Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-12 – PDF DOWNLOAD 

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Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-12 – PDF DOWNLOAD

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Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-12 – PDF DOWNLOAD 

Language : English
Pages : 3196
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-12 – PDF DOWNLOAD 

SERIAL NUMBERS 85001 and up

Cover 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 22
HOW TO READ THE SHOP MANUAL 22
SAFETY NOTICE FOR OPERATION 24
PRECAUTIONS TO PREVENT FIRE 32
ACTIONS IF FIRE OCCURS 33
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS 33
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS 34
PRECAUTIONS FOR DEF 35
GENERAL CHARACTER AND PRECAUTIONS FOR USAGE 35
PRECAUTIONS WHEN YOU ADD DEF 35
PRECAUTIONS WHEN YOU STORE DEF 35
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 35
THE OTHER PRECAUTIONS 35
STORE DEF 36
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 39
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 46
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 48
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 49
PRACTICAL USE OF KOMTRAX 50
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 52
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 55
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 59
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 60
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 64
STANDARD TIGHTENING TORQUE TABLE 65
CONVERSION TABLE 72
ABBREVIATIONS 77
01 SPECIFICATIONS 81
CONTENTS 82
SPECIFICATIONS 83
SPECIFICATION DRAWING 83
SPECIFICATION DRAWING: HD1500-8E0 83
SPECIFICATIONS 85
SPECIFICATIONS: HD1500-8E0 85
WEIGHT TABLE 91
WEIGHT TABLE: HD1500-8E0 91
FUEL, COOLANT, AND LUBRICATING OIL 93
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 93
10 STRUCTURE AND FUNCTION 95
CONTENTS 96
UREA SCR SYSTEM 101
LAYOUT DRAWING OF UREA SCR STSTEM 101
UREA SCR SYSTEM DIAGRAM 104
FUNCTION OF UREA SCR SYSTEM 106
FUNCTION OF DEF SYSTEM 106
INDUCEMENT STRATEGY 107
COMPONENT PARTS OF UREA SCR SYSTEM 112
DEF TANK 112
DEF PUMP 114
DEF INJECTOR 115
DEF HOSE 116
DEF TANK HEATING VALVE 117
BOOT-UP SYSTEM 118
LAYOUT DRAWING OF BOOT-UP SYSTEM 118
SYSTEM OPERATING LAMP SYSTEM 121
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 121
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 121
BATTERY DISCONNECT SWITCH 122
FUNCTION OF BATTERY DISCONNECT SWITCH 122
STARTING MOTOR DISCONNECT SWITCH 123
FUNCTION OF STARTING MOTOR DISCONNECT SWITCH 123
OPERATION OF STARTING MOTOR DISCONNECT SWITCH 123
ENGINE SHUTDOWN SECONDARY SWITCH 124
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 124
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 124
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 125
EXTERNAL POWER SUPPLY ENGINE PREHEATER 126
LAYOUT DRAWING OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 126
FUNCTION OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 127
ENGINE SYSTEM 129
LAYOUT DRAWING OF ENGINE SYSTEM 129
ENGINE CONTROL SYSTEM 131
ENGINE CONTROL SYSTEM DIAGRAM 131
COMPONENT PARTS OF ENGINE SYSTEM 135
DAMPER 135
COOLING SYSTEM 136
LAYOUT DRAWING OF COOLING SYSTEM 136
SPECIFICATIONS OF COOLING SYSTEM 137
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 138
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 138
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 138
COMPONENT PARTS OF COOLING SYSTEM 139
DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 139
REAR BRAKE COOLING REMOTE AND AXLE OIL CIRCULATION 4-SPOOL PUMP 149
FRONT BRAKE COOLING REMOTE PUMP 150
FRONT BRAKE COOLING REMOTE MOTOR 151
REAR BRAKE COOLING REMOTE MOTOR 159
FAN CLUTCH 165
HYDRAULIC OIL COOLER BYPASS VALVE 166
CONTROL SYSTEM 167
LAYOUT DRAWING OF CONTROL SYSTEM 167
RETARDER AND HOIST CONTROL SYSTEM 169
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 169
MACHINE MONITOR SYSTEM 171
MACHINE MONITOR SYSTEM DIAGRAM 171
FUNCTION OF MACHINE MONITOR SYSTEM 172
REARVIEW MONITOR SYSTEM 173
REARVIEW MONITOR SYSTEM DIAGRAM 173
FUNCTION OF REARVIEW MONITOR SYSTEM 173
KOMTRAX Plus SYSTEM 174
KOMTRAX Plus SYSTEM DIAGRAM 174
FUNCTION OF KOMTRAX Plus SYSTEM 176
PAYLOAD METER SYSTEM 179
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 179
PAYLOAD METER SYSTEM DIAGRAM 180
FUNCTION OF PAYLOAD METER SYSTEM 180
MEASUREMENT PRINCIPLE OF LOADING MASS 182
DATA DOWNLOAD FUNCTION 183
FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING 183
MACHINE LOCK-OUT SYSTEM 191
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM 191
MACHINE LOCK-OUT SYSTEM DRAWING 192
FUNCTION OF MACHINE LOCK-OUT SYSTEM 193
Gear shift lever 193
Dump lever 193
Steering wheel 193
Parking brake switch 193
OPERATION OF MACHINE LOCK-OUT SYSTEM 194
COMPONENT PARTS OF CONTROL SYSTEM 195
MACHINE MONITOR 195
SWITCH PANEL 211
REARVIEW MONITOR 212
REARVIEW CAMERA 214
KOMTRAX TERMINAL 215
KOMTRAX Plus CONTROLLER 217
WIRELESS LAN UNIT 222
TRANSMISSION CONTROLLER 223
RETARDER AND HOIST CONTROLLER 227
OPTION CONTROLLER 231
MONITOR CONTROLLER 235
ACCELERATOR PEDAL 240
GEAR SHIFT LEVER 241
RETARDER CONTROL LEVER 242
HYDRAULIC SYSTEM 243
LAYOUT DRAWING OF HYDRAULIC SYSTEM 243
COMPONENT PARTS OF HYDRAULIC SYSTEM 244
HYDRAULIC TANK 244
STEERING PUMP 246
LS VALVE 252
CO VALVE 257
DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR 260
FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP 273
HOIST VALVE 274
POWER TRAIN SYSTEM 279
LAYOUT DRAWING OF POWER TRAIN SYSTEM 279
TRANSMISSION CONTROL SYSTEM 282
TRANSMISSION CONTROL SYSTEM DIAGRAM 282
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 284
GEAR SHIFT CONTROL SYSTEM 288
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 288
DIRECTION CONTROL SYSTEM 291
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM WHEN TCS IS ACTUATED 291
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 291
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 292
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 292
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 292
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 293
TRAVEL SPEED LIMITATION SYSTEM 294
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 294
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 295
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 296
REAR AXLE OIL FILTRATION SYSTEM 298
LAYOUT DRAWING OF REAR AXLE OIL FILTRATION SYSTEM 298
SYSTEM DIAGRAM OF REAR AXLE OIL FILTRATION SYSTEM 299
FUNCTION OF REAR AXLE OIL FILTRATION SYSTEM 299
OPERATION OF REAR AXLE OIL FILTRATION SYSTEM 299
