA]3705
Failure Code [DWPSKZ]3710
Failure Code [DWPSMA]3713
Failure Code [DWPTKZ]3718
Failure Code [DWPTMA]3721
Failure Code [DX13KA]3726
Failure Code [DX13KB]3728
Failure Code [DX13KY]3731
Failure Code [DX16KA]3733
Failure Code [DX16KB]3735
Failure Code [DX16KY]3738
Failure Code [DX21KA]3740
Failure Code [DX21KB]3742
Failure Code [DX21KY]3745
Failure Code [DX21MA]3747
Failure Code [DX22KA]3751
Failure Code [DX22KB]3753
Failure Code [DX22KY]3756
Failure Code [DX22MA]3758
Failure Code [DX23KA]3762
Failure Code [DX23KB]3764
Failure Code [DX23KY]3767
Failure Code [DX23MA]3769
Failure Code [DX24KA]3773
Failure Code [DX24KB]3775
Failure Code [DX24KY]3778
Failure Code [DX24MA]3780
Failure Code [DX25MA]3784
Failure Code [DX26MA]3786
Failure Code [DX30K4]3788
Failure Code [DX30KA]3791
Failure Code [DX30KB]3793
Failure Code [DX30KY]3796
Failure Code [DX30MA]3798
Failure Code [DX33K4]3801
Failure Code [DX33KA]3804
Failure Code [DX33KB]3806
Failure Code [DX33KY]3809
Failure Code [DX33MA]3811
Failure Code [DX37K4]3814
Failure Code [DX37KA]3817
Failure Code [DX37KB]3819
Failure Code [DX37KY]3822
Failure Code [DX37MA]3824
Failure Code [DX38K4]3827
Failure Code [DX38KA]3830
Failure Code [DX38KB]3832
Failure Code [DX38KY]3835
Failure Code [DX38MA]3837
Failure Code [DXH1KA]3840
Failure Code [DXH1KB]3843
Failure Code [DXH1KY]3846
Failure Code [DXH2KA]3848
List of Number of Gear Shift When Failure is Found3850
Failure Code [DXH2KB]3852
List of Number of Gear Shift When Failure is Found3855
Failure Code [DXH2KY]3856
List of Number of Gear Shift When Failure is Found3858
Failure Code [DXH3KA]3860
List of Number of Gear Shift When Failure is Found3862
Failure Code [DXH3KB]3864
List of Number of Gear Shift When Failure is Found3867
Failure Code [DXH3KY]3868
List of Number of Gear Shift When Failure is Found3870
Failure Code [DXH4KA]3872
List of Number of Gear Shift When Failure is Found3874
Failure Code [DXH4KB]3876
List of Number of Gear Shift When Failure is Found3879
Failure Code [DXH4KY]3880
List of Number of Gear Shift When Failure is Found3882
Failure Code [DXH5KA]3884
List of Number of Gear Shift When Failure is Found3886
Failure Code [DXH5KB]3888
List of Number of Gear Shift When Failure is Found3891
Failure Code [DXH5KY]3892
List of Number of Gear Shift When Failure is Found3894
Failure Code [DXH6KA]3896
List of Number of Gear Shift When Failure is Found3898
Failure Code [DXH6KB]3900
List of Number of Gear Shift When Failure is Found3903
Failure Code [DXH6KY]3904
List of Number of Gear Shift When Failure is Found3906
Failure Code [DXH7KA]3908
Failure Code [DXH7KB]3911
Failure Code [DXH7KY]3914
Failure Code [DXHHKA]3916
Failure Code [DXHHKB]3919
Failure Code [DXHHKY]3922
List of Number of Gear Shift When Failure is Found3924
Failure Code [DY30MA]3926
Failure Code [DY30MC]3930
Failure Code [DY30ME]3937
Failure Code [F@BWNR]3940
Failure Code [F@BWNS]3942
Failure Code [F@BXNR]3944
Failure Code [F@BXNS]3946
Troubleshooting of Electrical System (E-Mode)3948
Engine Does Not Start (Engine Does Not Crank)3948
Manual Preheating System Does Not Operate3959
Automatic Preheating System Does Not Operate3965
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On3969
LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything3972
LCD Unit on Machine Monitor Shows Nothing3981
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)3984
LCD Screen on Machine Monitor Does Not Show Correctly3987
Meter Unit Display on Machine Monitor is Abnormal3990
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal3995
LED Unit Lamp on Machine Monitor is Abnormal3999
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly4004
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate4009
Switch Panel Buzzer of Machine Monitor is Abnormal4014
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly4019
Rearview Monitor Does Not Come On or Backlight Flickers4020
Rearview Monitor Images are Not Shown Clearly4025
Rearview Monitor Brightness Cannot be Adjusted4031
Night Mode Lamp of Rearview Monitor is Abnormal4037
Air Cleaner Clogging Caution Lamp Does Not Come On4041
Transmission Oil Filter Clogging Caution Lamp Does Not Come On4044
Radiator Coolant Level Caution Lamp Does Not Come On4048
