Komatsu DUMP TRUCK HD785-8E0 Shop Manual SEN06801-16 PDF

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Komatsu DUMP TRUCK HD785-8E0 Shop Manual SEN06801-16 -PDF DOWNLOAD

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Komatsu DUMP TRUCK HD785-8E0 Shop Manual SEN06801-16 -PDF DOWNLOAD

Language : English
Pages :6822
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu DUMP TRUCK HD785-8E0 Shop Manual SEN06801-16 -PDF DOWNLOAD

SERIAL NUMBERS 55001 and up

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD785-8E0 Shop Manual SEN06801-16 -PDF DOWNLOAD

SERIAL NUMBERS 55001 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 HD785-8E0 91
Specifications 93
Specifications HD785-8E0 93
Weight Table 98
Weight Table HD785-8E0 98
Fuel, Coolant, Lubricant 100
How to Use Fuel, Coolant and Lubricant to Meet Ambient Temperature (Applicable Machine: 55001 to 55023) 100
How to Use Fuel, Coolant and Lubricant to Meet Ambient Temperature (Applicable Machine: 55024 and up) 102
10 Structure and Function 105
Table of Contents 106
NOx Control System 111
Function of NOx Control System 111
Inducement Strategy 111
Inducement Strategy When Abnormality is Found in the EGR System (EU Specification) 111
Function of Temporary Restoration from Inducement (EU Specification) 112
Inducement Strategy for Abnormality Recurrence (EU Specification) 113
Boot-up System 114
Layout Drawing of Boot-up System 114
Pre-lubrication System 117
Pre-lubrication System Diagram 117
Function of Pre-lubrication System 117
Operation of Pre-lubrication System 118
System Operating Lamp System 120
System Diagram of System Operating Lamp System 120
Function of Operation Lamp System 120
Operation of System Operating Lamp System 120
Battery Disconnect Switch 121
Function of Battery Disconnect Switch 121
Operation of Battery Disconnect Switch 121
Starting Motor Disconnect Switch 122
Function of Starting Motor Disconnect Switch 122
Operation of Starting Motor Disconnect Switch 122
Preheating System 123
System Diagram of Preheating System 123
Function of Automatic Preheating System 123
Operation of Automatic Preheating System 124
Function of Manual Preheating System 124
Operation of Manual Preheating System 124
Engine Shutdown Secondary Switch 125
Function of Engine Shutdown Secondary Switch 125
Operation of Engine Shutdown Secondary Switch 125
Emergency Engine Stop Switch 126
Function of Emergency Engine Stop Switch 126
Operation of Emergency Engine Stop Switch 126
Engine System 127
Layout Drawing of Engine System 127
Engine Control System 129
System Diagram of Engine Control 129
Operation of Engine Control System 130
Engine Power Mode Selector System 131
Engine Power Mode Selector System Diagram 131
Function of Engine Power Mode Selector System 131
Operation of Engine Power Mode Selector System 131
Automatic Idle Stop System 132
Function of Automatic Idle Stop System 132
Operation of Automatic Idle Stop System 132
Component Parts of Engine System 134
Damper 134
VGT 136
EGR System 140
EGR Valve 144
EGR Cooler 146
KCCV System 147
KCCV 149
KDPF 151
Cooling System 155
Layout Drawing of Cooling System 155
Specifications of Cooling System 156
Cooling Fan Control System 157
System Diagram of Cooling Fan Control System 157
Component Parts of Cooling System 162
Cooling Fan, Hoist Pump 162
Cooling Fan Motor 170
Control System 175
Layout Drawing of Control System 175
Layout Drawing of Control System (Machine with Mobile Communication Terminal) 177
Machine Monitor System 179
System Diagram of Machine Monitor System 179
Function of Machine Monitor System 180
Rearview Monitor System 181
System Diagram of Rearview Monitor System 181
Function of Rearview Monitor System 181
KOMTRAX Plus System 182
System Diagram of KOMTRAX Plus System 182
System Diagram of KOMTRAX Plus System (Machine with Mobile Communication Terminal) 184
Function of KOMTRAX Plus System 185
Payload Meter System 189
Layout Drawing of Payload Meter System 189
Payload Meter System Diagram 191
Function of Payload Meter System 192
Measurement Principle of Loading Mass 193
Make Download Function 194
Communication Function with External Device Other Than Data Download 195
Machine Lock-out System 197
Layout Drawing of Machine Lock-out System 197
Machine Lock-out System Drawing 198
Function of Machine Lock-out System 199
Operation of Machine Lock-out System 200
Automatic Suspension System 201
Layout Drawing of Automatic Suspension System 201
Function of Automatic Suspension System 201
Drowsiness Detection System 204
Layout Drawing of Drowsiness Detection System 204
System Diagram of Drowsiness Detection System 205
Function of Drowsiness Detection System 207
Operation of Drowsiness Detection System 208
Component Parts of Control System 209
Machine Monitor 209
Switch Panel 229
Rearview Monitor 230
Rearview Camera 232
KOMTRAX Terminal 233
KOMTRAX Plus Controller 235
Communication Terminal 241
Wireless LAN Unit 242
Transmission Controller 243
Retarder and Hoist Controller 247
Monitor Controller 251
CAN Terminating Resistor 256
Engine Controller 257
ABS Controller 270
Translator Controller 275
Drowsiness Detection Camera 279
Driver Status Monitor 280
Solenoid Valve (Automatic Suspension) 282
Accelerator Pedal 283
Gear Shift Lever 285
Retarder Control Lever 287
Fuel Feed Pump 289
Fuel Feed Pump Switch 290
Hydraulic System 291
Layout Drawing of Hydraulic System 291
Component Parts of Hydraulic System 292
Hydraulic Tank 292
Pump Assembly (Steering, Hoist) 293
Pump Assembly (Power Train) 305
Pump Assembly (Rear Brake Cooling, Brake Charge) 306
Steering, Hoist Filter 308
Hoist Valve 309
Power Train System 315
Layout Drawing of Power Train System 315
Operation of Power Train System 318
Transmission Control System 319
Transmission Control System Diagram 319
Transmission Gear Shift Control System 321
Electric Modulation Function System Diagram 321
Electric Modulation Function 322
Gear Shift Display Function 322
Hunting Prevention Function 322
Transmission Initial Learning and ECMV Current Adjustment Function 322
Transmission Protection Function 323
Gear Shift Lever Positions and Automatic Gear Shift Range 323
Safe Travel Function of Transmission Control System 326
Protection Function of Transmission Control System 326
Self-Diagnosis Function of Transmission Control System 326
Gear Shift Control System 327
Automatic Gear Shift Control of Gear Shift Control System 327
How to Shift in Each Shift Lever Positions of Gear Shift Control System 328
Gear Shift Disabled Time Control of Gear Shift Control System 328
Throttle Limit Function at F1 Start at D Position Setting of Direction Control System 329
Komatsu Traction Control System (KTCS) 330
Komatsu Traction Control System (KTCS) Diagram 330
Function of Komatsu Traction Control System (KTCS) 330
Operation of Komatsu Traction Control System (KTCS) 331
Travel Speed Limitation System 332
System Diagram of Travel Speed Limitation System 332
Function of Travel Speed Limitation System 333
Operation of Travel Speed Limitation System 333
Component Parts of Power Train System 336
Drive Shaft 336
Torque Converter and PTO 337
Transmission 341
Transmission Control Valve 364
Lockup Clutch ECMV 367
H, L, R, 1st, 2nd, 3rd, 4th Clutch ECMV 370
Valve Assembly (Main Pressure Variable, Torque Converter Relief, Main Flow Rate Select) 374
Transmission Lubricating Oil Level Selector Valve 381
Axle 383
Differential 385
Final Drive 387
Work Equipment System 388
Layout Drawing of Work Equipment System 388
Hoist Control System 390
Hoist Control System Diagram 390
Function of Hoist Control System 390
Buddy System 392
Structure of Buddy System 392
Function of Buddy System 393
Operation of Buddy System 393
Component Parts of Work Equipment System 394
Solenoid Valve (Cooling Fan, Hoist Selector) 394
Dump Lever 395
Hoist EPC Valve 399
Steering System 400
Layout Drawing of Steering System 400
Secondary Steering System 401
Secondary Steering System Diagram 401
Function of Secondary Steering System 401
Steering Column 402
Structure of Steering Column 402
Steering Linkage 403
Structure of Steering Linkage 403
Component Parts of Steering System 404
Demand Valve 404
Steering Relief Valve 409
Steering Unit 410
Solenoid Valve (Steering Pump Selector) 415
Cross over Relief Valve 416
Secondary Steering Pump 417
Secondary Steering Motor 418
Brake System 419
Layout Drawing of Brake System 419
Retarder Control 422
Retarder Control System Diagram 422
Function of Retarder Control 423
ARSC System 424
ARSC System Diagram 424
Function of ARSC System 424
ABS 426
Layout Drawing of ABS 426
ABS System Diagram 427
Function of ABS 428
Operation of ABS 429
Component Parts of Brake System 431
Solenoid Valve (Parking Brake) 431
Accumulator Charge Valve 432
Accumulator (Brake Circuit) 436
Brake Valve 437
Secondary Brake Valve 440
Solenoid Valve (Retarder Shut-off) 441
Proportional Pressure Reducing Valve 442
Slack Adjuster 443
Brake Cooling Oil Control Valve 447
Brake 448
Parking Brake 452
Brake Sub-Tank 453
ABS Control Valve 454
ABS Cut Valve 455
Undercarriage and Frame 456
Suspension 456
Structure of Suspension 456
Function of Suspension 457
Front Suspension 458
Function of Front Suspension 458
Rear Suspension 459
Function of Rear Suspension 459
Front Suspension Cylinder 460
Structure of Front Suspension Cylinder 460
Function of Front Suspension Cylinder 463
Operation of Front Suspension Cylinder 463
Rear Suspension Cylinder 466
Structure of Rear Suspension Cylinder 466
Function of Rear Suspension Cylinder 467
Operation of Rear Suspension Cylinder 467
Tires 468
Structure of Radial Tire 468
Function of Radial Tire 468
Work Equipment 469
Structure of Work Equipment 469
Function of Work Equipment 470
CAB Related Parts 471
ROPS CAB 471
Structure of ROPS CAB 471
Function of ROPS CAB 471
CAB Mount 472
Structure of CAB Mount 472
Function of CAB Mount 472
Lifting System 473
Power Ladder System 473