COMPONENT PARTS OF POWER TRAIN SYSTEM 300
DRIVE SHAFT 300
TORQUE CONVERTER AND PTO 301
LOCKUP CLUTCH ECMV 306
TRANSMISSION 309
TRANSMISSION CONTROL VALVE 330
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 332
TORQUE CONVERTER REGULATOR VALVE 338
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 340
TRANSMISSION LUBRICATION OIL FLOW SELECTOR VALVE 349
AXLE 351
DIFFERENTIAL 353
FINAL DRIVE 355
WORK EQUIPMENT SYSTEM 356
WORK EQUIPMENT CONTROL 356
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 356
FUNCTION OF WORK EQUIPMENT CONTROL 356
HOIST CONTROL 357
HOIST CONTROL SYSTEM DIAGRAM 357
FUNCTION OF HOIST CONTROL 357
BUDDY SYSTEM 359
STRUCTURE OF BUDDY SYSTEM 359
FUNCTION OF BUDDY SYSTEM 360
OPERATION OF BUDDY SYSTEM 360
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 361
DUMP LEVER 361
HOIST EPC VALVE 366
HOIST AND FRONT BRAKE COOLING REMOTE SELECTOR VALVE 367
STEERING SYSTEM 368
LAYOUT DRAWING OF STEERING SYSTEM 368
FUNCTION OF STEERING SYSTEM 369
STEERING COLUMN 370
STRUCTURE OF STEERING COLUMN 370
STEERING CONTROL LINKAGE 371
STRUCTURE OF STEERING CONTROL LINKAGE 371
COMPONENT PARTS OF STEERING SYSTEM 372
FLOW AMPLIFIER VALVE 372
STEERING UNIT 376
STEERING PUMP SELECTOR SOLENOID VALVE 381
SECONDARY STEERING PUMP 382
SECONDARY STEERING MOTOR 383
BRAKE SYSTEM 384
LAYOUT DRAWING OF BRAKE SYSTEM 384
RETARDER CONTROL 387
RETARDER CONTROL SYSTEM DIAGRAM 387
FUNCTION OF RETARDER CONTROL 388
ARSC SYSTEM 389
ARSC SYSTEM DIAGRAM 389
FUNCTION OF ARSC SYSTEM 389
COMPONENT PARTS OF BRAKE SYSTEM 390
BRAKE CHARGE PUMP 390
PARKING BRAKE SOLENOID VALVE 391
ACCUMULATOR CHARGE VALVE 392
BRAKE CIRCUIT ACCUMULATOR 396
SHUT OFF SOLENOID VALVE 397
BRAKE VALVE 399
SECONDARY BRAKE VALVE 402
PROPORTIONAL PRESSURE REDUCING VALVE 403
SLACK ADJUSTER 405
FRONT BRAKE COOLING RELIEF VALVE 409
REAR BRAKE COOLING RELIEF VALVE 410
BRAKE 411
PARKING BRAKE 415
BRAKE TANK 418
AUTO-GREASING SYSTEM 419
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 419
AUTO-GREASING SYSTEM DIAGRAM 422
FUNCTION OF AUTO-GREASING SYSTEM 423
GREASE REFILL AUTOMATIC STOP SYSTEM 424
GREASE REFILL AUTOMATIC STOP SYSTEM DIAGRAM 424
FUNCTION OF GREASE REFILL AUTOMATIC STOP SYSTEM 424
OPERATION OF GREASE REFILL AUTOMATIC STOP SYSTEM 424
COMPONENT PARTS OF AUTO-GREASING SYSTEM 425
AUTO-GREASING PUMP 425
AUTO-GREASING INJECTOR 426
SERVICE CENTER 429
LAYOUT DRAWING OF SERVICE CENTER 429
FUNCTION OF SERVICE CENTER 429
UNDERCARRIAGE AND FRAME 430
REAR AXLE SUPPORT 430
STRUCTURE OF REAR AXLE SUPPORT 430
SUSPENSION 431
STRUCTURE OF SUSPENSION 431
FUNCTION OF SUSPENSION 431
FRONT SUSPENSION 432
STRUCTURE OF FRONT SUSPENSION 432
FUNCTION OF FRONT SUSPENSION 432
REAR SUSPENSION 433
STRUCTURE OF REAR SUSPENSION 433
FUNCTION OF REAR SUSPENSION 433
FRONT SUSPENSION CYLINDER 434
STRUCTURE OF FRONT SUSPENSION CYLINDER 434
FUNCTION OF FRONT SUSPENSION CYLINDER 434
OPERATION OF FRONT SUSPENSION CYLINDER 435
REAR SUSPENSION CYLINDER 436
STRUCTURE OF REAR SUSPENSION CYLINDER 436
FUNCTION OF REAR SUSPENSION CYLINDER 436
OPERATION OF REAR SUSPENSION CYLINDER 436
WORK EQUIPMENT 437
STRUCTURE OF WORK EQUIPMENT 437
FUNCTION OF WORK EQUIPMENT 437
CAB AND ITS ATTACHMENTS 438
ROPS CAB 438
STRUCTURE OF ROPS CAB 438
FUNCTION OF ROPS CAB 438
CAB MOUNT 439
STRUCTURE OF CAB MOUNT 439
FUNCTION OF CAB MOUNT 439
LIFTING SYSTEM 440
POWER LADDER SYSTEM 440
LAYOUT DRAWING OF POWER LADDER SYSTEM 440
POWER LADDER SYSTEM DIAGRAM 441
FUNCTION OF POWER LADDER SYSTEM 442
OPERATION OF POWER LADDER SYSTEM 442
POWER LADDER DRIVE PUMP 443
RELIEF VALVE A 444
RELIEF VALVE B 444
SOLENOID VALVE 445
SOLENOID VALVE (FOR POWER LADDER RAISE AND LOWER SWITCH) 446
20 STANDARD VALUE TABLE 447
CONTENTS 448
STANDARD VALUE TABLE FOR ENGINE 449
STANDARD VALUE TABLE FOR ENGINE: HD1500-8E0 449
Engine:SDA16V159E-3 449
STANDARD VALUE TABLE FOR MACHINE 451
STANDARD VALUE TABLE FOR MACHINE: HD1500-8E0 451
Engine:SDA16V159E-3 451
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 471
30 TEST AND ADJUST 473
CONTENTS 474
PRECAUTIONS BEFORE WORK 478
RELATED INFORMATION TO TEST AND ADJUST 479
TOOLS TO TEST AND ADJUST 479
ENGINE AND COOLING SYSTEM 487
TEST ENGINE SPEED 487
PROCEDURE TO TEST ENGINE SPEED 487
PROCEDURE TO TEST ENGINE HIGHT IDLE SPEED 487
PROCEDURE TO TEST ENGINE LOW IDLE SPEED 487
PROCEDURE TO TEST ENGINE SPEED WITH TORQUE CONVERTER STALLED 488
TEST EXHAUST GAS COLOR 490
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 491
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 492
TEST BLOWBY PRESSURE 493
PROCEDURE TO TEST BLOWBY PRESSURE 493
TEST FUEL PRESSURE 495
PROCEDURE TO TEST FUEL PRESSURE 495
BLEED AIR FROM FUEL CIRCUIT 497
PROCEDURE TO BLEED AIR FROM FUEL CIRCUIT 497
CLEAN DEF TANK 498
PROCEDURE TO CLEAN DEF TANK 498
POWER TRAIN 501
TEST POWER TRAIN OIL PRESSURE 501
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 504
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 517
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 517
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 518
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 518
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 519
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 519
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 520
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 520
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 521
PROCEDURE TO FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 521
CLEAN FINAL DRIVE CASE MAGNET 523
PROCEDURE TO CLEAN FINAL DRIVE CASE MAGNET 523
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 524
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 524
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 525
STEERING SYSTEM 529
TEST STEERING CIRCUIT OIL PRESSURE 529
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 529
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 529
TEST STEERING CYLINDER PRESSURE 531
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 531
BLEED AIR FROM STEERING CYLINDER CIRCUIT 532
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 532
BRAKE SYSTEM 534
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 534
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 534
TEST WHEEL BRAKE OIL PRESSURE 535
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 535
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE WITH TEST TOOLS 535
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 536
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE WITH TEST TOOLS 537
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 538
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE WITH TEST TOOLS 539
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 540