Rear View Monitor is Not Shown in Conjunction with Revers When the Constant Display Setting is Disable4051
Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is Turned ON4054
Fuel Gauge Does Not Show Normally4056
Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature Caution Lamp Does Not Come On4059
Retarder Oil Temperature Gauge Does Not Rise or Retarder Oil Temperature Caution Lamp Does Not Come On4062
Seatbelt Caution Lamp Does Not Show Normally4066
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position4070
Alarm Buzzer Does Not Operate4074
Alarm Buzzer Does Not Stop4076
Engine Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated4081
AISS Function Does Not Operate Correctly4085
Dump (Hoist) Control Lever Does Not Operate Correctly4089
Fuel Feed Pump Does Not Operate or Stop Automatically4092
Turn Signal Lamp and Hazard Lamp Do Not Operate Correctly4102
Horn Does Not Sound4110
Horn Does Not Stop4114
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On4117
Clearance Lamp Does Not Come On4122
Tail Lamp Does Not Come On4125
Headlamp (Low Beam) Does Not Come On4128
Headlamp (High Beam) Does Not Come On4132
Headlamp (Low Beam) and (High Beam) Do Not Come On4136
Passing Lamp Does Not Come On4139
KOMTRAX System Does Not Operate Correctly4142
Data Download with Wireless LAN Does Not Operate4144
KomVision Monitor Does Not Come On or Backlight Flickers4145
KomVision Monitor Images are Not Shown Clearly4150
KomVision Monitor Brightness Cannot be Adjusted4159
Night Mode Lamp of KomVision Monitor is Abnormal4165
A Part of Camera Image of KomVision Monitor is Not Shown4169
Example of Black Out on KomVision Monitor4170
KomVision Monitor is Not Shown Correctly After Calibration4172
Cannot Access to the Setting Screen of the Mobile Communication Terminal4174
Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in Password is Unknown4181
KOMTRAX Plus Controller is Not Found4183
KOMTRAX Plus Controller Does Not Become Active4185
Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus Server4186
Restrictions on Radio Reception4188
Data is Not Sent to KOMTRAX Plus Server4189
Alarm Buzzer Does Not Sound When Power Ladder is in Operation4191
Power Ladder Pump Does Not Operate4194
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)4199
Information Shown in Troubleshooting Table (H-Mode)4199
Failure Mode and Cause Table4200
Machine Does Not Start4205
Table of Clutch to be Used4211
Machine Does Not Travel Smoothly (Machine Hunts)4212
Table of Clutch to be Used4216
Lockup is Not Released4217
Strong Shock is Made When You Start Machine or Shift Gears4218
Table of Clutch to be Used4220
Shiftup Does Not Operate4221
Table of Clutch to be Used4225
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function4226
Travel Speed is Low or Power is Low During Travel with Torque Converter4230
Travel Speed is Low or Power is Low in Specified Gear Speed4234
Table of Clutch to be Used4237
Time Lag is Large When You Start Machine or Shift Gears4238
Table of Clutch to be Used4242
Torque Converter Oil Temperature is High4243
Torque Converter Oil Pressure is Low4247
Steering Wheel is Heavy to Operate4251
Steering Wheel is Disabled4255
Steering Wheel is Shaken4258
Parking Brake Does Not Operate or is Weak4260
Parking Brake is Not Released or Drags4261
Front Brake Does Not Operate Sufficiently4263
Rear Brake Does Not Operate Sufficiently4266
Speed is Low When Dump Body is Raised4269
Hydraulic Drift of Dump Body is Large4273
Dump Body is Disabled4274
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)4278
Unusual Noise is Heard from Around Fan4281
Power Ladder Does Not Operate or Moves Slow4282
Troubleshooting of Engine (S-Mode)4285
Information Shown in Troubleshooting Table (S-Mode)4285
Engine Does Not Crank When Starting Switch is Turned to Start Position4286
Engine Cranks but Does Not Start4288
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)4293
Engine Startability is Unsatisfactory4300
Engine Does Not Pick Up Smoothly4306
Engine Stops During Operation4313
Engine Does Not Rotate Smoothly4320
Engine Lacks Output (or Lacks Power)4326
KDPF Becomes Clogged in a Short Time4333
Engine Oil Consumption is Excessive4338