Layout Drawing of Power Ladder System 473
Power Ladder System Diagram 474
Function of Power Ladder System 474
Operation of Power Ladder System 475
Power Ladder System 476
Power Ladder Pump 476
Power Ladder Relief Valve 478
Solenoid Valve (Power Ladder Shock Reduction) 480
Solenoid Valve (Power Ladder Raise and Lower Switch) 481
20 Standard Value Table 483
Table of Contents 484
Standard Value Table for Engine 485
Standard Value Table for Engine HD785-8E0 485
Standard Value Table for Machine 490
Standard Value Table for Machine HD785-8E0 490
Machine Posture and Procedures to Measure Performance 510
30 Testing and Adjusting 511
Table of Contents 512
Precautions Before Work 517
Related Information on Testing and Adjusting 518
Tools for Testing and Adjusting 518
Sketch of Tools for Testing and Adjusting 530
Engine and Cooling System 531
Examine Engine Speed 531
How to Examine Engine Speed 531
Examine Boost Pressure 535
How to Examine Boost Pressure on Machine Monitor 535
How to Examine Boost Pressure by Testing Tool 536
Examine Exhaust Gas Temperature 541
How to Examine Exhaust Gas Temperature 541
Examine Exhaust Gas Color 543
How to Examine Exhaust Gas Color with the Handy Smoke Checker 543
How to Examine Exhaust Gas Color with Smoke Meter 546
Examine Mass Air Flow and Temperature Sensor 550
How to Examine Mass Air Flow and Temperature Sensor 550
Examine and Adjust Valve Clearance 556
How to Examine Valve Clearance 556
How to Adjust Valve Clearance 558
Examine Compression Pressure 559
How to Examine Compression Pressure 559
Examine Blowby Pressure 563
How to Examine Blowby Pressure 563
Examine Engine Oil Pressure 568
How to Examine Engine Oil Pressure on Machine Monitor 568
How to Examine Engine Oil Pressure by Testing Tool 568
Examine EGR Valve and VGT Oil Pressure 570
How to Examine EGR Valve and VGT Oil Pressure 570
Examine Fuel Pressure 572
How to Examine Fuel Pressure 572
Examine Fuel Return Rate and Leakage 575
How to Examine Fuel Return Rate and Leakage 576
Bleed Air from Fuel System 582
How to Bleed Air from Fuel System 582
Examine Fuel Circuit for Leakage 584
How to Examine Fuel System for Leakage 584
Examine Low Pressure Circuit Devices 585
How to Examine Low Pressure Circuit Devices 585
Handle Cylinder Cut-out Mode Operation 590
Handle No-Injection Cranking Operation 591
Examine KDPF and Muffler for Looseness and Damage 592
How to Examine KDPF and Muffler for Looseness and Damage 592
Examine Installation of Cylinder Head Cover and Manifolds 593
How to Examine Installed Condition of Cylinder Head covers and Manifolds 593
Examine Engine Piping for Damage and Looseness 594
How to Examine Engine Piping for Damage and Looseness 594
Clean Fuel Doser 595
How to Clean Fuel Doser 595
Write Injector Compensation Value to Engine Controller 598
How to Write Injector Compensation Value 598
Write Correction for Ash in Soot Accumulation to Engine Controller 604
How to Write Correction for Ash in Soot Accumulation to Engine Controller 604
Examine and Adjust Alternator Belt 605
How to Examine Alternator Belt 605
How to Adjust Tension of Alternator Belt 606
Examine and Adjust Air Conditioner Compressor Belt 607
How to Examine Air Conditioner Compressor Belt 607
How to Adjust Air Conditioner Compressor Belt Tension 608
Examine Cooling Fan Speed 609
How to Examine Cooling Fan Speed 609
Power Train 611
Examine Power Train Oil Pressure 611
How to Examine Power Train Oil Pressure 614
Adjust Speed Sensor (Transmission) 631
How to Adjust Speed Sensor (Transmission) 631
Examine After You Adjust Speed Sensor (Transmission) 633
How to Examine After You Adjust Speed Sensor (Transmission) 633
Flush Torque Converter and Transmission Hydraulic Circuit 634
How to Flush Torque Converter and Transmission Hydraulic Circuit 634
Clean Magnet of Final Drive Case 636
How to Clean Final Drive Case Magnet 636
Move Machine Which Has a Trouble in Electrical System 637
How to Move Machine Which Has a Trouble in Engine Control System 637
How to Move Machine Which Has a Trouble in Transmission Control System 639
Steering System 644
Examine Steering Wheel 644
How to Examine Play of Steering Wheel 644
How to Examine Operating Force of Steering Wheel 644
Examine and Adjust Steering Circuit Oil Pressure 646
How to Examine Steering Circuit Oil Pressure 646
How to Adjust Steering Circuit Oil Pressure 646
Examine Outlet Pressure of Demand Valve 648
How to Examine Outlet Pressure of Demand Valve 648
Examine Outlet Pressure of Steering Valve 650
How to Examine Outlet Pressure of Steering Valve 650
Bleed Air from Steering Cylinder Circuit 653
How to Bleed Air from Steering Cylinder Circuit 653
Brake System 655
Release Remained Pressure in Brake Accumulator Circuit 655
How to Release Remained Pressure in Brake Accumulator Circuit 655
Examine Wheel Brake Oil Pressure 656
How to Examine Operating Pressure of Front Brake 656
How to Examine Operating Pressure of Rear Brake 657
How to Examine Operating Pressure of Retarder Brake by Machine Monitor 659
How to Examine Operating Pressure of Retarder Brake by Testing Tool 659
Examine and Adjust Brake Accumulator Charge Pressure 662
How to Examine Brake Accumulator Charge Pressure on Machine Monitor 662
How to Examine Brake Accumulator Charge Pressure by Testing Tool 662
How to Adjust Brake Accumulator Charge Pressure 664
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 665
How to Examine Accumulator Nitrogen Gas Pressure for Brake 666
How to Charge Accumulator Nitrogen Gas for Brake 669
How to Release Nitrogen Gas When You Discard Accumulator 674
Examine Brake Performance 675
How to Examine Foot Brake Performance 675
How to Examine Retarder Brake Performance 675
How to Examine Parking Brake Performance 676
Bleed Air from Brake Circuit 678
How to Bleed Air from Front Brake Circuit 678
How to Bleed Air from Front Brake Circuit (Machine with ABS) 679
How to Bleed Air from Rear Brake Circuit 682
How to Bleed Air from Rear Brake Circuit (Machine with ABS) 683
How to Bleed Air from Parking Brake Circuit 686
Examine Releasing Pressure of Parking Brake 690
How to Examine Releasing Pressure of Parking Brake by Machine Monitor 690
How to Examine Releasing Pressure of Parking Brake on Front Brake Side 690
How to Examine Releasing Pressure of Parking Brake on Rear Brake Side 692
Examine Operating Pressure of Secondary Brake 694
How to Examine Operating Pressure of Secondary Brake 694
Release Parking Brake Manually 695
How to Release Front Parking Brake Manually 695
How to Release Rear Parking Brake Manually 696
Examine Wear of Wheel Brake Disc 698
How to Examine Front Brake Disc Wear Volume 698
How to Examine Rear Brake Disc Wear Volume 699
Hydraulic System 700
Examine and Adjust Hoist Circuit Oil Pressure 700
How to Examine Hoist Circuit Oil Pressure 700
How to Adjust Hoist Circuit Oil Pressure 701
Examine Hoist Cylinder Source Pressure 702
How to Examine Source Pressure of Hoist Cylinder 702
Examine Oil Pressure of Hoist EPC Valve Circuit 704
How to Examine Source Pressure of Hoist EPC Valve 704
How to Examine Outlet Pressure of Hoist EPC Valve 705
Examine Cooling Fan Circuit Oil Pressure 708
How to Examine Cooling Fan Circuit Oil Pressure 708
Examine and Adjust Front Suspension Cylinder 710
How to Examine Front Suspension Cylinder 710
How to Adjust Front Suspension Cylinder 711
Examine and Adjust Front Suspension Cylinder (Automatic Suspension Specification) 715
How to Examine Front Suspension Cylinder (Automatic Suspension Specification) 715
How to Adjust Front Suspension Cylinder (Automatic Suspension Specification) 716
Examine and Adjust Rear Suspension Cylinder 717
How to Examine Rear Suspension Cylinder 717
How to Adjust Rear Suspension Cylinder 718
Examine Oil Pressure of KTCS Circuit 723
How to Examine Oil Pressure of KTCS Circuit 723
Bleed Air from Hydraulic System 725
How to Bleed Air from Piston Pump 725
How to Bleed Air from Hoist Cylinder 726
Device to Get on or Off Machine 729
Bleed Air from Power Ladder Cylinder 729
How to Bleed Air in Power Ladder Cylinder 729
Calibrate Ladder Position 730
How to Calibrate Ladder Store Position 730
How to Calibrate Ladder Lower Position 730
Work Equipment 732
Examine and Adjust Dump Body Positioner Sensor 732
How to Examine Dump Body Positioner Sensor 732
How to Adjust Dump Body Positioner Sensor 732
Lower Dump Body Manually 734
How to Lower Dump Body Manually 734
How to Lower Dump Body Manually (Machine with 2 Pieces of Forced Lower Valves) 734
Lift Dump Body Manually 736
How to Lift Dump Body Manually 736
Lift Dump Body by Buddy System 737
How to Lift Dump Body by Buddy System 737
CAB Related Parts 741
Adjust Tilt Lock Lever of Steering Wheel 741
How to Adjust Tilt Lock Lever of Steering Wheel 741
Adjust Play of Operator Seat 743
How to Adjust Play of Operator Seat 743
Adjust Door Lock Link 744
How to Adjust Door Lock Link 744
Examine and Adjust Clearance of Escape Door 746
How to Examine Clearance of Escape Door 746
How to Adjust Clearance of Escape Door 746
Electrical System 747
Set and Adjust Each Equipment 747
Set and Operate Machine Monitor 750
Operator Mode 754
Function to Show Operator Identification Input Screen 754
Examine Function by LCD (Liquid Crystal Display) 756
Examine Function of Service Meter and Odometer 756
How to Set Usage Limitation Setting and Change Password 757
Travel Speed Limit Function 760
Service Mode 769
How to Operate Service Mode 769
How to See Pre-defined Monitoring Information 771
How to Examine Monitoring Information 781
Abnormality Record Menu 799
How to See Maintenance Record 805
Maintenance Mode Setting 806
How to Set Phone Number Entry 813
Default Setting Menu 815
Testing Menu 838
Adjustment Menu 853
No-Injection Cranking Operation 875
Set Payload Meter 878
Communication with External Device Specification of Payload Meter System 900
KOMTRAX Settings Menu 908
How to Show Service Message 912
How to Operate Snap Shot Manually 913