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 540
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 541
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 542
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 543
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (FRONT BRAKE) 543
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (REAR AND PARKING) 547
PROCEDURE TO PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 550
PROCEDURE TO RELEASE NITROGEN GAS WHEN DISPOSING ACCUMULATOR 554
TEST BRAKE PERFORMANCE 555
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 555
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 556
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 557
BLEED AIR FROM BRAKE CIRCUIT 558
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 558
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT 559
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 561
TEST PARKING BRAKE OIL PRESSURE 562
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE WITH MACHINE MONITOR 562
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE WITH WITH TEST TOOLS 562
RELEASE PARKING BRAKE MANUALLY 564
PROCEDURE TO RELEASE FRONT PARKING BRAKE MANUALLY 564
PROCEDURE TO RELEASE REAR PARKING BRAKE MANUALLY 565
TEST THE AMOUNT OF WHEEL BRAKE DISC WEAR 566
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE DISC WEAR 566
PROCEDURE TO TEST THE AMOUNT OF REAR BRAKE DISC WEAR 567
HYDRAULIC SYSTEM 568
TEST HOIST CIRCUIT OIL PRESSURE 568
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 568
TEST HOIST CYLINDER SUPPLY PRESSURE 570
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 570
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 571
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 571
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 572
TEST AND ADJUST FRONT SUSPENSION CYLINDER 574
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 574
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 575
TEST AND ADJUST REAR SUSPENSION CYLINDER 580
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 580
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 581
BLEED AIR FROM HYDRAULIC CIRCUIT 586
PROCEDURE TO BLEED AIR FROM PISTON PUMP 586
PROCEDURE TO BLEED AIR IN HOIST CYLINDER CIRCUIT 588
PROCEDURE TO BLEED AIR FROM FRONT BRAKE COOLING REMOTE MOTOR 590
PROCEDURE TO BLEED AIR FROM REAR BRAKE COOLING REMOTE MOTOR 592
CALIBRATION OF LADDER POSITION 594
CALIBRATION METHOD OF STOWED POSITION OF LADDER 594
CALIBRATION METHOD OF LOWEST POSITION OF LADDER 594
WORK EQUIPMENT 595
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 595
PROCEDURE TO TEST DUMP BODY POSITIONER SENSOR 595
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 595
PROCEDURE TO CALIBRATE AFTER YOU ADJUST DUMP BODY POSITION SENSOR 595
LOWER THE DUMP BODY MANUALLY 597
PROCEDURE TO LOWER THE DUMP BODY MANUALLY 597
LIFT THE DUMP BODY MANUALLY 598
PROCEDURE TO LIFT THE DUMP BODY MANUALLY 598
LIFT THE DUMP BODY WITH BUDDY SYSTEM 600
PROCEDURE TO LIFT THE DUMP BODY WITH BUDDY SYSTEM 600
CAB AND ITS ATTACHMENTS 604
ADJUST STEERING WHEEL TILT LOCK LEVER 604
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 604
ADJUST RATTLING OPERATOR’S SEAT 605
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 605
ADJUST CLEARANCE OF ESCAPE DOOR 606
PROCEDURE TO ADJUST CLEARANCE OF ESCAPE DOOR 606
LIFTING SYSTEM 608
BLEED AIR FROM POWER LADDER CYLINDER 608
PROCEDURE TO BLEED AIR FROM POWER LADDER CYLINDER 608
ELECTRICAL SYSTEM 609
SET AND ADJUST EACH EQUIPMENT 609
SET AND OPERATE OF MACHINE MONITOR 613
OPERATOR MODE 616
SERVICE MODE 630
ABNORMALITY RECORD MENU 656
DEFAULT MENU 673
ADJUSTMENT MENU 692
PAYLOAD METER SETTING 711
KOMTRAX SETTINGS MENU 733
PROCEDURE TO DISPLAY SERVICE MESSAGE 738
PROCEDURE TO HANDLE MANUAL SNAP SHOT 740
START UP KOMTRAX TERMINAL 744
STOP USE OF KOMTRAX TERMINAL 749
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 751
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 751
DEFAULT SETTING OF WIRELESS LAN MODEM 754
DEFAULT SETTING OF WIRELESS LAN MODEM 754
CHECK WIRELESS LAN MODEM COMMUNICATION 755
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 756
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 756
DOWNLOAD DATA FROM SERVICE CONNECTOR IN CAB 756
DOWNLOAD DATA THROUGH THE SERVICE CONNECTOR OUTSIDETHE CAB (GROUND LEVEL DOWNLOAD SPECIFICATION) 758
DOWNLOAD DATA FROM WIRELESS LAN (WIRELESS LAN SPEC) 759
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 760
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 760
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 763
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 763
SET REGION OF Bluetooth® COMPATIBLE RADIO 766
SET REGION OF Bluetooth® COMPATIBLE RADIO 766
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 768
BATTERY DISCONNECT SWITCH WORK 769
TEST DIODES 770
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 770
PROCEDURE TO TEST DIODE USING ANALOG TESTER 770
Pm CLINIC 771
Pm CLINIC SERVICE 771
Pm CLINIC CHECK SHEET 776
PERFORM QUICK Pm 783
PROCEDURE TO PERFORM QUICK Pm 783
40 TROUBLESHOOTING 789
CONTENTS 790
PRECAUTIONS BEFORE WORK 800
RELATED INFORMATION ON TROUBLESHOOTING 801
GENERAL TROUBLESHOOTING POINTS 801
SEQUENCE OF EVENTS IN TROUBLESHOOTING 802
CHECKS BEFORE TROUBLESHOOTING 804
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 807
WALK-AROUND CHECK 807
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 809
CHECK FUEL LEVEL 809
CHECK IMPURE INGREDIENT IN FUEL 810
CHECK DEF LEVEL AND TYPE 810
CHECK FUEL FILTER 813
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 815
CHECK COOLANT LEVEL 816
CHECK CLOGGING OF AIR CLEANER 817
OUTER ELEMENT – CLEAN 818
REPLACE ELEMENT 821
CHECK HYDRAULIC OIL LEVEL 823
CHECK OIL LEVEL IN BRAKE OIL TANK 823
CHECK HYDRAULIC OIL STRAINER 824
CHECK HYDRAULIC OIL FILTER 825
CHECK OIL LEVEL IN TRANSMISSION CASE 825
CHECK OIL LEVEL IN DIFFERENTIAL CASE 826
CHECK OIL LEVEL IN FINAL DRIVE CASE 826
BLEED AIR FROM FUEL SYSTEM 827
BLEED AIR FROM HYDRAULIC SYSTEM 827
PROCEDURE TO CHECK ELECTRIC EQUIPMENT 827
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 833
PROCEDURE FOR TESTING AND TROUBLESHOOTING 839
SYMPTOM AND TROUBLESHOOTING NUMBERS 842
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 845
CONNECTORS LIST AND LAYOUT 847
CONNECTOR CONTACT IDENTIFICATION 884
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 926
FUSE LOCATION TABLE 932
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 938
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 940
FAILURE CODES TABLE 946
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 985