Engine Oil Becomes Dirty Quickly4342
Fuel Consumption is Excessive4346
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)4350
Engine Oil Pressure Drops4352
Fuel Mixes Into Engine Oil4356
Water Mixes Into Engine Oil (Milky)4358
Coolant Temperature Increases Too High (Overheat)4361
Unusual Noise is Heard4366
Vibration is Excessive4369
Air Cannot be Bled from Fuel Circuit4371
Active Regeneration is Done Frequently4375
Active Regeneration Continues Long4381
White Smoke is Exhausted During Active Regeneration4386
50 Disassembly and Assembly4389
Table of Contents4390
Precautions Before Work4396
Related Information on Disassembly and Assembly4397
How to Read This Manual4397
Coating Materials List4399
Special Tool List4404
Sketches of Special Tools4421
Engine and Cooling System4428
Remove and Install Supply Pump Assembly (Right Bank)4428
How to Remove Supply Pump Assembly (Right Bank)4429
How to Install Supply Pump Assembly (Right Bank)4438
Remove and Install Supply Pump Assembly (Left Bank)4455
How to Remove Supply Pump Assembly (Left Bank)4455
How to Install Supply Pump Assembly (Left Bank)4461
Remove and Install Injector Assembly (Right Bank)4470
How to Remove Injector Assembly (Right Bank)4471
How to Install Injector Assembly (Right Bank)4480
Remove and Install Injector Assembly (Left Bank)4492
How to Remove Injector Assembly (Left Bank)4493
How to Install Injector Assembly (Left Bank)4502
Remove and Install Fuel Doser Assembly (Right Bank)4516
How to Remove Fuel Doser Assembly (Right Bank)4516
How to Install Fuel Doser Assembly (Right Bank)4520
Remove and Install Fuel Doser Assembly (Left Bank)4525
How to Remove Fuel Doser Assembly (Left Bank)4525
How to Install Fuel Doser Assembly (Left Bank)4529
Remove and Install Cylinder Head Assembly (Right Bank)4533
How to Remove Cylinder Head Assembly (Right Bank)4535
How to Install Cylinder Head Assembly (Right Bank)4565
Remove and Install Cylinder Head Assembly (Left Bank)4610
How to Remove Cylinder Head Assembly (Left Bank)4611
How to Install Cylinder Head Assembly (Left Bank)4644
Remove and Install EGR Valve Assembly (Right Bank)4692
How to Remove EGR Valve Assembly (Right Bank)4693
How to Install EGR Valve Assembly (Right Bank)4702
Remove and Install EGR Valve Assembly (Left Bank)4715
How to Remove EGR Valve Assembly (Left Bank)4716
How to Install EGR Valve Assembly (Left Bank)4726
Remove and Install EGR Cooler Assembly (Right Bank)4742
How to Remove EGR Cooler Assembly (Right Bank)4743
How to Install EGR Cooler Assembly (Right Bank)4761
Remove and Install EGR Cooler Assembly (Left Bank)4785
How to Remove EGR Cooler Assembly (Left Bank)4786
How to Install EGR Cooler Assembly (Left Bank)4805
Remove and Install Starter Assembly4830
How to Remove Starting Motor Assembly4830
How to Install Starting Motor Assembly4833
Remove and Install Alternator Belt4836
How to Remove Alternator Belt4836
How to Install Alternator Belt4840
Remove and Install Alternator Assembly4845
How to Remove Alternator Assembly4846
How to Install Alternator Assembly4848
Drain and Add Fuel4853
How to Drain Fuel4853
How to Add Fuel4855
Remove and Install Cooler Assembly4856
How to Remove Cooling Assembly4858
How to Install Cooling Assembly4890
Remove and Install Radiator Core4930
How to Remove Radiator Core4930
How to Install Radiator Core4938
Remove and Install Cooling Fan and Fan Motor Assembly4946
How to Remove Cooling Fan and Fan Motor Assembly4946
How to Install Cooling Fan and Fan Motor Assembly4950
Remove and Install Aftercooler Assembly4955
How to Remove Aftercooler Assembly4956
How to Install Aftercooler Assembly4963
Remove and Install Oil Cooler Assembly4971
How to Remove Oil Cooler Assembly4972
How to Install Oil Cooler Assembly4975
Remove and Install Engine Assembly4978
How to Remove Engine Assembly4980
How to Install Engine Assembly5000
Remove and Install Engine Front Oil Seal5021
How to Remove Engine Front Oil Seal5021
How to Install Engine Front Oil Seal5023
Remove and Install Engine Rear Oil Seal5026
How to Remove Engine Rear Oil Seal5026
How to Install Engine Rear Oil Seal5028
Remove and Install Fuel Tank Assembly5031
How to Remove Fuel Tank Assembly5032
How to Install Fuel Tank Assembly5036