How to Start Up KOMTRAX Terminal 918
How to Stop Use of KOMTRAX Terminal 923
How to Stop Use of KOMTRAX Terminal (Machine with Mobile Communication Terminal) 925
Default Setting of KOMTRAX Plus Controller 927
Default Setting of KOMTRAX Plus Controller 927
Default Setting of Wireless LAN Modem 930
Default Setting of Wireless LAN Modem 930
How to Examine Wireless LAN Modem Communication 931
Download Data from KOMTRAX Plus Controller 932
How to Download Data from KOMTRAX Plus Controller 932
How to Download Data from Service Connector in Cab 932
How to Download Data Through the Service Connector Outside Cab (Ground Level Download Specification) 934
How to Download Data from Wireless LAN (Wireless LAN Spec) 935
Adjust After Replacement of KOMTRAX Plus Controller 937
How to Adjust After Replacement of KOMTRAX Plus Controller 937
Adjust After Replacement of Wireless LAN Modem 940
How to Adjust After Replacement of Wireless LAN Modem 940
Setting of Mobile Communication Terminal 943
How to Set Mobile Communication Terminal 943
Set Driver Status Monitor 953
Preparation for Driver Status Monitor Setting 953
How to Set Driver Status Monitor 960
How to Do Operation Check of Driver Status Monitor 962
How to Adjust Drowsiness Detection Camera Angle 963
Adjust Rearview Camera Angle 964
How to Adjust Rearview Camera Angle 964
Set Region of Bluetooth(R) Compatible Radio 965
How to Set Region of Bluetooth(R) Compatible Radio 965
Handle Voltage Circuit of Engine Controller 967
Handle Battery Disconnect Switch 968
Battery Disconnect Switch (Machine with Mobile Communication Terminal) 970
Examine Diodes 972
How to Examine Diodes by Digital Tester 972
How to Examine Diodes by Analog Tester 972
Pm Clinic 973
Pm Clinic Service 973
Pm Clinic Check Sheet HD785-8E0 976
Perform Quick Pm 987
How to Perform Quick Pm 987
40 Troubleshooting 993
Table of Contents 994
Precautions Before Work1012
Related Information for Troubleshooting1013
General Troubleshooting Points1013
Troubleshooting Points for Aftertreatment System1014
Sequence of Events in Troubleshooting1023
Checks Before Troubleshooting1025
Inspection Procedure Before Troubleshooting1027
Walk-Around Check1027
Test in Accordance with Testing Procedure1029
Examine Fuel Level1029
Examine for Impure Ingredient in Fuel1030
Examine Fuel Prefilter1030
Examine Fuel Main Filter1032
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1034
Examine Coolant Level (Sub-Tank)1035
Examine Air Cleaner Clogging1036
Clean Outer Element1037
Replace Element1039
Examine Hydraulic Oil Level1041
Examine Hydraulic Oil Filter or Hydraulic Oil Strainer1041
Examine Oil Level in Transmission Case1042
Examine Oil Level in Differential Case1043
Examine Oil Level in Final Drive Case1043
Bleed Air from Fuel System1043
Bleed Air from Hydraulic System1043
How to Examine Electric Equipment1043
Preparation for Troubleshooting of Electrical System1050
How to Connect Adapter for Troubleshooting Machine Monitor1050
How to Connect Adapter to Troubleshoot Transmission Controller1050
How to Connect Adapter to Troubleshoot Retarder and Hoist Controller1051
How to Connect Adapter to Troubleshoot Monitor Controller1051
How to Connect Adapter to Troubleshoot KOMTRAX Terminal1054
How to Connect Adapter to Troubleshoot KOMTRAX Plus Controller1054
How to Connect Adapter to Troubleshoot KomVision Controller1055
How to Connect Adapter to Troubleshoot ABS Controller1055
How to Connect Adapter for Troubleshooting Engine Controller1056
How to Connect Connectors for Engine Related Parts1057
How to Disconnect KomVision Radar Connector1061
Procedure for Troubleshooting1063
Symptom and Troubleshooting Numbers1066
Information Shown in Troubleshooting1076
Connectors List1079
Connector List (Machine with KomVision)1100
Connector List (Machine with Mobile Communication Terminal)1103
Connector List (Machine with Power Ladder)1104
Connector List (Machine with Drowsiness Detection System)1106
Connector Layout1107
Connector Contact Connection Table1126
T-Branch Box and T-Branch Adapter Table1173
Fuse Location Table1179
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1184
Prepare Troubleshoot Machine Monitor1188
Procedure to Make Harness Checker on Machine Monitor LCD Unit1190
Prepare of Short Circuit Electrical Connector (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1195
Failure Code Table1197
Troubleshooting by Failure Code (Display of Code)1232
Failure Code [1500L0]1232
Failure Code [15B0NX]1233
Failure Code [15F0KM]1237
Failure Code [15F0MB]1238
Failure Code [15F7KM]1239
Failure Code [15G0MW]1240
List of Number of Gear Shift When Failure is Found1241
Failure Code [15G7KM]1242
Failure Code [15H0MW]1243
List of Number of Gear Shift When Failure is Found1244
Failure Code [15J0MW]1245
List of Number of Gear Shift When Failure is Found1246
Failure Code [15K0MW]1247
List of Number of Gear Shift When Failure is Found1248
Failure Code [15L0MW]1249
List of Number of Gear Shift When Failure is Found1250
Failure Code [15M0MW]1251
List of Number of Gear Shift When Failure is Found1252
Failure Code [15N0MW]1253
List of Number of Gear Shift When Failure is Found1254
Failure Code [15SBL1]1255
List of Number of Gear Shift When Failure is Found1257
Failure Code [15SBMA]1259
List of Number of Gear Shift When Failure is Found1260
Failure Code [15SCL1]1261
List of Number of Gear Shift When Failure is Found1263
Failure Code [15SCMA]1265
List of Number of Gear Shift When Failure is Found1266
Failure Code [15SDL1]1267
List of Number of Gear Shift When Failure is Found1269
Failure Code [15SDMA]1271
List of Number of Gear Shift When Failure is Found1272
Failure Code [15SEL1]1273
List of Number of Gear Shift When Failure is Found1275
Failure Code [15SEMA]1277
List of Number of Gear Shift When Failure is Found1278
Failure Code [15SFL1]1280
List of Number of Gear Shift When Failure is Found1282
Failure Code [15SFMA]1284
List of Number of Gear Shift When Failure is Found1285
Failure Code [15SGL1]1287
List of Number of Gear Shift When Failure is Found1289
Failure Code [15SGMA]1291
List of Number of Gear Shift When Failure is Found1292
Failure Code [15SHL1]1294
List of Number of Gear Shift When Failure is Found1296
Failure Code [15SHMA]1298
List of Number of Gear Shift When Failure is Found1299
Failure Code [15SJMA]1300
Failure Code [2C4MNX]1302
Failure Code [2F00KM]1306
Failure Code [2G42ZG]1310
Failure Code [2G43ZG]1312
Failure Code [6014NX]1314
Failure Code [879AKA]1317
Failure Code [879AKB]1318
Failure Code [879BKA]1319
Failure Code [879BKB]1322
Failure Code [879CKA]1325
Failure Code [879CKB]1326
Failure Code [879EMC]1327
Failure Code [879FMC]1328
Failure Code [879GKX]1329
Failure Code [989D00]1332
Failure Code [989L00]1334
Failure Code [989M00]1335
Failure Code [989N00]1336
Failure Code [989X00]1337
Failure Code [989Y00]1338
Failure Code [98A000]1340
Failure Code [98A100]1341
Failure Code [98A200]1342
Failure Code [98A300]1343
Failure Code [98A400]1344
Failure Code [98A500]1345
Failure Code [98A600]1346
Failure Code [A1U0N3]1347
Failure Code [A1U0N4]1351
Failure Code [AA10NX]1355
Failure Code [AB00KE]1358
Failure Code [AB00KY]1362
Failure Code [AQ10N3]1364
Failure Code [AS00R2]1367
Failure Code [AS00R3]1369
Failure Code [AS00R4]1371
Failure Code [AS00R6]1373
Failure Code [B@BAZG]1374
Failure Code [B@BAZK]1377
Failure Code [B@BCNS]1380
Failure Code [B@BCQA]1383
Failure Code [B@BCZK]1386
Failure Code [B@C6NS]1389
Failure Code [B@C7NS]1392
Failure Code [B@CENS]1395
Failure Code [B@JANS]1398
Failure Code [CA115]1401
Failure Code [CA122]1406
Failure Code [CA123]1409
Failure Code [CA131]1413
Failure Code [CA132]1416
Failure Code [CA135]1419
Failure Code [CA141]1422
Failure Code [CA144]1425
Failure Code [CA145]1428
Failure Code [CA153]1431
Failure Code [CA154]1435
Failure Code [CA187]1439
Failure Code [CA212]1443
Failure Code [CA213]1446
Failure Code [CA221]1449
Failure Code [CA222]1452
Failure Code [CA227]1456
Failure Code [CA234]1459
Failure Code [CA238]1461
Failure Code [CA239]1464
Failure Code [CA271]1467
Failure Code [CA272]1470
Failure Code [CA273]1472
Failure Code [CA274]1475
Failure Code [CA322]1477
Failure Code [CA323]1480
Failure Code [CA324]1483
Failure Code [CA325]1486
Failure Code [CA331]1489
Failure Code [CA332]1492
Failure Code [CA343]1495
Failure Code [CA351]1501
Failure Code [CA352]1507
Failure Code [CA356]1511
Failure Code [CA357]1515
Failure Code [CA386]1519
Failure Code [CA431]1523
Failure Code [CA432]1528
Failure Code [CA441]1533
Failure Code [CA442]1536
Failure Code [CA449]1539
Failure Code [CA451]1542
Failure Code [CA452]1545
Failure Code [CA515]1548
Failure Code [CA516]1550
Failure Code [CA553]1553
Failure Code [CA555]1556
Failure Code [CA556]1559
Failure Code [CA559]1562
Failure Code [CA595]1568
Failure Code [CA687]1571
Failure Code [CA689]1575
Failure Code [CA691]1580
Failure Code [CA692]1583
Failure Code [CA697]1586
Failure Code [CA698]1588
Failure Code [CA731]1590
Failure Code [CA778]1599
Failure Code [CA1117]1604
Failure Code [CA1135]1608
Failure Code [CA1257]1619
Failure Code [CA1664]1621
Loaded Diagnostics Operation to Clear Failure Code1623
Failure Code [CA1691]1625
Failure Code [CA1695]1630
Failure Code [CA1696]1633
Failure Code [CA1843]1636
Failure Code [CA1844]1639
Failure Code [CA1879]1642
Failure Code [CA1881]1645
Failure Code [CA1883]1649
Loaded Diagnostics Operation to Clear Failure Code1652
Failure Code [CA1921]1654
Failure Code [CA1922]1662
Failure Code [CA1923]1669
Failure Code [CA1924]1672
Diagram Related to Fuel Doser1675
Failure Code [CA1925]1677
Diagram Related to Fuel Doser1679
Failure Code [CA1927]1681
Failure Code [CA1928]1684
Failure Code [CA1942]1687
Failure Code [CA1963]1690
Diagram Related to Fuel Doser1696
Failure Code [CA1977]1698
Loaded Diagnostics Operation to Clear Failure Code1701
Failure Code [CA1993]1702
Loaded Diagnostics Operation to Clear Failure Code1704
Failure Code [CA2185]1706