FAILURE CODE [1500L0] 985
FAILURE CODE [15B0NX] 986
FAILURE CODE [15F0KM] 988
FAILURE CODE [15F0MB] 989
FAILURE CODE [15F7KM] 990
FAILURE CODE [15G0MW] 991
FAILURE CODE [15G7KM] 993
FAILURE CODE [15H0MW] 994
FAILURE CODE [15J0MW] 996
FAILURE CODE [15K0MW] 998
FAILURE CODE [15L0MW] 1000
FAILURE CODE [15M0MW] 1002
FAILURE CODE [15N0MW] 1004
FAILURE CODE [15SBL1] 1006
FAILURE CODE [15SBMA] 1009
FAILURE CODE [15SCL1] 1010
FAILURE CODE [15SCMA] 1013
FAILURE CODE [15SDL1] 1014
FAILURE CODE [15SDMA] 1017
FAILURE CODE [15SEL1] 1018
FAILURE CODE [15SEMA] 1021
FAILURE CODE [15SFL1] 1023
FAILURE CODE [15SFMA] 1026
FAILURE CODE [15SGL1] 1028
FAILURE CODE [15SGMA] 1031
FAILURE CODE [15SHL1] 1033
FAILURE CODE [15SHMA] 1036
FAILURE CODE [15SJMA] 1037
FAILURE CODE [2B0QNX] 1038
FAILURE CODE [2F00KM] 1039
FAILURE CODE [2G42ZG] 1041
FAILURE CODE [2G43ZG] 1042
FAILURE CODE [2G44ZG] 1043
FAILURE CODE [879AKA] 1045
FAILURE CODE [879AKB] 1046
FAILURE CODE [879BKA] 1047
FAILURE CODE [879BKB] 1048
FAILURE CODE [879CKA] 1050
FAILURE CODE [879CKB] 1051
FAILURE CODE [879EMC] 1052
FAILURE CODE [879FMC] 1053
FAILURE CODE [879GKX] 1054
FAILURE CODE [989D00] 1055
FAILURE CODE [989X00] 1056
FAILURE CODE [989Y00] 1057
FAILURE CODE [AA10NX] 1058
FAILURE CODE [AB00KE] 1060
FAILURE CODE [AB00KY] 1062
FAILURE CODE [B@C6NS] 1063
FAILURE CODE [B@C7NS] 1064
FAILURE CODE [B@CENS] 1065
FAILURE CODE [B@JANS] 1066
FAILURE CODE [D150KB] 1067
FAILURE CODE [D150KZ] 1069
FAILURE CODE [D151KB] 1071
FAILURE CODE [D151KZ] 1073
FAILURE CODE [D164KY] 1075
FAILURE CODE [D19HKZ] 1076
FAILURE CODE [D19JKZ] 1078
FAILURE CODE [D19QKZ] 1079
FAILURE CODE [D1EHKA] 1081
FAILURE CODE [D1EHKB] 1082
FAILURE CODE [D1EHKY] 1083
FAILURE CODE [D1ENKZ] 1084
FAILURE CODE [D1EPKA] 1086
FAILURE CODE [D1EPKB] 1088
FAILURE CODE [D1EPKY] 1090
FAILURE CODE [D1EQKA] 1091
FAILURE CODE [D1EQKB] 1093
FAILURE CODE [D1EQKY] 1095
FAILURE CODE [D1ERKA] 1097
FAILURE CODE [D1ERKB] 1099
FAILURE CODE [D1ERKY] 1101
FAILURE CODE [D1ESKA] 1103
FAILURE CODE [D1ESKB] 1105
FAILURE CODE [D1ESKY] 1107
FAILURE CODE [D1EWKA] 1109
FAILURE CODE [D1EWKB] 1111
FAILURE CODE [D1EWKY] 1113
FAILURE CODE [D1J0KB] 1115
FAILURE CODE [D5ZHL6] 1117
FAILURE CODE [D862KA] 1119
FAILURE CODE [DAF0KT] 1120
FAILURE CODE [DAF0MB] 1121
FAILURE CODE [DAF0MC] 1122
FAILURE CODE [DAF3KK] 1123
FAILURE CODE [DAF8KB] 1125
FAILURE CODE [DAFDKB] 1126
FAILURE CODE [DAFGMC] 1128
FAILURE CODE [DAFLKA] 1129
FAILURE CODE [DAFLKB] 1131
FAILURE CODE [DAFQKR] 1133
FAILURE CODE [DAQ0KK] 1134
FAILURE CODE [DAQ0KT] 1137
FAILURE CODE [DAQ0MC] 1138
FAILURE CODE [DAQ1KA] 1139
FAILURE CODE [DAQ2KK] 1141
FAILURE CODE [DAQ9KQ] 1143
FAILURE CODE [DAQLKA] 1144
FAILURE CODE [DAQLKB] 1146
FAILURE CODE [DAQQKR] 1148
FAILURE CODE [DAQRKR] 1149
FAILURE CODE [DAQRMA] 1150
FAILURE CODE [DAQV00] 1151
FAILURE CODE [DAQW00] 1152
FAILURE CODE [DAZ9KQ] 1153
FAILURE CODE [DAZQKR] 1154
FAILURE CODE [DB10KT] 1155
FAILURE CODE [DB10MC] 1156
FAILURE CODE [DB11KA] 1157
FAILURE CODE [DB12KK] 1160
FAILURE CODE [DB13KK] 1163
FAILURE CODE [DB19KQ] 1165
FAILURE CODE [DB1LKA] 1166
FAILURE CODE [DB1LKB] 1168
FAILURE CODE [DB1QKR] 1170
FAILURE CODE [DB1QMA] 1171
FAILURE CODE [DB1RKR] 1172
FAILURE CODE [DB2QKR] 1178
FAILURE CODE [DBBUKM] 1184
FAILURE CODE [DBBUKR] 1185
FAILURE CODE [DBP0KM] 1187
FAILURE CODE [DBP0KT] 1188
FAILURE CODE [DBP0NR] 1189
FAILURE CODE [DBP5KP] 1190
FAILURE CODE [DBPLKA] 1192
FAILURE CODE [DBPLKB] 1194
FAILURE CODE [DBPQKR] 1196
FAILURE CODE [DBPRKR] 1199
FAILURE CODE [DBPRMA] 1202
FAILURE CODE [DBPUKR] 1203
FAILURE CODE [DBPVKR] 1208
FAILURE CODE [DBPWKR] 1213
FAILURE CODE [DBPXKR] 1214
FAILURE CODE [DBV0MC] 1215
FAILURE CODE [DBV1KK] 1216
FAILURE CODE [DBV6KB] 1218
FAILURE CODE [DBV7KB] 1220
FAILURE CODE [DBVLKA] 1221
FAILURE CODE [DBVLKB] 1223
FAILURE CODE [DBVQKR] 1225
FAILURE CODE [DBVRKR] 1226
FAILURE CODE [DBVVKR] 1227
FAILURE CODE [DBVWKR] 1228
FAILURE CODE [DDAAL6] 1229
FAILURE CODE [DDACL4] 1231
FAILURE CODE [DDADKA] 1235
FAILURE CODE [DDADKY] 1238
FAILURE CODE [DDD7KX] 1240
FAILURE CODE [DDDGL4] 1242
FAILURE CODE [DDDHL4] 1244
FAILURE CODE [DDTHKA] 1246
FAILURE CODE [DDTJKA] 1248
FAILURE CODE [DDTKKA] 1250
FAILURE CODE [DDTLKA] 1252
FAILURE CODE [DDTMKA] 1254
FAILURE CODE [DDTNKA] 1256
FAILURE CODE [DDTPKA] 1258
FAILURE CODE [DDU1KA] 1260
FAILURE CODE [DF10KA] 1262
FAILURE CODE [DF10KB] 1266
FAILURE CODE [DGE5KX] 1269
FAILURE CODE [DGF1KX] 1271
FAILURE CODE [DGR2KB] 1273
FAILURE CODE [DGR2L8] 1274
FAILURE CODE [DGR4KB] 1276
FAILURE CODE [DGR4L8] 1277
FAILURE CODE [DGR6KB] 1279
FAILURE CODE [DGR6L8] 1280
FAILURE CODE [DGREKB] 1282
FAILURE CODE [DGREL8] 1283
FAILURE CODE [DGT1KX] 1285
FAILURE CODE [DHP4KY] 1287
FAILURE CODE [DHP4KZ] 1289
FAILURE CODE [DHP5KY] 1291
FAILURE CODE [DHP5KZ] 1293
FAILURE CODE [DHP6KA] 1295
FAILURE CODE [DHP6KX] 1297
FAILURE CODE [DHP6KY] 1299
FAILURE CODE [DHP6KZ] 1301
FAILURE CODE [DHP7KA] 1303
FAILURE CODE [DHP7KX] 1305
FAILURE CODE [DHP7KY] 1307
FAILURE CODE [DHP7KZ] 1309
FAILURE CODE [DHQ2KX] 1311
FAILURE CODE [DHQ4KX] 1313
FAILURE CODE [DHQ6KX] 1315
FAILURE CODE [DHT5KX] 1317
FAILURE CODE [DHT5L6] 1319
FAILURE CODE [DHT7KX] 1320
FAILURE CODE [DHT7L6] 1322
FAILURE CODE [DHT8KX] 1323
FAILURE CODE [DHT8ZG] 1325
FAILURE CODE [DHU2KX] 1326
FAILURE CODE [DHU3KX] 1328
FAILURE CODE [DHUBKX] 1330
FAILURE CODE [DHUCKX] 1332
FAILURE CODE [DHUDKX] 1334
FAILURE CODE [DHUEKX] 1336
FAILURE CODE [DHUHKX] 1338
FAILURE CODE [DHUJKX] 1340
FAILURE CODE [DHUKKX] 1342
FAILURE CODE [DHULKX] 1344
FAILURE CODE [DHUMKX] 1346
FAILURE CODE [DHUQKX] 1348
FAILURE CODE [DHUSKX] 1350
FAILURE CODE [DHYAKX] 1352
FAILURE CODE [DHYBKX] 1355
FAILURE CODE [DJF1KA] 1358
FAILURE CODE [DK30KX] 1360
FAILURE CODE [DK51L5] 1362
FAILURE CODE [DK52KX] 1365
FAILURE CODE [DK53L8] 1367
FAILURE CODE [DK54KX] 1369
FAILURE CODE [DK5VKX] 1371
FAILURE CODE [DK5VMA] 1373
FAILURE CODE [DK60KX] 1374
FAILURE CODE [DKH0KX] 1376
FAILURE CODE [DKH1KX] 1378
FAILURE CODE [DLF1KA] 1380
FAILURE CODE [DLF1LC] 1381
FAILURE CODE [DLF2KA] 1383
FAILURE CODE [DLF2LC] 1384
FAILURE CODE [DLF8LC] 1386
FAILURE CODE [DLF9LC] 1388
FAILURE CODE [DLFKLC] 1390
FAILURE CODE [DLFLLC] 1392
FAILURE CODE [DLT3KA] 1394
FAILURE CODE [DLT3LC] 1395
FAILURE CODE [DPQ1KR] 1397
FAILURE CODE [DPQ1LD] 1400
FAILURE CODE [DPQ2KR] 1403
FAILURE CODE [DPQ3KR] 1406
FAILURE CODE [DPQ4KB] 1408
FAILURE CODE [DQ11KM] 1409
FAILURE CODE [DQ11KT] 1410
FAILURE CODE [DQ12KM] 1411
FAILURE CODE [DQ12KT] 1412
FAILURE CODE [DQ13KM] 1413
FAILURE CODE [DQ13KT] 1414
FAILURE CODE [DQ14KM] 1415
FAILURE CODE [DQ14KT] 1416
FAILURE CODE [DQ15KM] 1417
FAILURE CODE [DQ15KT] 1418
FAILURE CODE [DQ16KM] 1419