Remove and Install KDPF Assembly (with Bracket)5040
How to Remove KDPF Assembly (Together with Bracket)5041
How to Install KDPF Assembly (Together with Bracket)5066
Remove and Install KDPF Assembly (Without Bracket)5090
How to Remove KDPF Assembly (Single Unit)5091
How to Install KDPF Assembly (Single Unit)5116
Disassemble and Assemble KDPF Assembly5140
How to Disassemble KDPF Assembly5141
How to Assemble KDPF Assembly5148
Remove and Install KCCV Assembly (Right Bank)5157
How to Remove KCCV Assembly (Right Bank)5157
How to Install KCCV Assembly (Right Bank)5161
Remove and Install KCCV Assembly (Left Bank)5165
How to Remove KCCV Assembly (Left Bank)5165
How to Install KCCV Assembly (Left Bank)5169
Remove and Install VGT Assembly (Right Bank)5173
How to Remove VGT Assembly (Right Bank)5174
How to Install VGT Assembly (Right Bank)5185
Remove and Install VGT Assembly (Left Bank)5198
How to Remove VGT Assembly (Left Bank)5199
How to Install VGT Assembly (Left Bank)5209
Remove and Install Air Cleaner Assembly5221
How to Remove Air Cleaner Assembly5221
How to Install Air Cleaner Assembly5225
Remove and Install Air Conditioner Compressor Assembly5228
How to Remove Air Conditioner Compressor Assembly5229
How to Install Air Conditioner Compressor Assembly5233
Remove and Install Air Conditioner Condenser Assembly5239
How to Remove Air Conditioner Condenser Assembly5239
How to Install Air Conditioner Condenser Assembly5241
Power Train5244
Drain and Add Transmission Oil5244
How to Drain Transmission Oil5244
How to Add Transmission Oil5245
Remove and Install Damper Assembly5246
How to Remove Damper Assembly5247
How to Install Damper Assembly5255
Disassemble and Assemble Damper Assembly5265
How to Disassemble Damper Assembly5265
How to Assemble Damper Assembly5266
Remove and Install Front Drive Shaft5268
How to Remove Front Drive Shaft5268
How to Install Front Drive Shaft5270
Remove and Install Rear Drive Shaft5273
How to Remove Rear Drive Shaft5273
How to Install Rear Drive Shaft5275
Remove And Install Torque Converter and PTO Assembly, and Transmission Assembly5277
How to Remove Torque Converter and PTO Assembly, and Transmission Assembly5279
How to Install Torque Converter and PTO Assembly, and Transmission Assembly5295
Disconnect And Connect Torque Converter and PTO Assembly, and Transmission Assembly5311
How to Disconnect Torque Converter and PTO Assembly, and Transmission Assembly5312
How to Connect Torque Converter and PTO Assembly, and Transmission Assembly5320
Disassemble and Assemble Torque Converter and PTO Assembly5332
How to Disassemble Torque Converter and PTO Assembly5334
How to Assemble Torque Converter and PTO Assembly5342
Disassemble and Assemble Transmission Assembly5357
How to Disassemble Transmission Assembly5360
How to Assemble Transmission Assembly5378
Remove and Install Differential Assembly5406
How to Remove Differential Assembly5407
How to Install Differential Assembly5411
Disassemble and Assemble Differential Assembly5416
How to Disassemble Differential Assembly5418
How to Assemble Differential Assembly5432
Remove and Install Final Drive and Rear Brake Assembly5455
How to Remove Final Drive and Rear Brake Assembly5456
How to Install Final Drive and Rear Brake Assembly5459
Disassemble and Assemble Final Drive and Rear Brake Assembly5462
How to Disassemble Final Drive and Rear Brake Assembly5464
How to Assemble Final Drive and Rear Brake Assembly5477
Remove and Install Final Drive Carrier Assembly5501
How to Remove Final Drive Carrier Assembly5502
How to Install Final Drive Carrier Assembly5504
Disassemble and Assemble Final Drive Carrier Assembly5507
How to Disassemble Final Drive Carrier Assembly5507
How to Assemble Final Drive Carrier Assembly5508
Brake System5510
Drain and Add Brake Oil5510
How to Drain Brake Oil5510
How to Add Brake Oil5511
Remove and Install Slack Adjuster Assembly5512
How to Remove Slack Adjuster Assembly5513
How to Install Slack Adjuster Assembly5515
Remove and Install Brake Accumulator Charge Valve Assembly5517
How to Remove Brake Accumulator Charge Valve Assembly5518
How to Install Brake Accumulator Charge Valve Assembly5519
Remove and Install Front Wheel Hub and Brake Assembly5522
How to Remove Front Wheel Hub and Brake Assembly5524