Failure Code [CA2186]1708
Failure Code [CA2249]1711
Failure Code [CA2265]1718
Failure Code [CA2266]1721
Failure Code [CA2271]1724
Failure Code [CA2272]1727
Failure Code [CA2349]1731
Failure Code [CA2353]1735
Failure Code [CA2357]1738
Failure Code [CA2381]1743
Failure Code [CA2382]1746
Failure Code [CA2383]1750
Failure Code [CA2386]1754
Failure Code [CA2387]1756
Failure Code [CA2555]1766
Failure Code [CA2556]1770
Failure Code [CA2637]1773
Failure Code [CA2639]1780
Failure Code [CA2732]1788
Failure Code [CA2733]1791
Failure Code [CA2741]1794
Diagram Related to Fuel Doser1795
Failure Code [CA2765]1797
Failure Code [CA2777]1799
Failure Code [CA2878]1802
Diagram Related to Fuel Doser1806
Failure Code [CA2881]1808
Loaded Diagnostics Operation to Clear Failure Code1812
Failure Code [CA3133]1815
Failure Code [CA3134]1818
Failure Code [CA3135]1821
Loaded Diagnostics Operation to Clear Failure Code1824
Failure Code [CA3167]1826
How to Reset Fuel Doser Information1829
Failure Code [CA3251]1832
Loaded Diagnostics Operation to Clear Failure Code1839
Failure Code [CA3253]1840
Loaded Diagnostics Operation to Clear Failure Code1848
Failure Code [CA3254]1850
Loaded Diagnostics Operation to Clear Failure Code1857
Failure Code [CA3255]1858
Loaded Diagnostics Operation to Clear Failure Code1865
Failure Code [CA3256]1867
Loaded Diagnostics Operation to Clear Failure Code1874
Failure Code [CA3311]1875
Loaded Diagnostics Operation to Confirm Failure Correction1882
Failure Code [CA3312]1884
Loaded Diagnostics Operation to Confirm Failure Correction1891
Failure Code [CA3313]1893
Failure Code [CA3314]1896
Failure Code [CA3315]1899
Loaded Diagnostics Operation to Confirm Failure Correction1904
Failure Code [CA3316]1906
Failure Code [CA3317]1909
Failure Code [CA3318]1912
Loaded Diagnostics Operation to Confirm Failure Correction1917
Failure Code [CA3319]1919
Failure Code [CA3321]1922
Failure Code [CA3322]1925
Loaded Diagnostics Operation to Confirm Failure Correction1930
Failure Code [CA3419]1932
Failure Code [CA3421]1934
Failure Code [CA4151]1937
Failure Code [CA4158]1944
Failure Code [CA4161]1947
Failure Code [CA4162]1950
Failure Code [CA4163]1953
Loaded Diagnostics Operation to Confirm Failure Correction1955
Failure Code [CA4259]1956
Failure Code [CA4952]1959
Failure Code [CA5383]1962
Failure Code [CB115]1964
Failure Code [CB122]1969
Failure Code [CB123]1972
Failure Code [CB153]1976
Failure Code [CB154]1980
Failure Code [CB187]1984
Failure Code [CB227]1988
Failure Code [CB238]1991
Failure Code [CB239]1994
Failure Code [CB271]1997
Failure Code [CB272]2000
Failure Code [CB273]2002
Failure Code [CB274]2005
Failure Code [CB343]2007
Failure Code [CB351]2013
Failure Code [CB352]2019
Failure Code [CB356]2023
Failure Code [CB357]2027
Failure Code [CB386]2031
Failure Code [CB441]2034
Failure Code [CB442]2037
Failure Code [CB449]2040
Failure Code [CB451]2043
Failure Code [CB452]2046
Failure Code [CB515]2049
Failure Code [CB516]2051
Failure Code [CB553]2054
Failure Code [CB555]2057
Failure Code [CB556]2060
Failure Code [CB559]2063
Failure Code [CB595]2069
Failure Code [CB687]2072
Failure Code [CB689]2076
Failure Code [CB691]2081
Failure Code [CB692]2084
Failure Code [CB697]2087
Failure Code [CB698]2089
Failure Code [CB731]2091
Failure Code [CB778]2100
Failure Code [CB1117]2105
Failure Code [CB1257]2109
Failure Code [CB1548]2111
Failure Code [CB1549]2114
Failure Code [CB1551]2117
Failure Code [CB1552]2120
Failure Code [CB1553]2123
Failure Code [CB1622]2126
Failure Code [CB1664]2129
Loaded Diagnostics Operation to Clear Failure Code2131
Failure Code [CB1691]2133
Failure Code [CB1695]2138
Failure Code [CB1696]2141
Failure Code [CB1843]2144
Failure Code [CB1844]2147
Failure Code [CB1879]2150
Failure Code [CB1881]2153
Failure Code [CB1883]2157
Loaded Diagnostics Operation to Clear Failure Code2160
Failure Code [CB1921]2162
Failure Code [CB1922]2170
Failure Code [CB1923]2177
Failure Code [CB1924]2180
Diagram Related to Fuel Doser2183
Failure Code [CB1925]2185
Diagram Related to Fuel Doser2187
Failure Code [CB1927]2189
Failure Code [CB1928]2192
Failure Code [CB1942]2196
Failure Code [CB1963]2199
Diagram Related to Fuel Doser2205
Failure Code [CB1977]2207
Loaded Diagnostics Operation to Clear Failure Code2210
Failure Code [CB1993]2211
Loaded Diagnostics Operation to Clear Failure Code2213
Failure Code [CB2249]2215
Failure Code [CB2265]2221
Failure Code [CB2266]2224
Failure Code [CB2271]2227
Failure Code [CB2272]2230
Failure Code [CB2349]2234
Failure Code [CB2353]2238
Failure Code [CB2357]2241
Failure Code [CB2381]2246
Failure Code [CB2382]2249
Failure Code [CB2383]2253
Failure Code [CB2386]2257
Failure Code [CB2387]2259
Failure Code [CB2637]2269
Failure Code [CB2639]2276
Failure Code [CB2732]2285
Failure Code [CB2733]2288
Failure Code [CB2741]2291
Diagram Related to Fuel Doser2292
Failure Code [CB2765]2294
Failure Code [CB2777]2296
Failure Code [CB2878]2299
Diagram Related to Fuel Doser2303
Failure Code [CB2881]2305
Loaded Diagnostics Operation to Clear Failure Code2309
Failure Code [CB3133]2312
Failure Code [CB3134]2315
Failure Code [CB3135]2318
Loaded Diagnostics Operation to Clear Failure Code2321
Failure Code [CB3167]2323
How to Reset Fuel Doser Information2326
Failure Code [CB3251]2329
Loaded Diagnostics Operation to Clear Failure Code2336
Failure Code [CB3253]2337
Loaded Diagnostics Operation to Clear Failure Code2345
Failure Code [CB3254]2347
Loaded Diagnostics Operation to Clear Failure Code2354
Failure Code [CB3255]2355
Loaded Diagnostics Operation to Clear Failure Code2362
Failure Code [CB3256]2364
Loaded Diagnostics Operation to Clear Failure Code2371
Failure Code [CB3311]2372
Loaded Diagnostics Operation to Confirm Failure Correction2379
Failure Code [CB3312]2381
Loaded Diagnostics Operation to Confirm Failure Correction2388
Failure Code [CB3313]2390
Failure Code [CB3314]2393
Failure Code [CB3315]2396
Loaded Diagnostics Operation to Confirm Failure Correction2400
Failure Code [CB3316]2402
Failure Code [CB3317]2405
Failure Code [CB3318]2408
Loaded Diagnostics Operation to Confirm Failure Correction2413
Failure Code [CB3319]2415
Failure Code [CB3321]2418
Failure Code [CB3322]2421
Loaded Diagnostics Operation to Confirm Failure Correction2426
Failure Code [CB3419]2428
Failure Code [CB3421]2430
Failure Code [CB4151]2433
Failure Code [CB4158]2440
Failure Code [CB4161]2443
Failure Code [CB4162]2446
Failure Code [CB4163]2449
Loaded Diagnostics Operation to Confirm Failure Correction2451
Failure Code [CB4259]2452
Failure Code [CB4952]2455
Failure Code [CB5383]2458
Failure Code [D018KB]2460
Failure Code [D018KY]2462
Failure Code [D019KB]2464
Failure Code [D019KY]2466
Failure Code [D150KB]2468
Failure Code [D150KZ]2471
Failure Code [D164KY]2474
Failure Code [D180KA]2477
Failure Code [D180KB]2480
Failure Code [D180KY]2483
Failure Code [D19HKZ]2485
Failure Code [D19JKZ]2488
Failure Code [D19QKZ]2491
Failure Code [D1EFKA]2494
Failure Code [D1EFKB]2497
Failure Code [D1EFKY]2500
Failure Code [D1EHKA]2502
Failure Code [D1EHKB]2505
Failure Code [D1EHKY]2508
Failure Code [D1EMKA]2510
Failure Code [D1EMKB]2513
Failure Code [D1EMKY]2516
Failure Code [D1ENKZ]2518
Failure Code [D1EPKA]2521
Failure Code [D1EPKB]2524
Failure Code [D1EPKY]2527
Failure Code [D1EQKA]2529
Failure Code [D1EQKB]2532
Failure Code [D1EQKY]2535
Failure Code [D1ERKA]2537
Failure Code [D1ERKB]2540
Failure Code [D1ERKY]2543
Failure Code [D1ESKA]2545
Failure Code [D1ESKB]2548
Failure Code [D1ESKY]2551
Failure Code [D1EWKA]2553
Failure Code [D1EWKB]2556
Failure Code [D1EWKY]2559
Failure Code [D1FBKB]2561
Failure Code [D1J0KB]2564
Failure Code [D5WNKZ]2567
Failure Code [D5ZHL6]2569
Failure Code [D862KA]2572
Failure Code [DAF0KT]2575
Failure Code [DAF0MB]2576
Failure Code [DAF0MC]2577
Failure Code [DAF3KK]2578
Failure Code [DAF8KB]2583
Failure Code [DAFDKB]2586
Failure Code [DAFGMC]2589
Failure Code [DAFLKA]2590
Failure Code [DAFLKB]2594
Failure Code [DAFQKR]2597
Failure Code [DAQ0KK]2611
Failure Code [DAQ0KT]2615
Failure Code [DAQ0MC]2617
Failure Code [DAQ1KA]2618
Failure Code [DAQ2KK]2621
Failure Code [DAQ9KQ]2625
Failure Code [DAQLKA]2627
Failure Code [DAQLKB]2631
Failure Code [DAQQKR]2634
Failure Code [DAQRKR]2649
Failure Code [DAQRMA]2663
Failure Code [DAQV00]2665
Failure Code [DAQW00]2667
Failure Code [DAZ9KQ]2668
Failure Code [DAZQKR]2670
Failure Code [DB10KT]2684
Failure Code [DB10MC]2685
Failure Code [DB11KA]2686
Failure Code [DB12KK]2689
Failure Code [DB13KK]2693
Failure Code [DB19KQ]2697
Failure Code [DB1LKA]2699
Failure Code [DB1LKB]2703
Failure Code [DB1QKR]2706
Failure Code [DB1QMA]2721
Failure Code [DB1RKR]2723
Failure Code [DB2QKR]2737
Failure Code [DB2RKR]2755
Failure Code [DBC0KT]2770
Failure Code [DBC0MC]2771
Failure Code [DBC1KA]2772
Failure Code [DBC2KK]2775
Failure Code [DBC3KK]2779
Failure Code [DBC9KQ]2783
Failure Code [DBCLKA]2785
Failure Code [DBCLKB]2789
Failure Code [DBCQKR]2792
Failure Code [DBCQMA]2806
Failure Code [DBCRKR]2807
Failure Code [DBP0KM]2819
Failure Code [DBP0KT]2821
Failure Code [DBP0NR]2824
Failure Code [DBP5KP]2825
Failure Code [DBPLKA]2829
Failure Code [DBPLKB]2833
Failure Code [DBPQKR]2836
Failure Code [DBPRKR]2850
Failure Code [DBPRMA]2863
Failure Code [DBPUKR]2865
Failure Code [DBPVKR]2875
Failure Code [DBPWKR]2885
Failure Code [DBPXKR]2887
Failure Code [DBV0MC]2890
Failure Code [DBV1KK]2891
Failure Code [DBV6KB]2895
Failure Code [DBV7KB]2900
Failure Code [DBV8KB]2903
Failure Code [DBVLKA]2906
Failure Code [DBVLKB]2910
Failure Code [DBVQKR]2913
Failure Code [DBVRKR]2928
Failure Code [DBVVKR]2942
Failure Code [DBVWKR]2944
Failure Code [DCR0MC]2946
Failure Code [DCR2KK]2947
Failure Code [DCR8L4]2951
Failure Code [DCR9KQ]2955
Failure Code [DCRLKA]2957
Failure Code [DCRLKB]2961
Failure Code [DCRQKR]2963
Failure Code [DCRRKR]2978
Failure Code [DDAAL6]2992
Failure Code [DDACL4]2996
Failure Code [DDADKA]3001
Failure Code [DDADKY]3004