FAILURE CODE [DQ16KT] 1420
FAILURE CODE [DR10KA] 1421
FAILURE CODE [DR20KA] 1423
FAILURE CODE [DR30KA] 1425
FAILURE CODE [DR40KA] 1427
FAILURE CODE [DR50KA] 1429
FAILURE CODE [DR60KA] 1431
FAILURE CODE [DSJ0KR] 1433
FAILURE CODE [DUMBKB] 1434
FAILURE CODE [DV00KB] 1435
FAILURE CODE [DV01KB] 1437
FAILURE CODE [DW2AKA] 1439
FAILURE CODE [DW2AKB] 1440
FAILURE CODE [DW2AKY] 1442
FAILURE CODE [DW2AL1] 1443
FAILURE CODE [DW2ALH] 1444
FAILURE CODE [DW2BKA] 1445
FAILURE CODE [DW2BKB] 1446
FAILURE CODE [DW2BKY] 1447
FAILURE CODE [DW2BL1] 1448
FAILURE CODE [DW2BLH] 1449
FAILURE CODE [DW2CKA] 1450
FAILURE CODE [DW2CKB] 1451
FAILURE CODE [DW2CKY] 1453
FAILURE CODE [DW2CL1] 1454
FAILURE CODE [DW2CLH] 1455
FAILURE CODE [DW4BK4] 1456
FAILURE CODE [DW4BMA] 1459
FAILURE CODE [DW72KZ] 1462
FAILURE CODE [DW73KA] 1464
FAILURE CODE [DW73KB] 1466
FAILURE CODE [DW73KY] 1468
FAILURE CODE [DW7NKZ] 1469
FAILURE CODE [DW7SKZ] 1471
FAILURE CODE [DWNJKZ] 1473
FAILURE CODE [DWNMKZ] 1475
FAILURE CODE [DX13KA] 1477
FAILURE CODE [DX13KB] 1479
FAILURE CODE [DX13KY] 1481
FAILURE CODE [DX30K4] 1482
FAILURE CODE [DX30KA] 1484
FAILURE CODE [DX30KB] 1486
FAILURE CODE [DX30KY] 1488
FAILURE CODE [DX30MA] 1490
FAILURE CODE [DX33K4] 1492
FAILURE CODE [DX33KA] 1494
FAILURE CODE [DX33KB] 1496
FAILURE CODE [DX33KY] 1498
FAILURE CODE [DX33MA] 1500
FAILURE CODE [DX37K4] 1502
FAILURE CODE [DX37KA] 1504
FAILURE CODE [DX37KB] 1506
FAILURE CODE [DX37KY] 1508
FAILURE CODE [DX37MA] 1509
FAILURE CODE [DX38K4] 1511
FAILURE CODE [DX38KA] 1513
FAILURE CODE [DX38KB] 1515
FAILURE CODE [DX38KY] 1517
FAILURE CODE [DX38MA] 1518
FAILURE CODE [DX42KZ] 1520
FAILURE CODE [DX43KZ] 1522
FAILURE CODE [DXF5K4] 1524
FAILURE CODE [DXF5KA] 1526
FAILURE CODE [DXF5KB] 1528
FAILURE CODE [DXF5KY] 1531
FAILURE CODE [DXF5MA] 1533
FAILURE CODE [DXF6K4] 1536
FAILURE CODE [DXF6KA] 1538
FAILURE CODE [DXF6KB] 1540
FAILURE CODE [DXF6KY] 1543
FAILURE CODE [DXF6MA] 1545
FAILURE CODE [DXH1KA] 1548
FAILURE CODE [DXH1KB] 1550
FAILURE CODE [DXH1KY] 1552
FAILURE CODE [DXH2KA] 1553
FAILURE CODE [DXH2KB] 1556
FAILURE CODE [DXH2KY] 1559
FAILURE CODE [DXH3KA] 1562
FAILURE CODE [DXH3KB] 1565
FAILURE CODE [DXH3KY] 1568
FAILURE CODE [DXH4KA] 1571
FAILURE CODE [DXH4KB] 1574
FAILURE CODE [DXH4KY] 1577
FAILURE CODE [DXH5KA] 1580
FAILURE CODE [DXH5KB] 1583
FAILURE CODE [DXH5KY] 1586
FAILURE CODE [DXH6KA] 1589
FAILURE CODE [DXH6KB] 1592
FAILURE CODE [DXH6KY] 1595
FAILURE CODE [DXH7KA] 1598
FAILURE CODE [DXH7KB] 1601
FAILURE CODE [DXH7KY] 1604
FAILURE CODE [DXHHKA] 1607
FAILURE CODE [DXHHKB] 1609
FAILURE CODE [DXHHKY] 1611
FAILURE CODE [DY30MA] 1614
FAILURE CODE [DY30MC] 1617
FAILURE CODE [DY30ME] 1620
FAILURE CODE [DY32MC] 1622
FAILURE CODE [F9A0KT] 1625
FAILURE CODE [F9A0MC] 1626
FAILURE CODE [F9A1KK] 1627
FAILURE CODE [F9A2KK] 1630
FAILURE CODE [F9A9KQ] 1633
FAILURE CODE [F9ALKA] 1634
FAILURE CODE [F9ALKB] 1636
FAILURE CODE [F9AQKR] 1638
FAILURE CODE [F9AQMA] 1639
FAILURE CODE [F9ARKR] 1640
FAILURE CODE [F9AUKA] 1641
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1644
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1644
E-2 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 1652
E-3 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 1655
E-4 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 1657
E-5 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 1659
E-6 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 1661
E-7 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 1664
E-8 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 1667
E-9 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 1669
E-10 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 1671
E-11 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 1673
E-12 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 1675
E-13 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 1676
E-14 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 1678
E-15 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 1681
E-16 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 1684
E-17 REARVIEW MONITOR IS NOT DISPLAYED IN CONJUNCTION WITH REVERSE WHEN THE CONSTANT DISPLAY SETTING IS DISABLED 1686
E-18 REARVIEW MONITOR REFERENCE LINE IS NOT DISPLAYED WHEN THE REFERENCE LINE DISPLAY SETTING IS ENABLED 1689
E-19 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1691
E-20 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 1693
E-21 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 1695
E-22 ALARM BUZZER DOES NOT SOUND 1696
E-23 ALARM BUZZER DOES NOT STOP SOUNDING 1698
E-24 AISS FUNCTION DOES NOT OPERATE PROPERLY 1700
E-25 HOIST LEVER DOES NOT OPERATE PROPERLY 1702
E-26 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 1704
E-27 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 1708
E-28 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 1711
E-29 TAIL LAMP DOES NOT LIGHT UP 1714
E-30 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP 1717
E-31 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP 1720
E-32 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEADLAMPS LIGHTS UP 1723
E-33 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 1725
E-34 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1727
E-35 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 1729
E-36 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 1730
E-37 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 1733
E-38 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED 1738
E-39 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL 1741
E-40 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR 1744
E-41 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION 1746
E-42 EXTERNAL POWER SUPPLY ENGINE OIL PAN HEATER DOES NOT OPERATE 1747
E-43 EXTERNAL POWER SUPPLY BRAKE TANK HEATER DOES NOT OPERATE 1749
E-44 EXTERNAL POWER SUPPLY TRANSMISSION OIL PAN HEATER DOES NOT OPERATE 1751
E-45 EXTERNAL POWER SUPPLY HYDRAULIC TANK HEATER DOES NOT OPERATE 1753
E-46 BUZZER DOES NOT SOUND WHEN POWER LADDER IS OPERATED 1755
E-47 POWER LADDER PUMP DOES NOT OPERATE 1757
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1759
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1759
FAILURE MODE AND CAUSE TABLE 1760
H-1 MACHINE DOES NOT START 1773
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 1776
H-3 LOCKUP IS NOT RELEASED 1777
H-4 ABNORMALLY STRONG SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 1778
H-5 GEAR IS NOT UPSHIFTED 1780
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 1783
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 1784
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT PARTICULAR GEAR SPEED 1785