How to Install Front Wheel Hub and Brake Assembly5531
Disassemble and Assemble Front Wheel Hub and Brake Assembly5538
How to Disassemble Front Wheel Hub and Brake Assembly5539
How to Assemble Front Wheel Hub and Brake Assembly5546
Steering System5557
Remove and Install Steering Valve Assembly5557
How to Remove Steering Valve Assembly5558
How to Install Steering Valve Assembly5563
Remove and Install Steering Cylinder Assembly5568
How to Remove Steering Cylinder Assembly5570
How to Install Steering Cylinder Assembly5584
Disassemble and Assemble Steering Cylinder Assembly5598
How to Disassemble Steering Cylinder Assembly5599
How to Assemble Steering Cylinder Assembly5600
Undercarriage and Frame5603
Remove and Install Front Wheel Assembly5603
How to Remove Front Wheel Assembly5603
How to Install Front Wheel Assembly5607
Remove and Install Rear Wheel Assembly5610
How to Remove Rear Wheel Assembly5610
How to Install Rear Wheel Assembly5614
Remove and Install Right Front Suspension Cylinder Assembly5617
How to Remove Right Front Suspension Cylinder Assembly5619
How to Install Right Front Suspension Cylinder Assembly5636
Remove and Install Left Front Suspension Cylinder Assembly5652
How to Remove Left Front Suspension Cylinder Assembly5654
How to Install Left Front Suspension Cylinder Assembly5676
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5697
How to Disassemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5698
How to Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5700
Remove and Install Kingpin5703
How to Remove Kingpin5704
How to Install Kingpin5714
Remove and Install Rear Suspension Cylinder Assembly5724
How to Remove Rear Suspension Cylinder Assembly5724
How to Install Rear Suspension Cylinder Assembly5729
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5734
How to Disassemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5735
How to Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5736
Remove and Install Slanted Ladder Assembly5740
How to Remove Slanted Ladder Assembly5741
How to Install Slanted Ladder Assembly5743
Hydraulic System5746
Drain and Add Hydraulic Oil5746
How to Drain Hydraulic Oil5746
How to Add Hydraulic Oil5747
Remove and Install Hydraulic Tank Assembly5748
How to Remove Hydraulic Tank Assembly5749
How to Install Hydraulic Tank Assembly5755
Remove and Install Steering and Hoist Pump Assembly5762
How to Remove Steering and Hoist Pump Assembly5763
How to Install Steering and Hoist Pump Assembly5770
Remove and Install Power Train Duplex Pump Assembly5778
How to Remove Power Train Duplex Pump Assembly5779
How to Install Power Train Duplex Pump Assembly5787
Remove and Install Rear Brake Cooling and Brake Charge Triplex Pump Assembly5795
How to Remove Rear Brake Cooling and Brake Charge Triplex Pump Assembly5796
How to Install Rear Brake Cooling and Brake Charge Triplex Pump Assembly5800
Remove and Install Cooling Fan and Hoist Pump Assembly5803
How to Remove Cooling Fan and Hoist Pump Assembly5804
How to Install Cooling Fan and Hoist Pump Assembly5808
Remove and Install Demand Valve Assembly5811
How to Remove Demand Valve Assembly5812
How to Install Demand Valve Assembly5819
Remove and Install Hoist Valve Assembly5827
How to Remove Hoist Valve Assembly5828
How to Install Hoist Valve Assembly5830
Remove and Install Hoist Cylinder Assembly5834
How to Remove Hoist Cylinder Assembly5835
How to Install Hoist Cylinder Assembly5838
Disassemble and Assemble Hoist Cylinder Assembly5840
How to Disassemble Hoist Cylinder Assembly5841
How to Assemble Hoist Cylinder Assembly5844
Work Equipment5849
Fix and Release Body RAISE Position5849
How to Fix Body RAISE Position5849
How to Release Body RAISE Position5850
Remove and Install Dump Body Assembly5853
How to Remove Body Assembly5854
How to Install Body Assembly5858
CAB Related Parts5864
Remove and Install Operator Cab Assembly5864
How to Remove Operator Cab Assembly5866
How to Install Operator Cab Assembly5894
Remove and Install Operator CAB Glass5924
How to Remove Operator Cab Front Window Glass5925
How to Install Operator Cab Front Window Glass5927
How to Remove Operator Cab Glass (Adhered Glass)5930
How to Install Operator Cab Glass (Adhered Glass)5931