Failure Code [DDD7KX]3007
Failure Code [DDDGL4]3011
Failure Code [DDDHL4]3014
Failure Code [DDE2KB]3017
Failure Code [DDE2L6]3020
Failure Code [DDP6L4]3023
Failure Code [DDTHKA]3027
Failure Code [DDTJKA]3030
Failure Code [DDTKKA]3033
Failure Code [DDTLKA]3036
Failure Code [DDTMKA]3039
Failure Code [DDTNKA]3042
Failure Code [DDTPKA]3045
Failure Code [DDU1KA]3048
Failure Code [DF10KA]3051
Failure Code [DF10KB]3057
Failure Code [DGE5KX]3062
Failure Code [DGF1KX]3066
Failure Code [DGR2KB]3070
Failure Code [DGR2L8]3073
Failure Code [DGR4KB]3076
Failure Code [DGR4L8]3079
Failure Code [DGR6KB]3082
Failure Code [DGR6L8]3085
Failure Code [DGT1KX]3088
Failure Code [DGT5KY]3092
Failure Code [DGT5KZ]3096
Failure Code [DGT6KY]3101
Failure Code [DGT6KZ]3105
Failure Code [DHAAMA]3110
Failure Code [DHABMA]3112
Failure Code [DHACMA]3114
Failure Code [DHADMA]3116
Failure Code [DHP4KY]3118
Failure Code [DHP4KZ]3121
Failure Code [DHP5KY]3125
Failure Code [DHP5KZ]3128
Failure Code [DHP6KA]3132
Failure Code [DHP6KX]3137
Failure Code [DHP6KY]3141
Failure Code [DHP6KZ]3144
Failure Code [DHP7KA]3148
Failure Code [DHP7KX]3153
Failure Code [DHP7KY]3158
Failure Code [DHP7KZ]3161
Failure Code [DHQ2KX]3165
Failure Code [DHQ4KX]3169
Failure Code [DHQ6KX]3173
Failure Code [DHT5KX]3177
Failure Code [DHT5L6]3180
Failure Code [DHT8KX]3182
Failure Code [DHT8ZG]3186
Failure Code [DHU2KX]3189
Failure Code [DHU3KX]3193
Failure Code [DHU6KX]3197
Failure Code [DHU7KX]3201
Failure Code [DHU8KX]3205
Failure Code [DHU9KX]3209
Failure Code [DHUBKX]3213
Failure Code [DHUCKX]3217
Failure Code [DHUDKX]3221
Failure Code [DHUHKX]3225
Failure Code [DHULKX]3229
Failure Code [DHUMKX]3233
Failure Code [DHUQKX]3237
Failure Code [DHUTKX]3241
Failure Code [DHY9KX]3245
Failure Code [DJF1KA]3248
Failure Code [DK30KX]3251
Failure Code [DK51L5]3255
Failure Code [DK52KX]3263
Failure Code [DK53L8]3267
Failure Code [DK54KX]3270
Failure Code [DK5VKX]3274
Failure Code [DK5VMA]3277
Failure Code [DK60KX]3279
Failure Code [DKD0L6]3283
Failure Code [DKH0KX]3287
Failure Code [DKH1KX]3290
Failure Code [DKR2KY]3294
Failure Code [DKR2KZ]3297
Failure Code [DLF1KA]3300
Failure Code [DLF1LC]3303
Failure Code [DLF2KA]3307
Failure Code [DLF2LC]3310
Failure Code [DLF6L3]3314
Failure Code [DLF7L3]3318
Failure Code [DLF8L3]3322
Failure Code [DLF8LC]3327
Failure Code [DLF9L3]3331
Failure Code [DLF9LC]3336
Failure Code [DLM3KA]3340
Failure Code [DLM3LC]3342
Failure Code [DLM3MB]3345
Failure Code [DLT3KA]3347
Failure Code [DLT3LC]3349
Failure Code [DPQ1KR]3352
Failure Code [DPQ1LD]3358
Failure Code [DPQ2KR]3364
Failure Code [DPQ3KR]3370
Failure Code [DPQ4KB]3376
Failure Code [DQ11KQ]3379
Sensor Addresses List3383
Failure Code [DQ11KR]3384
Failure Code [DQ11KT]3387
Failure Code [DQ11MA]3390
Failure Code [DQ11NR]3395
Failure Code [DQ12KQ]3398
Sensor Addresses List3402
Failure Code [DQ12KR]3403
Failure Code [DQ12KT]3406
Failure Code [DQ12MA]3409
Failure Code [DQ12NR]3414
Failure Code [DQ13KQ]3417
Sensor Addresses List3421
Failure Code [DQ13KR]3422
Failure Code [DQ13KT]3425
Failure Code [DQ13MA]3428
Failure Code [DQ13NR]3433
Failure Code [DQ14KQ]3436
Sensor Addresses List3440
Failure Code [DQ14KR]3441
Failure Code [DQ14KT]3444
Failure Code [DQ14MA]3447
Failure Code [DQ14NR]3452
Failure Code [DQ15KQ]3455
Sensor Addresses List3459
Failure Code [DQ15KR]3460
Failure Code [DQ15KT]3463
Failure Code [DQ15MA]3466
Failure Code [DQ15NR]3471
Failure Code [DQ16KQ]3474
Sensor Addresses List3478
Failure Code [DQ16KR]3479
Failure Code [DQ16KT]3482
Failure Code [DQ16MA]3485
Failure Code [DQ16NR]3490
Failure Code [DQ17KQ]3493
Sensor Addresses List3497
Failure Code [DQ17KR]3498
Failure Code [DQ17KT]3501
Failure Code [DQ17MA]3504
Failure Code [DQ17NR]3509
Failure Code [DQ18KQ]3512
Sensor Addresses List3516
Failure Code [DQ18KR]3517
Failure Code [DQ18KT]3520
Failure Code [DQ18MA]3523
Failure Code [DQ18NR]3528
Failure Code [DR10KA]3531
Failure Code [DR20KA]3535
Failure Code [DR30KA]3539
Failure Code [DR40KA]3543
Failure Code [DR50KA]3547
Failure Code [DR60KA]3551
Failure Code [DR81KR]3555
Failure Code [DR81MA]3565
Failure Code [DSJ0KR]3566
Failure Code [DUMBKB]3579
Failure Code [DV00KB]3582
Failure Code [DV01KB]3585
Failure Code [DV03KB]3588
Failure Code [DV03KY]3591
Failure Code [DW2AKA]3593
Failure Code [DW2AKB]3596
Failure Code [DW2AKY]3599
Failure Code [DW2AL1]3601
Failure Code [DW2ALH]3604
Failure Code [DW2BKA]3607
Failure Code [DW2BKB]3610
Failure Code [DW2BKY]3613
Failure Code [DW2BL1]3615
Failure Code [DW2BLH]3618
Failure Code [DW2CKA]3621
Failure Code [DW2CKB]3623
Failure Code [DW2CKY]3626
Failure Code [DW2CL1]3628
Failure Code [DW2CLH]3631
Failure Code [DW35KZ]3634
Failure Code [DW36KZ]3637
Failure Code [DW4BK4]3640
Failure Code [DW4BMA]3644
Failure Code [DW72KZ]3648
Failure Code [DW73KA]3651
Failure Code [DW73KB]3653
Failure Code [DW73KY]3656
Failure Code [DW78KZ]3658
Failure Code [DW7BKB]3662
Failure Code [DW7BKY]3665
Failure Code [DW7BKZ]3667
Failure Code [DW7MKB]3669
Failure Code [DW7MKY]3672
Failure Code [DW7MKZ]3674
Failure Code [DW7NKZ]3676
Failure Code [DWD6KA]3679
Failure Code [DWD6KB]3681
Failure Code [DWD6KY]3684
Failure Code [DWD6MA]3686
Failure Code [DWD7K4]3690
Failure Code [DWD7KA]3693
Failure Code [DWD7KB]3695
Failure Code [DWD7KY]3698
Failure Code [DWD7MA]3700
Failure Code [DWNJKZ]3703
Failure Code [DWNLKA]3706
Failure Code [DWNLKB]3708
Failure Code [DWNLKY]3711
Failure Code [DWNMKZ]3713
Failure Code [DWPQKZ]3716
Failure Code [DWPQMA]3719
Failure Code [DWPRKZ]3724
Failure Code [DWPRMA]3727
Failure Code [DWPSKZ]3732
Failure Code [DWPSMA]3735
Failure Code [DWPTKZ]3740
Failure Code [DWPTMA]3743
Failure Code [DX13KA]3748
Failure Code [DX13KB]3750
Failure Code [DX13KY]3753
Failure Code [DX16KA]3755
Failure Code [DX16KB]3757
Failure Code [DX16KY]3760
Failure Code [DX21KA]3762
Failure Code [DX21KB]3764
Failure Code [DX21KY]3767
Failure Code [DX21MA]3769
Failure Code [DX22KA]3773
Failure Code [DX22KB]3775
Failure Code [DX22KY]3778
Failure Code [DX22MA]3780
Failure Code [DX23KA]3784
Failure Code [DX23KB]3786
Failure Code [DX23KY]3789
Failure Code [DX23MA]3791
Failure Code [DX24KA]3795
Failure Code [DX24KB]3797
Failure Code [DX24KY]3800
Failure Code [DX24MA]3802
Failure Code [DX25MA]3806
Failure Code [DX26MA]3808
Failure Code [DX30K4]3810
Failure Code [DX30KA]3813
Failure Code [DX30KB]3815
Failure Code [DX30KY]3818
Failure Code [DX30MA]3820
Failure Code [DX33K4]3823
Failure Code [DX33KA]3826
Failure Code [DX33KB]3828
Failure Code [DX33KY]3831
Failure Code [DX33MA]3833
Failure Code [DX37K4]3836
Failure Code [DX37KA]3839
Failure Code [DX37KB]3841
Failure Code [DX37KY]3844
Failure Code [DX37MA]3846
Failure Code [DX38K4]3849
Failure Code [DX38KA]3852
Failure Code [DX38KB]3854
Failure Code [DX38KY]3857
Failure Code [DX38MA]3859
Failure Code [DXH1KA]3862
Failure Code [DXH1KB]3865
Failure Code [DXH1KY]3868
Failure Code [DXH2KA]3870
List of Number of Gear Shift When Failure is Found3872
Failure Code [DXH2KB]3874
List of Number of Gear Shift When Failure is Found3877
Failure Code [DXH2KY]3878
List of Number of Gear Shift When Failure is Found3880
Failure Code [DXH3KA]3882
List of Number of Gear Shift When Failure is Found3884
Failure Code [DXH3KB]3886
List of Number of Gear Shift When Failure is Found3889
Failure Code [DXH3KY]3890
List of Number of Gear Shift When Failure is Found3892
Failure Code [DXH4KA]3894
List of Number of Gear Shift When Failure is Found3896
Failure Code [DXH4KB]3898
List of Number of Gear Shift When Failure is Found3901
Failure Code [DXH4KY]3902
List of Number of Gear Shift When Failure is Found3904
Failure Code [DXH5KA]3906
List of Number of Gear Shift When Failure is Found3908
Failure Code [DXH5KB]3910
List of Number of Gear Shift When Failure is Found3913
Failure Code [DXH5KY]3914
List of Number of Gear Shift When Failure is Found3916
Failure Code [DXH6KA]3918
List of Number of Gear Shift When Failure is Found3920
Failure Code [DXH6KB]3922
List of Number of Gear Shift When Failure is Found3925
Failure Code [DXH6KY]3926
List of Number of Gear Shift When Failure is Found3928
Failure Code [DXH7KA]3930
Failure Code [DXH7KB]3933
Failure Code [DXH7KY]3936
Failure Code [DXHHKA]3938
Failure Code [DXHHKB]3941
Failure Code [DXHHKY]3944
List of Number of Gear Shift When Failure is Found3946
Failure Code [DY30MA]3948
Failure Code [DY30MC]3952
Failure Code [DY30ME]3959
Failure Code [F@BWNR]3962
Failure Code [F@BWNS]3964
Failure Code [F@BXNR]3966
Failure Code [F@BXNS]3968
Troubleshooting of Electrical System (E-Mode)3970
Engine Does Not Start (Engine Does Not Crank)3970
Manual Preheating System Does Not Operate3981
Automatic Preheating System Does Not Operate3987
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On3991
LCD Unit, LED Unit, and Meter Unit on Machine Monitor Do Not Show Anything3994
LCD Unit on Machine Monitor Shows Nothing4003
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)4006
LCD Screen on Machine Monitor Does Not Show Correctly4009
Meter Unit Display on Machine Monitor is Abnormal4012
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal4017
LED Unit Lamp on Machine Monitor is Abnormal4021
Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly4026
Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate4031
Switch Panel Buzzer of Machine Monitor is Abnormal4036
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly4041
Rearview Monitor Does Not Come On or Backlight Flickers4042
Rearview Monitor Images are Not Shown Clearly4047
Rearview Monitor Brightness Cannot be Adjusted4053
Night Mode Lamp of Rearview Monitor is Abnormal4059
Air Cleaner Clogging Caution Lamp Does Not Come On4063
Transmission Oil Filter Clogging Caution Lamp Does Not Come On4066
Radiator Coolant Level Caution Lamp Does Not Come On4070
Rear View Monitor is Not Shown in Conjunction with Revers When the Constant Display Setting is Disable4073