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 1787
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 1790
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 1791
H-12 STEERING WHEEL IS HEAVY TO OPERATE 1792
H-13 STEERING WHEEL CANNOT BE OPERATED 1793
H-14 STEERING WHEEL WAGGLES 1794
H-15 FRONT BRAKE DOES NOT APPLY SUFFICIENTLY 1795
H-16 REAR BRAKE DOES NOT APPLY SUFFICIENTLY 1797
H-17 DUMP BODY RISING SPEED IS LOW 1799
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 1801
H-19 DUMP BODY DOES NOT MOVE 1802
H-20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 1804
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN 1805
H-22 POWER LADDER DOES NOT MOVE OR ITS SPEED IS LOW 1806
50 DISASSEMBLY AND ASSEMBLY 1807
CONTENTS 1808
PRECAUTIONS BEFORE WORK 1813
ABBREVIATIONS 1814
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION 1819
HOW TO READ THIS MANUAL 1819
COATING MATERIALS LIST 1821
SPECIAL TOOL LIST 1824
DIAGRAMS OF SPECIAL TOOLS 1846
ENGINE AND COOLING SYSTEM 1857
REMOVE AND INSTALL RADIATOR ASSEMBLY 1857
PROCEDURE TO REMOVE RADIATOR ASSEMBLY 1859
PROCEDURE TO INSTALL RADIATOR ASSEMBLY 1892
REMOVE AND INSTALL OIL COOLER ASSEMBLY 1925
PROCEDURE TO REMOVE OIL COOLER ASSEMBLY 1926
PROCEDURE TO INSTALL OIL COOLER ASSEMBLY 1941
REMOVE AND INSTALL ENGINE ASSEMBLY 1956
PROCEDURE TO REMOVE ENGINE ASSEMBLY 1958
PROCEDURE TO INSTALL ENGINE ASSEMBLY 1996
REMOVE AND INSTALL DAMPER ASSEMBLY 2039
PROCEDURE TO REMOVE DAMPER ASSEMBLY 2039
PROCEDURE TO INSTALL DAMPER ASSEMBLY 2041
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 2043
PROCEDURE TO DISASSEMBLE DAMPER ASSEMBLY 2043
PROCEDURE TO ASSEMBLE DAMPER ASSEMBLY 2045
DISASSEMBLE AND ASSEMBLE OF RADIATOR ASSEMBLY 2050
PROCEDURE TO DISASSEMBLE RADIATOR ASSEMBLY 2052
PROCEDURE TO ASSEMBLE RADIATOR ASSEMBLY 2056
REMOVE AND INSTALL DEF TANK ASSEMBLY 2062
PROCEDURE TO REMOVE DEF TANK ASSEMBLY 2063
PROCEDURE TO INSTALL DEF TANK ASSEMBLY 2079
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY 2094
PROCEDURE TO REMOVE DEF TANK SENSOR FLANGE ASSEMBLY 2095
PROCEDURE TO INSTALL DEF TANK SENSOR FLANGE ASSEMBLY 2103
REMOVE AND INSTALL DEF TANK SENSOR 2114
PROCEDURE TO REMOVE DEF TANK SENSOR 2114
PROCEDURE TO INSTALL DEF TANK SENSOR 2115
REMOVE AND INSTALL DEF TANK STRAINER 2118
PROCEDURE TO REMOVE DEF TANK STRAINER 2118
PROCEDURE TO INSTALL DEF TANK STRAINER 2119
REMOVE AND INSTALL SCR ASSEMBLY 2120
PROCEDURE TO REMOVE SCR ASSEMBLY 2121
PROCEDURE TO INSTALL SCR ASSEMBLY 2137
REMOVE AND INSTALL DEF INJECTOR 2150
PROCEDURE TO REMOVE DEF INJECTOR 2150
PROCEDURE TO INSTALL DEF INJECTOR 2150
REMOVE AND INSTALL DEF PUMP 2151
PROCEDURE TO REMOVE DEF PUMP 2151
PROCEDURE TO INSTALL DEF PUMP 2156
REMOVE AND INSTALL DEF HOSE 2160
PROCEDURE TO REMOVE DEF HOSE 2161
PROCEDURE TO INSTALL DEF HOSE 2176
POWER TRAIN 2190
REMOVE AND INSTALL FRONT DRIVE SHAFT 2190
PROCEDURE TO REMOVE FRONT DRIVE SHAFT 2190
PROCEDURE TO INSTALL FRONT DRIVE SHAFT 2195
REMOVE AND INSTALL REAR DRIVE SHAFT ASSEMBLY 2199
PROCEDURE TO REMOVE REAR DRIVE SHAFT ASSEMBLY 2199
PROCEDURE TO INSTALL REAR DRIVE SHAFT ASSEMBLY 2202
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2205
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2205
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2223
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2241
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2241
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2251
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER AND PTO ASSEMBLY 2266
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER AND PTO ASSEMBLY 2268
PROCEDURE TO ASSEMBLE TORQUE CONVERTER AND PTO ASSEMBLY 2284
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 2303
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY 2306
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY 2335
REMOVE AND INSTALL DIFFERENCIAL ASSEMBLY 2364
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY 2364
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY 2366
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 2370
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY 2370
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY 2380
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 2399
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY 2399
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY 2401
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 2404
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2404
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2407
BRAKE SYSTEM 2418
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY 2418
PROCEDURE TO REMOVE FRONT WHEEL HUB AND BRAKE ASSEMBLY 2418
PROCEDURE TO INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY 2425
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB AND BRAKE ASSEMBLY 2433
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB AND BRAKE ASSEMBLY 2433
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB AND BRAKE ASSEMBLY 2442
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2456
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2456
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2456
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE AND REAR BRAKE ASSEMBLY 2458
PROCEDURE TO DISASSEMBLE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2458
PROCEDURE TO ASSEMBLE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2472
STEERING SYSTEM 2494
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 2494
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY 2494
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY 2497
REMOVE AND INSTALL O-RING OF STEERING VALVE ASSEMBLY 2500
PROCEDURE TO REMOVE O-RING OF STEERING VALVE ASSEMBLY 2500
PROCEDURE TO INSTALL O-RING OF STEERING VALVE ASSEMBLY 2502
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 2506
PROCEDURE TO REMOVE STEERING CYLINDER ASSEMBLY 2506
PROCEDURE TO INSTALL STEERING CYLINDER ASSEMBLY 2513
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 2520
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY 2520
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY 2522
UNDERCARRIAGE AND FRAME 2525
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 2525
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY 2525
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY 2528
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 2532
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY 2532
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY 2534
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2537
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY 2537