Remove and Install Air Conditioner Unit Assembly5935
How to Remove Air Conditioner Unit Assembly5936
How to Install Air Conditioner Unit Assembly5944
Remove and Install Operator Seat Assembly5952
How to Remove Operator Seat Assembly5952
How to Install Operator Seat Assembly5955
How to Remove and Install Seat Belt5958
How to Remove Seat Belt5958
How to Install Seatbelt5959
Electrical System5961
Remove and Install Engine Controller Assembly (Right Bank)5961
How to Remove Engine Controller Assembly (Right Bank)5961
How to Install Engine Controller Assembly (Right Bank)5964
Remove and Install Engine Controller Assembly (Left Bank)5967
How to Remove Engine Controller Assembly (Left Bank)5967
How to Install Engine Controller Assembly (Left Bank)5970
Remove and Install Retarder and Hoist Controller Assembly5973
How to Remove Retarder and Hoist Controller Assembly5973
How to Install Retarder and Hoist Controller Assembly5974
Remove and Install ABS and Power Ladder Controller Assembly5976
How to Remove ABS and Power Ladder Controller Assembly5976
How to Install ABS and Power Ladder Controller Assembly5978
Remove and Install Transmission Controller Assembly5980
How to Remove Transmission Controller Assembly5980
How to Install Transmission Controller Assembly5981
Remove and Install Machine Monitor Assembly5983
How to Remove Machine Monitor Assembly5984
How to Install Machine Monitor Assembly5986
Remove and Install Monitor Controller Assembly5989
How to Remove Monitor Controller Assembly5989
How to Install Monitor Controller Assembly5990
Remove and Install Mass Air Flow and Temperature Sensor5992
How to Remove Mass Air Flow and Temperature Sensor5992
How to Install Mass Air Flow and Temperature Sensor5994
Remove and Install KCCV Crankcase Pressure Sensor (Right Bank)5996
How to Remove KCCV Crankcase Pressure Sensor (Right Bank)5996
How to Install KCCV Crankcase Pressure Sensor (Right Bank)5998
Remove and Install KCCV Crankcase Pressure Sensor (Left Bank)6001
How to Remove KCCV Crankcase Pressure Sensor (Left Bank)6001
How to Install KCCV Crankcase Pressure Sensor (Left Bank)6003
Remove And Install KOMTRAX Plus Controller Assembly6006
How to Remove KOMTRAX Plus Controller Assembly6007
How to Install KOMTRAX Plus Controller Assembly6008
Remove and Install Mobile Communication Terminal6010
How to Remove Mobile Communication Terminal6010
How to Install Mobile Communication Terminal6011
Remove and Install DC-DC Converter6013
How to Remove DC-DC Converter6013
How to Install DC-DC Converter6014
Remove and Install Mobile Communication Terminal Wiring Harness6015
How to Remove Mobile Communication Terminal Wiring Harness6015
How to Install Mobile Communication Terminal Wiring Harness6020
Remove and Install KOMTRAX Terminal Assembly6026
How to Remove KOMTRAX Terminal Assembly6026
How to Install KOMTRAX Terminal Assembly6028
Remove and Install Rearview Camera6029
How to Remove Rearview Camera6029
How to Install Rearview Camera6030
Remove and Install KomVision Camera6031
How to Remove KomVision Camera6031
How to Install KomVision Camera6036
Remove and Install KomVision Radar6041
How to Remove KomVision Radar6042
How to Install KomVision Radar6055
Remove and Install KomVision Controller Assembly6069
How to Remove KomVision Controller Assembly6069
How to Install KomVision Controller Assembly6071
Remove and Install Wireless LAN Unit Assembly6073
How to Remove Wireless LAN Unit Assembly6073
How to Install Wireless LAN Unit Assembly6075
Remove and Install Driver Status Monitor6079
How to Remove Driver Status Monitor6079
How to Install Driver Status Monitor6080
Remove and Install Translator Controller6082
How to Remove Translator Controller6082
How to Install Translator Controller6083
Remove and Install Drowsiness Detection Camera6085
How to Remove Drowsiness Detection Camera6085
How to Install Drowsiness Detection Camera6086
Remove and Install Drowsiness Alarm Buzzer6088
How to Remove Drowsiness Alarm Buzzer6088
How to Install Drowsiness Alarm Buzzer6089
Remove and Install Drowsiness Detection Wiring Harness6091
How to Remove Drowsiness Detection Wiring Harness6091
How to Install Drowsiness Detection Wiring Harness6101
60 Maintenance Standard6113