Rear View Monitor Reference Line is Not Shown When the Reference Line Display Setting is Turned ON4076
Fuel Gauge Does Not Show Normally4078
Torque Converter Oil Temperature Gauge Does Not Rise or Torque Converter Oil Temperature Caution Lamp Does Not Come On4081
Retarder Oil Temperature Gauge Does Not Rise or Retarder Oil Temperature Caution Lamp Does Not Come On4084
Seatbelt Caution Lamp Does Not Show Normally4088
Machine Monitor Cannot be Operated When Starting Switch is in OFF Position4092
Alarm Buzzer Does Not Operate4096
Alarm Buzzer Does Not Stop4098
Engine Mode Selector Function Does Not Operate Correctly When Engine Power Mode Selector Switch is Operated4103
AISS Function Does Not Operate Correctly4107
Dump (Hoist) Control Lever Does Not Operate Correctly4111
Fuel Feed Pump Does Not Operate or Stop Automatically4114
Turn Signal Lamp and Hazard Lamp Do Not Operate Correctly4124
Horn Does Not Sound4132
Horn Does Not Stop4136
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On4139
Clearance Lamp Does Not Come On4144
Tail Lamp Does Not Come On4147
Headlamp (Low Beam) Does Not Come On4150
Headlamp (High Beam) Does Not Come On4154
Headlamp (Low Beam) and (High Beam) Do Not Come On4158
Passing Lamp Does Not Come On4161
KOMTRAX System Does Not Operate Correctly4164
Data Download with Wireless LAN Does Not Operate4166
KomVision Monitor Does Not Come On or Backlight Flickers4167
KomVision Monitor Images are Not Shown Clearly4172
KomVision Monitor Brightness Cannot be Adjusted4181
Night Mode Lamp of KomVision Monitor is Abnormal4187
A Part of Camera Image of KomVision Monitor is Not Shown4191
Example of Black Out on KomVision Monitor4192
KomVision Monitor is Not Shown Correctly After Calibration4194
Cannot Access to the Setting Screen of the Mobile Communication Terminal4196
Cannot Log in to the Setting Screen of the Mobile Communication Terminal Because the Log in Password is Unknown4203
KOMTRAX Plus Controller is Not Found4205
KOMTRAX Plus Controller Does Not Become Active4207
Communication Failure Occurs Between Mobile Communication Terminal and KOMTRAX Plus Server4208
Restrictions on Radio Reception4210
Data is Not Sent to KOMTRAX Plus Server4211
Alarm Buzzer Does Not Sound When Power Ladder is in Operation4213
Power Ladder Pump Does Not Operate4216
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)4221
Information Shown in Troubleshooting Table (H-Mode)4221
Failure Mode and Cause Table4222
Machine Does Not Start4227
Table of Clutch to be Used4233
Machine Does Not Travel Smoothly (Machine Hunts)4234
Table of Clutch to be Used4238
Lockup is Not Released4239
Strong Shock is Made When You Start Machine or Shift Gears4240
Table of Clutch to be Used4242
Shiftup Does Not Operate4243
Table of Clutch to be Used4247
Travel Speed in All Gear Speed is Low or Power is Low During Travel with Lockup Function4248
Travel Speed is Low or Power is Low During Travel with Torque Converter4252
Travel Speed is Low or Power is Low in Specified Gear Speed4256
Table of Clutch to be Used4259
Time Lag is Large When You Start Machine or Shift Gears4260
Table of Clutch to be Used4264
Torque Converter Oil Temperature is High4265
Torque Converter Oil Pressure is Low4269
Steering Wheel is Heavy to Operate4273
Steering Wheel is Disabled4277
Steering Wheel is Shaken4280
Parking Brake Does Not Operate or is Weak4282
Parking Brake is Not Released or Drags4283
Front Brake Does Not Operate Sufficiently4285
Rear Brake Does Not Operate Sufficiently4288
Speed is Low When Dump Body is Raised4291
Hydraulic Drift of Dump Body is Large4295
Dump Body is Disabled4296
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)4300
Unusual Noise is Heard from Around Fan4303
Power Ladder Does Not Operate or Moves Slow4304
Troubleshooting of Engine (S-Mode)4307
Information Shown in Troubleshooting Table (S-Mode)4307
Engine Does Not Crank When Starting Switch is Turned to Start Position4308
Engine Cranks but Does Not Start4310
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)4315
Engine Startability is Unsatisfactory4322
Engine Does Not Pick Up Smoothly4328
Engine Stops During Operation4335
Engine Does Not Rotate Smoothly4342
Engine Lacks Output (or Lacks Power)4348
KDPF Becomes Clogged in a Short Time4355
Engine Oil Consumption is Excessive4360
Engine Oil Becomes Dirty Quickly4364
Fuel Consumption is Excessive4368
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)4372
Engine Oil Pressure Drops4374
Fuel Mixes Into Engine Oil4378
Water Mixes Into Engine Oil (Milky)4380
Coolant Temperature Increases Too High (Overheat)4383
Unusual Noise is Heard4388
Vibration is Excessive4391
Air Cannot be Bled from Fuel Circuit4393
Active Regeneration is Done Frequently4397
Active Regeneration Continues Long4403
White Smoke is Exhausted During Active Regeneration4408
50 Disassembly and Assembly4411
Table of Contents4412
Precautions Before Work4418
Related Information on Disassembly and Assembly4419
How to Read This Manual4419
Coating Materials List4421
Special Tool List4426
Sketches of Special Tools4443
Engine and Cooling System4450
Remove and Install Supply Pump Assembly (Right Bank)4450
How to Remove Supply Pump Assembly (Right Bank)4451
How to Install Supply Pump Assembly (Right Bank)4460
Remove and Install Supply Pump Assembly (Left Bank)4477
How to Remove Supply Pump Assembly (Left Bank)4477
How to Install Supply Pump Assembly (Left Bank)4483
Remove and Install Injector Assembly (Right Bank)4492
How to Remove Injector Assembly (Right Bank)4493
How to Install Injector Assembly (Right Bank)4502
Remove and Install Injector Assembly (Left Bank)4514
How to Remove Injector Assembly (Left Bank)4515
How to Install Injector Assembly (Left Bank)4524
Remove and Install Fuel Doser Assembly (Right Bank)4538
How to Remove Fuel Doser Assembly (Right Bank)4538
How to Install Fuel Doser Assembly (Right Bank)4542
Remove and Install Fuel Doser Assembly (Left Bank)4547
How to Remove Fuel Doser Assembly (Left Bank)4547
How to Install Fuel Doser Assembly (Left Bank)4551
Remove and Install Cylinder Head Assembly (Right Bank)4555
How to Remove Cylinder Head Assembly (Right Bank)4557
How to Install Cylinder Head Assembly (Right Bank)4587
Remove and Install Cylinder Head Assembly (Left Bank)4632
How to Remove Cylinder Head Assembly (Left Bank)4633
How to Install Cylinder Head Assembly (Left Bank)4666
Remove and Install EGR Valve Assembly (Right Bank)4714
How to Remove EGR Valve Assembly (Right Bank)4715
How to Install EGR Valve Assembly (Right Bank)4724
Remove and Install EGR Valve Assembly (Left Bank)4737
How to Remove EGR Valve Assembly (Left Bank)4738
How to Install EGR Valve Assembly (Left Bank)4748
Remove and Install EGR Cooler Assembly (Right Bank)4764
How to Remove EGR Cooler Assembly (Right Bank)4765
How to Install EGR Cooler Assembly (Right Bank)4783
Remove and Install EGR Cooler Assembly (Left Bank)4807
How to Remove EGR Cooler Assembly (Left Bank)4808
How to Install EGR Cooler Assembly (Left Bank)4827
Remove and Install Starter Assembly4852
How to Remove Starting Motor Assembly4852
How to Install Starting Motor Assembly4855
Remove and Install Alternator Belt4858
How to Remove Alternator Belt4858
How to Install Alternator Belt4862
Remove and Install Alternator Assembly4867
How to Remove Alternator Assembly4868
How to Install Alternator Assembly4870
Drain and Add Fuel4875
How to Drain Fuel4875
How to Add Fuel4877
Remove and Install Cooler Assembly4878
How to Remove Cooling Assembly4880
How to Install Cooling Assembly4912
Remove and Install Radiator Core4952
How to Remove Radiator Core4952
How to Install Radiator Core4960
Remove and Install Cooling Fan and Fan Motor Assembly4968
How to Remove Cooling Fan and Fan Motor Assembly4968
How to Install Cooling Fan and Fan Motor Assembly4972
Remove and Install Aftercooler Assembly4977
How to Remove Aftercooler Assembly4978
How to Install Aftercooler Assembly4985
Remove and Install Oil Cooler Assembly4993
How to Remove Oil Cooler Assembly4994
How to Install Oil Cooler Assembly4997
Remove and Install Engine Assembly5000
How to Remove Engine Assembly5002
How to Install Engine Assembly5022
Remove and Install Engine Front Oil Seal5043
How to Remove Engine Front Oil Seal5043
How to Install Engine Front Oil Seal5045
Remove and Install Engine Rear Oil Seal5048
How to Remove Engine Rear Oil Seal5048
How to Install Engine Rear Oil Seal5050
Remove and Install Fuel Tank Assembly5053
How to Remove Fuel Tank Assembly5054
How to Install Fuel Tank Assembly5058
Remove and Install KDPF Assembly (with Bracket)5062
How to Remove KDPF Assembly (Together with Bracket)5063
How to Install KDPF Assembly (Together with Bracket)5088
Remove and Install KDPF Assembly (Without Bracket)5112
How to Remove KDPF Assembly (Single Unit)5113
How to Install KDPF Assembly (Single Unit)5138
Disassemble and Assemble KDPF Assembly5162
How to Disassemble KDPF Assembly5163
How to Assemble KDPF Assembly5170
Remove and Install KCCV Assembly (Right Bank)5179
How to Remove KCCV Assembly (Right Bank)5179
How to Install KCCV Assembly (Right Bank)5183
Remove and Install KCCV Assembly (Left Bank)5187
How to Remove KCCV Assembly (Left Bank)5187
How to Install KCCV Assembly (Left Bank)5191
Remove and Install VGT Assembly (Right Bank)5195
How to Remove VGT Assembly (Right Bank)5196
How to Install VGT Assembly (Right Bank)5207
Remove and Install VGT Assembly (Left Bank)5220
How to Remove VGT Assembly (Left Bank)5221
How to Install VGT Assembly (Left Bank)5231
Remove and Install Air Cleaner Assembly5243
How to Remove Air Cleaner Assembly5243
How to Install Air Cleaner Assembly5247
Remove and Install Air Conditioner Compressor Assembly5250
How to Remove Air Conditioner Compressor Assembly5251
How to Install Air Conditioner Compressor Assembly5255
Remove and Install Air Conditioner Condenser Assembly5261
How to Remove Air Conditioner Condenser Assembly5261
How to Install Air Conditioner Condenser Assembly5263