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2544
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2551
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2551
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2553
REMOVE AND INSTALL KING PIN 2555
PROCEDURE TO REMOVE KING PIN 2555
PROCEDURE TO INSTALL KING PIN 2556
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2558
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY 2558
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2561
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2564
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2564
PROCEDURE TOASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2566
HYDRAULIC SYSTEM 2569
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 2569
PROCEDURE TO REMOVE FLOW AMPLIFIER VALVE ASSEMBLY 2569
PROCEDURE TO INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 2576
REMOVE AND INSTALL O-RING of FLOW AMPLIFIER VALVE ASSEMBLY 2584
PROCEDURE TO REMOVE O-RING OF FLOW AMPLIFIER VALVE ASSEMBLY 2584
PROCEDURE TO INSTALL O-RING OF FLOW AMPLIFIER VALVE ASSEMBLY 2587
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 2590
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY 2590
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY 2597
REMOVE AND INSTALL HOIST CYLINDER HEAD ASSEMBLY 2605
PROCEDURE TO REMOVE HOIST CYLINDER HEAD ASSEMBLY 2605
PROCEDURE TO INSTALL HOIST CYLINDER ASSEMBLY 2606
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 2608
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY 2608
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY 2613
WORK EQUIPMENT 2620
REMOVE AND INSTALL DUMP BODY ASSEMBLY 2620
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY 2620
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY 2624
CAB AND ITS ATTACHMENTS 2630
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY 2630
PROCEDURE TO REMOVE OPERATOR CAB ASSEMBLY 2632
PROCEDURE TO INSTALL OPERATOR CAB ASSEMBLY 2665
REMOVE AND INSTALL OPERATOR CAB GLASS 2700
PROCEDURE TO REMOVE OPERATOR CAB FRONT GLASS 2701
PROCEDURE TO INSTALL OPERATOR CAB FRONT GLASS 2703
PROCEDURE TO REMOVE OPERATOR CAB GLASS (ADHERED GLASS) 2706
PROCEDURE TO INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2708
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2713
PROCEDURE TO REMOVE AIR CONDITIONER UNIT ASSEMBLY 2713
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY 2723
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 2733
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY 2733
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY 2735
REMOVE AND INSTALL SEAT BELT 2738
PROCEDURE TO REMOVE SEAT BELT 2738
PROCEDURE TO INSTALL SEAT BELT 2738
ELECTRICAL SYSTEM 2740
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2740
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY 2740
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2741
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2742
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY 2742
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2743
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 2744
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY 2744
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY 2744
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2746
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY 2746
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY 2748
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 2751
PROCEDURE TO REMOVE KOMTRAX PLUS CONTROLLER ASSEMBLY 2751
PROCEDURE TO INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 2752
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2753
PROCEDURE TO REMOVE KOMTRAX TERMINAL ASSEMBLY 2753
PROCEDURE TO INSTALL KOMTRAX TERMINAL ASSEMBLY 2754
REMOVE AND INSTALL REARVIEW CAMERA 2755
PROCEDURE TO REMOVE REARVIEW CAMERA 2755
PROCEDURE TO INSTALL REARVIEW CAMERA 2755
REMOVE AND INSTALL KomVision CAMERA 2756
PROCEDURE TO REMOVE KomVision CAMERA 2757
PROCEDURE TO INSTALL KomVision CAMERA 2763
REMOVE AND INSTALL KomVision RADAR 2769
PROCEDURE TO REMOVE KomVision RADAR 2770
PROCEDURE TO INSTALL KomVision RADAR 2775
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2780
PROCEDURE TO REMOVE KomVision CONTROLLER ASSEMBLY 2780
PROCEDURE TO INSTALL KomVision CONTROLLER ASSEMBLY 2781
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 2782
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY 2782
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY 2783
60 MAINTENANCE STANDARD 2787
CONTENTS 2788
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 2790
ENGINE AND COOLING SYSTEM 2792
MAINTENANCE STANDARD OF ENGINE MOUNT 2792
MAINTENANCE STANDARD OF DAMPER 2793
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE MOTOR 2795
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE MOTOR 2797
POWER TRAIN 2799
MAINTENANCE STANDARD OF DRIVE SHAFT 2799
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 2801
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 2802
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE 2806
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE 2808
MAINTENANCE STANDARD OF TRANSMISSION 2809
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 2815
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 2816
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 2817
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION SELECTOR VALVE 2818
MAINTENANCE STANDARD OF FRONT AXLE 2819
MAINTENANCE STANDARD OF REAR AXLE 2820
MAINTENANCE STANDARD OF DIFFERENTIAL 2821
MAINTENANCE STANDARD OF FINAL DRIVE 2822
STEERING SYSTEM 2823
MAINTENANCE STANDARD OF STEERING COLUMN 2823
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE 2824
MAINTENANCE STANDARD OF STEERING CYLINDER 2827
BRAKE SYSTEM 2828
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER 2828
MAINTENANCE STANDARD OF REAR SLACK ADJUSTER 2829
MAINTENANCE STANDARD OF FRONT BRAKE AND PARKING BRAKE 2830
MAINTENANCE STANDARD OF REAR BRAKE AND PARKING BRAKE 2831
UNDERCARRIAGE AND FRAME 2832
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 2832
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 2834
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 2835
HYDRAULIC SYSTEM 2836
MAINTENANCE STANDARD OF STEERING PUMP 2836
MAINTENANCE STANDARD OF DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR 2840
MAINTENANCE STANDARD OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 2842
MAINTENANCE STANDARD OF SERVO VALVE OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 2844
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP 2845