Table of Contents6114
Explanation of Terms for Maintenance Standard6115
Engine and Cooling System6117
Maintenance Standard for Engine Mount6117
Maintenance Standard for Damper6118
Maintenance Standard for Cooling Fan, Hoist Pump6120
Maintenance Standard for Servo Valve of Cooling Fan, Hoist Pump6122
Maintenance Standard for Cooling Fan Motor6123
Power Train6126
Maintenance Standard for Drive Shaft6126
Maintenance Standard for Torque Converter and Transmission Mount6127
Maintenance Standard for Torque Converter and PTO6128
Maintenance Standard for Transmission6132
Maintenance Standard for Transmission Control Valve6140
Maintenance Standard for Lockup Clutch ECMV6141
Maintenance Standard for H, L, R, 1st, 2nd, 3rd, 4th Clutch ECMV6142
Maintenance Standard for Valve Assembly (Main Pressure Variable, Torque Converter Relief, Main Flow Rate Select)6143
Maintenance Standard for Transmission Lubricating Oil Selector Valve6145
Maintenance Standard for Front Axle6147
Maintenance Standard for Rear Axle6148
Maintenance Standard for Differential6149
Maintenance Standard for Final Drive6151
Steering System6153
Maintenance Standard for Steering Column6153
Maintenance Standard for Steering Linkage6154
Maintenance Standard for Demand Valve6157
Maintenance Standard for Steering Cylinder6160
Brake System6161
Maintenance Standard for Front Brake, Parking Brake6161
Maintenance Standard for Rear Brake, Parking Brake6163
Undercarriage and Frame6165
Maintenance Standard for Front Suspension Cylinder6165
Maintenance Standard for Rear Suspension Cylinder6169
Maintenance Standard for Rear Axle Support6171
Hydraulic System6173
Maintenance Standard for Hydraulic Tank6173
Maintenance Standard for Pump Assembly (Steering, Hoist)6174
Maintenance Standard for Servo Valve of Pump Assembly (Steering, Hoist)6176
Maintenance Standard for Hoist Valve6177
Work Equipment6179
Maintenance Standard for Hoist Cylinder6179
CAB Related Parts6180
Maintenance Standard for CAB Mount6180
80 Others6181
Table of Contents6182
Precautions Before Work6184
Air Conditioner System6185
Precautions for Refrigerant6185
Layout Drawing of Air Conditioner System6186
Specifications of Air Conditioner6188
Structure of Refrigeration Cycle6189
Function of Refrigeration Cycle6190
System Diagram of Air Conditioner6191
Component Parts of Air Conditioner System6192
Air Conditioner Unit6192
Component Parts of Air Conditioner Unit6195
Function of Evaporator in Air Conditioner Unit6195
Function of Heater Core in Air Conditioner Unit6195
Function of Servomotor in Air Conditioner Unit6195
Operation of Servo Motor of Air Conditioner Unit6195
Structure of Expansion Valve in Air Conditioner Unit6196
Function of Expansion Valve in Air Conditioner Unit6196
Operation of Expansion Valve in Air Conditioner Unit6196
Function of Dual Pressure Switch6197
Air Conditioner Controller6198
Structure of Air Conditioner Controller6198
Input and Output Signals of Air Conditioner Controller6199
Compressor6200
Structure of Compressor6200
Specifications of Compressor6200
Function of Compressor6200
Operation of Compressor6201
Condenser6202
Structure of Condenser6202
Specifications of Condenser6202
Function of Condenser6202
Air Conditioner Related Sensors6204
Structure of Temperature Sensor (Fresh Air)6204
Function of Temperature Sensor (Fresh Air)6204
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner6205
Circuit Diagram and Configuration of Connector Pins of Air Conditioner6207
Locations of Air Conditioner Parts and Layout of Connectors6209
Examine Air Leakage (Duct)6213
How to Examine Air Leakage in Duct Connection6213
Examine Air Conditioner with Self-Diagnosis Function6216
Examine Vent (Mode) Changeover6217
How to Examine Vent (Mode) Changeover6217
Examine Fresh/Recirc Air Changeover6219
How to Examine Fresh/Recirc Air Changeover6219
Examine Refrigerant (Dual) Pressure Switch6220
How to Examine Refrigerant (Dual) Pressure Switch6220
Examine Relay6221
How to Examine Relay6221
Simple Check of Refrigerant Level Through Sight Glass6222
Air Conditioner Troubleshooting Chart 16223
Air Conditioner Troubleshooting Chart 26225
Information Shown in Troubleshooting6228
Troubleshooting by Failure Code (Display of Code)6231