Power Train5266
Drain and Add Transmission Oil5266
How to Drain Transmission Oil5266
How to Add Transmission Oil5267
Remove and Install Damper Assembly5268
How to Remove Damper Assembly5269
How to Install Damper Assembly5277
Disassemble and Assemble Damper Assembly5287
How to Disassemble Damper Assembly5287
How to Assemble Damper Assembly5288
Remove and Install Front Drive Shaft5290
How to Remove Front Drive Shaft5290
How to Install Front Drive Shaft5292
Remove and Install Rear Drive Shaft5295
How to Remove Rear Drive Shaft5295
How to Install Rear Drive Shaft5297
Remove And Install Torque Converter and PTO Assembly, and Transmission Assembly5299
How to Remove Torque Converter and PTO Assembly, and Transmission Assembly5301
How to Install Torque Converter and PTO Assembly, and Transmission Assembly5317
Disconnect And Connect Torque Converter and PTO Assembly, and Transmission Assembly5333
How to Disconnect Torque Converter and PTO Assembly, and Transmission Assembly5334
How to Connect Torque Converter and PTO Assembly, and Transmission Assembly5342
Disassemble and Assemble Torque Converter and PTO Assembly5354
How to Disassemble Torque Converter and PTO Assembly5356
How to Assemble Torque Converter and PTO Assembly5364
Disassemble and Assemble Transmission Assembly5379
How to Disassemble Transmission Assembly5382
How to Assemble Transmission Assembly5400
Remove and Install Differential Assembly5428
How to Remove Differential Assembly5429
How to Install Differential Assembly5433
Disassemble and Assemble Differential Assembly5438
How to Disassemble Differential Assembly5440
How to Assemble Differential Assembly5454
Remove and Install Final Drive and Rear Brake Assembly5477
How to Remove Final Drive and Rear Brake Assembly5478
How to Install Final Drive and Rear Brake Assembly5481
Disassemble and Assemble Final Drive and Rear Brake Assembly5484
How to Disassemble Final Drive and Rear Brake Assembly5486
How to Assemble Final Drive and Rear Brake Assembly5499
Remove and Install Final Drive Carrier Assembly5523
How to Remove Final Drive Carrier Assembly5524
How to Install Final Drive Carrier Assembly5526
Disassemble and Assemble Final Drive Carrier Assembly5529
How to Disassemble Final Drive Carrier Assembly5529
How to Assemble Final Drive Carrier Assembly5530
Brake System5532
Drain and Add Brake Oil5532
How to Drain Brake Oil5532
How to Add Brake Oil5533
Remove and Install Slack Adjuster Assembly5534
How to Remove Slack Adjuster Assembly5535
How to Install Slack Adjuster Assembly5537
Remove and Install Brake Accumulator Charge Valve Assembly5539
How to Remove Brake Accumulator Charge Valve Assembly5540
How to Install Brake Accumulator Charge Valve Assembly5541
Remove and Install Front Wheel Hub and Brake Assembly5544
How to Remove Front Wheel Hub and Brake Assembly5546
How to Install Front Wheel Hub and Brake Assembly5553
Disassemble and Assemble Front Wheel Hub and Brake Assembly5560
How to Disassemble Front Wheel Hub and Brake Assembly5561
How to Assemble Front Wheel Hub and Brake Assembly5568
Steering System5579
Remove and Install Steering Valve Assembly5579
How to Remove Steering Valve Assembly5580
How to Install Steering Valve Assembly5585
Remove and Install Steering Cylinder Assembly5590
How to Remove Steering Cylinder Assembly5592
How to Install Steering Cylinder Assembly5606
Disassemble and Assemble Steering Cylinder Assembly5620
How to Disassemble Steering Cylinder Assembly5621
How to Assemble Steering Cylinder Assembly5622
Undercarriage and Frame5625
Remove and Install Front Wheel Assembly5625
How to Remove Front Wheel Assembly5625
How to Install Front Wheel Assembly5629
Remove and Install Rear Wheel Assembly5632
How to Remove Rear Wheel Assembly5632
How to Install Rear Wheel Assembly5636
Remove and Install Right Front Suspension Cylinder Assembly5639
How to Remove Right Front Suspension Cylinder Assembly5641
How to Install Right Front Suspension Cylinder Assembly5658
Remove and Install Left Front Suspension Cylinder Assembly5674
How to Remove Left Front Suspension Cylinder Assembly5676
How to Install Left Front Suspension Cylinder Assembly5698
Disassemble and Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5719
How to Disassemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5720
How to Assemble Front Suspension Cylinder Assembly (Cylinder with Buffer Ring)5722
Remove and Install Kingpin5725
How to Remove Kingpin5726
How to Install Kingpin5736
Remove and Install Rear Suspension Cylinder Assembly5746
How to Remove Rear Suspension Cylinder Assembly5746
How to Install Rear Suspension Cylinder Assembly5751
Disassemble and Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5756
How to Disassemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5757
How to Assemble Rear Suspension Cylinder Assembly (Cylinder with Buffer Ring)5758
Remove and Install Slanted Ladder Assembly5762
How to Remove Slanted Ladder Assembly5763
How to Install Slanted Ladder Assembly5765
Hydraulic System5768
Drain and Add Hydraulic Oil5768
How to Drain Hydraulic Oil5768
How to Add Hydraulic Oil5769
Remove and Install Hydraulic Tank Assembly5770
How to Remove Hydraulic Tank Assembly5771
How to Install Hydraulic Tank Assembly5777
Remove and Install Steering and Hoist Pump Assembly5784
How to Remove Steering and Hoist Pump Assembly5785
How to Install Steering and Hoist Pump Assembly5792
Remove and Install Power Train Duplex Pump Assembly5800
How to Remove Power Train Duplex Pump Assembly5801
How to Install Power Train Duplex Pump Assembly5809
Remove and Install Rear Brake Cooling and Brake Charge Triplex Pump Assembly5817
How to Remove Rear Brake Cooling and Brake Charge Triplex Pump Assembly5818
How to Install Rear Brake Cooling and Brake Charge Triplex Pump Assembly5822
Remove and Install Cooling Fan and Hoist Pump Assembly5825
How to Remove Cooling Fan and Hoist Pump Assembly5826
How to Install Cooling Fan and Hoist Pump Assembly5830
Remove and Install Demand Valve Assembly5833
How to Remove Demand Valve Assembly5834
How to Install Demand Valve Assembly5841
Remove and Install Hoist Valve Assembly5849
How to Remove Hoist Valve Assembly5850
How to Install Hoist Valve Assembly5852
Remove and Install Hoist Cylinder Assembly5856
How to Remove Hoist Cylinder Assembly5857
How to Install Hoist Cylinder Assembly5860
Disassemble and Assemble Hoist Cylinder Assembly5862
How to Disassemble Hoist Cylinder Assembly5863
How to Assemble Hoist Cylinder Assembly5866
Work Equipment5871
Fix and Release Body RAISE Position5871
How to Fix Body RAISE Position5871
How to Release Body RAISE Position5872
Remove and Install Dump Body Assembly5875
How to Remove Body Assembly5876
How to Install Body Assembly5880
CAB Related Parts5886
Remove and Install Operator Cab Assembly5886
How to Remove Operator Cab Assembly5888
How to Install Operator Cab Assembly5916
Remove and Install Operator CAB Glass5946
How to Remove Operator Cab Front Window Glass5947
How to Install Operator Cab Front Window Glass5949
How to Remove Operator Cab Glass (Adhered Glass)5952
How to Install Operator Cab Glass (Adhered Glass)5953
Remove and Install Air Conditioner Unit Assembly5957
How to Remove Air Conditioner Unit Assembly5958
How to Install Air Conditioner Unit Assembly5966
Remove and Install Operator Seat Assembly5974
How to Remove Operator Seat Assembly5974
How to Install Operator Seat Assembly5977
How to Remove and Install Seat Belt5980
How to Remove Seat Belt5980
How to Install Seatbelt5981
Electrical System5983
Remove and Install Engine Controller Assembly (Right Bank)5983
How to Remove Engine Controller Assembly (Right Bank)5983
How to Install Engine Controller Assembly (Right Bank)5986
Remove and Install Engine Controller Assembly (Left Bank)5989
How to Remove Engine Controller Assembly (Left Bank)5989
How to Install Engine Controller Assembly (Left Bank)5992
Remove and Install Retarder and Hoist Controller Assembly5995
How to Remove Retarder and Hoist Controller Assembly5995
How to Install Retarder and Hoist Controller Assembly5996
Remove and Install ABS and Power Ladder Controller Assembly5998
How to Remove ABS and Power Ladder Controller Assembly5998
How to Install ABS and Power Ladder Controller Assembly6000
Remove and Install Transmission Controller Assembly6002
How to Remove Transmission Controller Assembly6002
How to Install Transmission Controller Assembly6003
Remove and Install Machine Monitor Assembly6005
How to Remove Machine Monitor Assembly6006
How to Install Machine Monitor Assembly6008
Remove and Install Monitor Controller Assembly6011
How to Remove Monitor Controller Assembly6011
How to Install Monitor Controller Assembly6012
Remove and Install Mass Air Flow and Temperature Sensor6014
How to Remove Mass Air Flow and Temperature Sensor6014
How to Install Mass Air Flow and Temperature Sensor6016
Remove and Install KCCV Crankcase Pressure Sensor (Right Bank)6018
How to Remove KCCV Crankcase Pressure Sensor (Right Bank)6018
How to Install KCCV Crankcase Pressure Sensor (Right Bank)6020
Remove and Install KCCV Crankcase Pressure Sensor (Left Bank)6023
How to Remove KCCV Crankcase Pressure Sensor (Left Bank)6023
How to Install KCCV Crankcase Pressure Sensor (Left Bank)6025
Remove And Install KOMTRAX Plus Controller Assembly6028
How to Remove KOMTRAX Plus Controller Assembly6029
How to Install KOMTRAX Plus Controller Assembly6030
Remove and Install Mobile Communication Terminal6032
How to Remove Mobile Communication Terminal6032
How to Install Mobile Communication Terminal6033
Remove and Install DC-DC Converter6035
How to Remove DC-DC Converter6035
How to Install DC-DC Converter6036
Remove and Install Mobile Communication Terminal Wiring Harness6037
How to Remove Mobile Communication Terminal Wiring Harness6037
How to Install Mobile Communication Terminal Wiring Harness6042
Remove and Install KOMTRAX Terminal Assembly6048