MAINTENANCE STANDARD OF FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP 2847
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE PUMP 2849
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE AND AXLE OIL CIRCULATION 4-SPOOL PUMP 2851
WORK EQUIPMENT 2853
MAINTENANCE STANDARD OF HOIST CYLINDER 2853
CAB AND ITS ATTACHMENTS 2854
MAINTENANCE STANDARD OF CAB MOUNT 2854
80 THE OTHER INFORMATION 2855
CONTENTS 2856
PRECAUTIONS BEFORE WORK 2858
AIR CONDITIONER SYSTEM 2859
PRECAUTIONS FOR REFRIGERANT 2859
AIR CONDITIONER COMPONENT 2860
SPECIFICATIONS OF AIR CONDITIONER 2862
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2863
OUTLINE OF REFRIGERATION CYCLE 2864
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2866
AIR CONDITIONER UNIT 2866
COMPONENT PARTS OF AIR CONDITIONER UNIT 2869
FUNCTION OF EVAPORATOR 2870
FUNCTION OF HEATER CORE 2870
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR 2870
FUNCTION OF SERVO MOTOR 2870
STRUCTURE OF EXPANSION VALVE 2871
FUNCTION OF EXPANSION VALVE 2871
OPERATE EXPANSION VALVE 2871
FUNCTION OF TRIPLE PRESSURE SWITCH 2872
AIR CONDITIONER CONTROLLER 2873
STRUCTURE OF AIR CONDITIONER CONTROLLER 2873
COMPRESSOR 2874
STRUCTURE OF COMPRESSOR 2874
SPECIFICATIONS OF COMPRESSOR 2874
FUNCTION OF COMPRESSOR 2874
CONDENSER 2875
STRUCTURE OF CONDENSER 2875
SPECIFICATIONS OF CONDENSER 2875
FUNCTION OF CONDENSER 2875
SENSORS FOR AIR CONDITIONER SYSTEM 2876
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2876
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2876
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2877
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2879
AIR CONDITIONER SYSTEM DIAGRAM 2881
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2882
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2884
TESTING AIR LEAKAGE (DUCT) 2887
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2887
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2890
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2891
TEST VENT (MODE) CHANGEOVER 2893
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2893
TESTING FRESH/RECIRC AIR CHANGEOVER 2894
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2894
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 2895
PROCEDURE TO TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 2895
TEST RELAYS 2897
METHOD FOR TESTING RELAYS 2897
AIR CONDITIONER TROUBLESHOOTING CHART 1 2898
AIR CONDITIONER TROUBLESHOOTING CHART 2 2899
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2902
FAILURE CODE [879AKA] 2903
FAILURE CODE [879AKB] 2904
FAILURE CODE [879BKA] 2905
FAILURE CODE [879BKB] 2906
FAILURE CODE [879CKA] 2907
FAILURE CODE [879CKB] 2908
FAILURE CODE [879EMC] 2909
FAILURE CODE [879FMC] 2910
FAILURE CODE [879GKX] 2911
A-1 TROUBLESHOOT POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2912
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2914
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2917
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2919
TROUBLESHOOTING USING GAUGE PRESSURE 2921
CONNECTION OF SERVICE TOOL 2923
METHOD FOR CONNECTING SERVICE TOOL 2923
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2924
HANDLE COMPRESSOR OIL 2926
METHOD FOR REPLACING DESICCANT 2928
KomVision SYSTEM 2930
STRUCTURE AND OPERATION OF KomVision SYSTEM 2930
PRECAUTIONS FOR KomVision SYSTEM 2930
LAYOUT DRAWING OF KomVision SYSTEM 2931
COMPONENT PARTS OF KomVision SYSTEM 2937
TESTING AND ADJUSTING KomVision SYSTEM 2948
SET AND OPERATE KomVision MONITOR 2948
CAMERA CALIBRATION 2971
6 CAMERAS CALIBRATION 2972
1 CAMERA CALIBRATION 3001
RADAR ADJUSTMENT 3008
CHECK DETAILS OF RADAR 3011
TROUBLESHOOTING OF KomVision SYSTEM 3012
RELATED INFORMATION ON TROUBLESHOOTING 3012
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 3027
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 3088
90 CIRCUIT DIAGRAMS 3105
CONTENTS 3106
HOW TO READ ELECTRICAL WIRE CODE 3107
HYDRAULIC CIRCUIT DIAGRAM 3111
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3111
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST 3115
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3117
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM 3119
HYDRAULIC CIRCUIT DIAGRAM FOR POWER LADDER 3121
HYDRAULIC CIRCUIT DIAGRAM OF MACHINE LOCKOUT SYSTEM 3123
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3125
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3127
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE (REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3129
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (HOIST RAISE, FORWARD 2ND) 3131
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT HOIST RAISE + FORWARD 2ND OPERATION) 3133
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE (RETARDER BRAKE OPERATION) 3135
ELECTRICAL CIRCUIT DIAGRAM 3137
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3137
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/10) 3141
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/10) 3143
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/10) 3145
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/10) 3147
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/10) 3149
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/10) 3151
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/10) 3153
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/10) 3155
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (9/10) 3157
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (10/10) 3159
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/11) 3161
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/11) 3163
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/11) 3165
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/11) 3167
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/11) 3169
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/11) 3171
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/11) 3173
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/11) 3175
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/11) 3177
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/11) 3179
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/11) 3181
INDEX 3183

DESCRIPTION:

Komatsu HD1500-8E0 Dump Truck Shop Manual SEN06836-12 – PDF DOWNLOAD 

SERIAL NUMBERS 85001 and up

Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting.
Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TEST AND ADJUST
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TEST AND ADJUST are described in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.

S.V 31/12/24