Failure Code [879AKA]6231
Failure Code [879AKB]6232
Failure Code [879BKA]6233
Failure Code [879BKB]6236
Failure Code [879CKA]6239
Failure Code [879CKB]6240
Failure Code [879EMC]6241
Failure Code [879FMC]6242
Failure Code [879GKX]6243
Troubleshooting of Air Conditioner System (A-Mode)6246
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)6246
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)6250
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)6255
Troubleshooting for Fresh/Recirc Air Changeover6259
Troubleshooting by Gauge Pressure6263
Connect Service Tool6266
How to Connect Service Tool6266
Precautions for Disconnection and Connection of Air Conditioner Piping6268
Handle Compressor Oil6270
How to Replace Desiccant6272
How to Remove Desiccant6272
How to Attach Desiccant6273
KomVision System6274
Structure and Operation of KomVision System6274
Precautions for KomVision System6274
Layout Drawing of KomVision System6275
Component Parts of KomVision System6283
Examine and Adjust KomVision System6296
Set and Operate KomVision Monitor6296
Camera Calibration6317
6 Camera Calibration6318
1 Camera Calibration6344
Adjust Radars (For Machine with Radars)6350
How to Adjust Radar6350
How to Adjust Radars Separately6357
Troubleshooting for KomVision System6364
Related Information to Troubleshooting6364
Troubleshooting by Failure Code (Display of Code)6384
Troubleshooting of Electrical System (E-Mode)6649
90 Circuit Diagrams6677
Table of Contents6678
How to Read the Codes for Electric Cable6679
Hydraulic Circuit Diagram6683
Symbols Used in Hydraulic Circuit Diagram6683
Hydraulic Circuit Diagram of Steering, Hoist6687
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves)6689
Hydraulic Circuit Diagram of Brake Control6691
Hydraulic Circuit Diagram of Transmission, Brake Cooling System6693
Hydraulic Circuit Diagram of Power Ladder (Machine with Power Ladder)6695
Hydraulic Circuit Diagram of Steering, Hoist (at Reverse 1st, Right Turn, Brake Operation)6697
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Reverse 1st, Right Turn, Brake Operation)6699
Hydraulic Circuit Diagram of Brake Control (at Reverse 1st, Right Turn, Brake Operation)6701
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Reverse 1st, Right Turn, Brake Operation)6703
Hydraulic Circuit Diagram of Steering, Hoist (at Hoist Raise, Forward 2nd Operation)6705
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Hoist Raise, Forward 2nd Operation)6707
Hydraulic Circuit Diagram of Brake Control (at Retarder Brake Operation)6709
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Hoist Raise, Forward 2nd Operation)6711
Electrical Circuit Diagram6713
Symbols Used in Electric Circuit Diagram6713
Electrical Circuit Diagram of Inside of CAB (1/12)6717
Electrical Circuit Diagram of Inside of CAB (2/12)6719
Electrical Circuit Diagram of Inside of CAB (3/12)6721
Electrical Circuit Diagram of Inside of CAB (4/12)6723
Electrical Circuit Diagram of Inside of CAB (5/12)6725
Electrical Circuit Diagram of Inside of CAB (6/12)6727
Electrical Circuit Diagram of Inside of CAB (7/12)6729
Electrical Circuit Diagram of Inside of CAB (8/12)6731
Electrical Circuit Diagram of Inside of CAB (9/12)6733
Electrical Circuit Diagram of Inside of CAB (10/12)6735
Electrical Circuit Diagram of Inside of CAB (11/12)6737
Electrical Circuit Diagram of Inside of CAB (12/12)6739
Electrical Circuit Diagram of Machine (1/13)6741
Electrical Circuit Diagram of Machine (2/13)6743
Electrical Circuit Diagram of Machine (3/13)6745
Electrical Circuit Diagram of Machine (4/13)6747
Electrical Circuit Diagram of Machine (5/13)6749
Electrical Circuit Diagram of Machine (6/13)6751
Electrical Circuit Diagram of Machine (7/13)6753
Electrical Circuit Diagram of Machine (8/13)6755
Electrical Circuit Diagram of Machine (9/13)6757
Electrical Circuit Diagram of Machine (10/13)6759
Electrical Circuit Diagram of Machine (11/13)6761
Electrical Circuit Diagram of Machine (12/13)6763
Electrical Circuit Diagram of Machine (13/13)6765
Electrical Circuit Diagram of Engine (1/2)6767
Electrical Circuit Diagram of Engine (2/2)6769
Electrical Circuit Diagram (Drowsiness Detection System (DDS))6771
Index6773

S.M 30/12/24