How to Remove KOMTRAX Terminal Assembly6048
How to Install KOMTRAX Terminal Assembly6050
Remove and Install Rearview Camera6051
How to Remove Rearview Camera6051
How to Install Rearview Camera6052
Remove and Install KomVision Camera6053
How to Remove KomVision Camera6053
How to Install KomVision Camera6058
Remove and Install KomVision Radar6063
How to Remove KomVision Radar6064
How to Install KomVision Radar6077
Remove and Install KomVision Controller Assembly6091
How to Remove KomVision Controller Assembly6091
How to Install KomVision Controller Assembly6093
Remove and Install Wireless LAN Unit Assembly6095
How to Remove Wireless LAN Unit Assembly6095
How to Install Wireless LAN Unit Assembly6097
Remove and Install Driver Status Monitor6101
How to Remove Driver Status Monitor6101
How to Install Driver Status Monitor6102
Remove and Install Translator Controller6104
How to Remove Translator Controller6104
How to Install Translator Controller6105
Remove and Install Drowsiness Detection Camera6107
How to Remove Drowsiness Detection Camera6107
How to Install Drowsiness Detection Camera6108
Remove and Install Drowsiness Alarm Buzzer6110
How to Remove Drowsiness Alarm Buzzer6110
How to Install Drowsiness Alarm Buzzer6111
Remove and Install Drowsiness Detection Wiring Harness6113
How to Remove Drowsiness Detection Wiring Harness6113
How to Install Drowsiness Detection Wiring Harness6123
60 Maintenance Standard6135
Table of Contents6136
Explanation of Terms for Maintenance Standard6137
Engine and Cooling System6139
Maintenance Standard for Engine Mount6139
Maintenance Standard for Damper6140
Maintenance Standard for Cooling Fan, Hoist Pump6142
Maintenance Standard for Servo Valve of Cooling Fan, Hoist Pump6144
Maintenance Standard for Cooling Fan Motor6145
Power Train6148
Maintenance Standard for Drive Shaft6148
Maintenance Standard for Torque Converter and Transmission Mount6149
Maintenance Standard for Torque Converter and PTO6150
Maintenance Standard for Transmission6154
Maintenance Standard for Transmission Control Valve6162
Maintenance Standard for Lockup Clutch ECMV6163
Maintenance Standard for H, L, R, 1st, 2nd, 3rd, 4th Clutch ECMV6164
Maintenance Standard for Valve Assembly (Main Pressure Variable, Torque Converter Relief, Main Flow Rate Select)6165
Maintenance Standard for Transmission Lubricating Oil Selector Valve6167
Maintenance Standard for Front Axle6169
Maintenance Standard for Rear Axle6170
Maintenance Standard for Differential6171
Maintenance Standard for Final Drive6173
Steering System6175
Maintenance Standard for Steering Column6175
Maintenance Standard for Steering Linkage6176
Maintenance Standard for Demand Valve6179
Maintenance Standard for Steering Cylinder6182
Brake System6183
Maintenance Standard for Front Brake, Parking Brake6183
Maintenance Standard for Rear Brake, Parking Brake6185
Undercarriage and Frame6187
Maintenance Standard for Front Suspension Cylinder6187
Maintenance Standard for Rear Suspension Cylinder6191
Maintenance Standard for Rear Axle Support6193
Hydraulic System6195
Maintenance Standard for Hydraulic Tank6195
Maintenance Standard for Pump Assembly (Steering, Hoist)6196
Maintenance Standard for Servo Valve of Pump Assembly (Steering, Hoist)6198
Maintenance Standard for Hoist Valve6199
Work Equipment6201
Maintenance Standard for Hoist Cylinder6201
CAB Related Parts6202
Maintenance Standard for CAB Mount6202
80 Others6203
Table of Contents6204
Precautions Before Work6206
Air Conditioner System6207
Precautions for Refrigerant6207
Layout Drawing of Air Conditioner System6208
Specifications of Air Conditioner6210
Structure of Refrigeration Cycle6211
Function of Refrigeration Cycle6212
System Diagram of Air Conditioner6213
Component Parts of Air Conditioner System6214
Air Conditioner Unit6214
Component Parts of Air Conditioner Unit6217
Function of Evaporator in Air Conditioner Unit6217
Function of Heater Core in Air Conditioner Unit6217
Function of Servomotor in Air Conditioner Unit6217
Operation of Servo Motor of Air Conditioner Unit6217
Structure of Expansion Valve in Air Conditioner Unit6218
Function of Expansion Valve in Air Conditioner Unit6218
Operation of Expansion Valve in Air Conditioner Unit6218
Function of Dual Pressure Switch6219
Air Conditioner Controller6220
Structure of Air Conditioner Controller6220
Input and Output Signals of Air Conditioner Controller6221
Compressor6222
Structure of Compressor6222
Specifications of Compressor6222
Function of Compressor6222
Operation of Compressor6223
Condenser6224
Structure of Condenser6224
Specifications of Condenser6224
Function of Condenser6224
Air Conditioner Related Sensors6226
Structure of Temperature Sensor (Fresh Air)6226
Function of Temperature Sensor (Fresh Air)6226
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner6227
Circuit Diagram and Configuration of Connector Pins of Air Conditioner6229
Locations of Air Conditioner Parts and Layout of Connectors6231
Examine Air Leakage (Duct)6235
How to Examine Air Leakage in Duct Connection6235
Examine Air Conditioner with Self-Diagnosis Function6238
Examine Vent (Mode) Changeover6239
How to Examine Vent (Mode) Changeover6239
Examine Fresh/Recirc Air Changeover6241
How to Examine Fresh/Recirc Air Changeover6241
Examine Refrigerant (Dual) Pressure Switch6242
How to Examine Refrigerant (Dual) Pressure Switch6242
Examine Relay6243
How to Examine Relay6243
Simple Check of Refrigerant Level Through Sight Glass6244
Air Conditioner Troubleshooting Chart 16245
Air Conditioner Troubleshooting Chart 26247
Information Shown in Troubleshooting6250
Troubleshooting by Failure Code (Display of Code)6253
Failure Code [879AKA]6253
Failure Code [879AKB]6254
Failure Code [879BKA]6255
Failure Code [879BKB]6258
Failure Code [879CKA]6261
Failure Code [879CKB]6262
Failure Code [879EMC]6263
Failure Code [879FMC]6264
Failure Code [879GKX]6265
Troubleshooting of Air Conditioner System (A-Mode)6268
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)6268
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)6272
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)6277
Troubleshooting for Fresh/Recirc Air Changeover6281
Troubleshooting by Gauge Pressure6285
Connect Service Tool6288
How to Connect Service Tool6288
Precautions for Disconnection and Connection of Air Conditioner Piping6290
Handle Compressor Oil6292
How to Replace Desiccant6294
How to Remove Desiccant6294
How to Attach Desiccant6295
KomVision System6296
Structure and Operation of KomVision System6296
Precautions for KomVision System6296
Layout Drawing of KomVision System6297
Component Parts of KomVision System6305
Examine and Adjust KomVision System6318
Set and Operate KomVision Monitor6318
Camera Calibration6339
6 Camera Calibration6340
1 Camera Calibration6366
Adjust Radars (For Machine with Radars)6372
How to Adjust Radar6372
How to Adjust Radars Separately6379
Troubleshooting for KomVision System6386
Related Information to Troubleshooting6386
Troubleshooting by Failure Code (Display of Code)6406
Troubleshooting of Electrical System (E-Mode)6671
90 Circuit Diagrams6699
Table of Contents6700
How to Read the Codes for Electric Cable6701
Hydraulic Circuit Diagram6705
Symbols Used in Hydraulic Circuit Diagram6705
Hydraulic Circuit Diagram of Steering, Hoist6709
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves)6711
Hydraulic Circuit Diagram of Brake Control6713
Hydraulic Circuit Diagram of Transmission, Brake Cooling System6715
Hydraulic Circuit Diagram of Power Ladder (Machine with Power Ladder)6717
Hydraulic Circuit Diagram of Steering, Hoist (at Reverse 1st, Right Turn, Brake Operation)6719
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Reverse 1st, Right Turn, Brake Operation)6721
Hydraulic Circuit Diagram of Brake Control (at Reverse 1st, Right Turn, Brake Operation)6723
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Reverse 1st, Right Turn, Brake Operation)6725
Hydraulic Circuit Diagram of Steering, Hoist (at Hoist Raise, Forward 2nd Operation)6727
Hydraulic Circuit Diagram of Steering, Hoist (Machine with 2 Pieces of Forced Lower Valves) (at Hoist Raise, Forward 2nd Operation)6729
Hydraulic Circuit Diagram of Brake Control (at Retarder Brake Operation)6731
Hydraulic Circuit Diagram of Transmission, Brake Cooling System (at Hoist Raise, Forward 2nd Operation)6733
Electrical Circuit Diagram6735
Symbols Used in Electric Circuit Diagram6735
Electrical Circuit Diagram of Inside of CAB (1/12)6739
Electrical Circuit Diagram of Inside of CAB (2/12)6741
Electrical Circuit Diagram of Inside of CAB (3/12)6743
Electrical Circuit Diagram of Inside of CAB (4/12)6745
Electrical Circuit Diagram of Inside of CAB (5/12)6747
Electrical Circuit Diagram of Inside of CAB (6/12)6749
Electrical Circuit Diagram of Inside of CAB (7/12)6751
Electrical Circuit Diagram of Inside of CAB (8/12)6753
Electrical Circuit Diagram of Inside of CAB (9/12)6755
Electrical Circuit Diagram of Inside of CAB (10/12)6757
Electrical Circuit Diagram of Inside of CAB (11/12)6759
Electrical Circuit Diagram of Inside of CAB (12/12)6761
Electrical Circuit Diagram of Machine (1/13)6763
Electrical Circuit Diagram of Machine (2/13)6765
Electrical Circuit Diagram of Machine (3/13)6767
Electrical Circuit Diagram of Machine (4/13)6769
Electrical Circuit Diagram of Machine (5/13)6771
Electrical Circuit Diagram of Machine (6/13)6773
Electrical Circuit Diagram of Machine (7/13)6775
Electrical Circuit Diagram of Machine (8/13)6777
Electrical Circuit Diagram of Machine (9/13)6779
Electrical Circuit Diagram of Machine (10/13)6781
Electrical Circuit Diagram of Machine (11/13)6783
Electrical Circuit Diagram of Machine (12/13)6785
Electrical Circuit Diagram of Machine (13/13)6787
Electrical Circuit Diagram of Engine (1/2)6789
Electrical Circuit Diagram of Engine (2/2)6791
Electrical Circuit Diagram (Drowsiness Detection System (DDS))6793
Index6795

S.M 29/12/24