Komatsu HD325-8 HD405-8 Dump Truck Shop Manual SEN06618-12 – PDF DOWNLOAD

Description

Komatsu HD325-8 HD405-8 Dump Truck Shop Manual SEN06618-12 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HD325-8 HD405-8 Dump Truck Shop Manual SEN06618-12 – PDF DOWNLOAD

SERIAL NUMBERS

HD325-50001 and up
HD405-50001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:

•  Some of the attachments and options described in this shop manual may not be available in some areas. If they are required,
  consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
•  Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.

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 TESTING AND ADJUSTING
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 TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.

TABLE OF CONTENTS:

Komatsu HD325-8 HD405-8 Dump Truck Shop Manual SEN06618-12 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATIONS 27
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
Composition of the shop manual 32
Symbols 33
Signal word 33
Unit 33
SAFETY NOTICE FOR OPERATION 34
Safety matters 34
General precautions 34
Precautions for preparatory work 35
Precautions during work 35
Precautions for slinging work and making signals 37
Precautions for using mobile crane 38
Precautions for using overhead traveling crane 39
Selecting wire ropes 39
Precautions for disconnecting air conditioner piping 39
Precautions for air conditioner piping 40
PRECAUTIONS TO PREVENT FIRE 41
Fire caused by fuel, oil, coolant or window washer fluid 41
Fire caused by accumulation or attachment of flammable material 41
Fire coming from electric wiring 41
Fire caused by piping 41
Fire around the machine due to highly heated exhaust gas 41
Explosion caused by lighting equipment 42
ACTIONS IF FIRE OCCURS 42
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
Handling AdBlue/DEF in cold weather 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
Select an appropriate workplace 46
Disassembly and maintenance work in the field 46
Sealing of openings (prevention of flowing out of oil) 46
Preventing intrusion of foreign materials during refilling 46
Replacing hydraulic oil while its temperature is high 47
Flushing operation 47
Cleaning operation 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 48
Precautions for removal and disassembling work 48
Introduction of parts for the disassembly of the face seal type hoses and tubes 48
Introduction of parts for the disconnection of the taper seal type hoses and tubes 49
Introduction of parts for the disconnection of the split flange type hoses and tubes 49
Introduction of parts for the removal of O-ring boss type joint 50
Introduction of parts for the removal of taper pipe thread type joint 51
Precautions for installation and assembling work 51
Precautions at the time of completion of work 52
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
Handling wiring harnesses and connectors 54
Main causes of failure in wiring harness 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
Select an appropriate workplace 56
Sealing the opening 56
How to clean parts when dirt is stuck 56
Precautions for replacing fuel filter cartridge 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
Select an appropriate workplace 57
Sealing the opening 57
PRACTICAL USE OF KOMTRAX 58
Merit of using KOMTRAX 58
How to make a full use of KOMTRAX 58
How to operate KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
Disconnecting connectors 63
Connecting connectors 64
Drying wiring harness 65
Handling controller 66
Precautions for troubleshooting electrical circuits 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
Method for disconnecting Deutsch connector 67
Method for connecting Deutsch connector 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 68
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 68
Method for disconnecting slide lock type connector (FRAMATOME-24) 68
Method for connecting slide lock type connector (FRAMATOME-24) 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 69
Method for disconnecting connector with lock to pull 69
Method for connecting connector with lock to pull 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 70
Method for disconnecting connector with lock to push (BOSCH-3) 70
Method for connecting connector with lock to push (BOSCH-3) 70
Method for disconnecting connector with lock to push (AMP-3) 71
Method for connecting connector with lock to push (AMP-3) 71
Method for disconnecting connector with lock to push (SUMITOMO-3) 71
Method for connecting connector with lock to push (SUMITOMO-3) 71
Method for disconnecting connector with lock to push (SUMITOMO-4) 71
Method for connecting connector with lock to push (SUMITOMO-4) 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
Method for disconnecting connector with housing to rotate 72
Method for connecting connector with housing to rotate 72
HOW TO READ ELECTRICAL WIRE CODE 73
Type, symbol, and material 73
Dimensions 73
Color codes table 75
Types of circuits and color codes 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 77
Standard dimension and tolerance 77
Standard clearance and standard value 78
Standard interference 78
Repair limit and allowable value or allowable dimension 78
Allowable clearance 78
Allowable interference 78
STANDARD TIGHTENING TORQUE TABLE 79
Table of tightening torque for bolts and nuts 79
Table of tightening torque for O-ring boss piping joints 82
Table of tightening torque for O-ring boss plugs 82
Table of tightening torque for hose (taper seal type and face seal type) 83
Table of tightening torque for face seal joints 84
Tightening torque table for bolts and nuts on 102,107 and 114 series engines 84
Tightening torque table for 102, 107, and 114 series engines (joint bolts) 85
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) 85
CONVERSION TABLE 86
Method of using the conversion table 86
Examples of using the conversion table to convert a unit from mm to in 86
mm to in 86
mm to in 86
kg to lb 87
l to U S Gal 87
l to U K Gal 87
kgm to lbft 88
kg/cm2 to lb/in2 88
Temperature 89
01 SPECIFICATIONS 91
CONTENTS 92
ABBREVIATIONS 93
SPECIFICATIONS 98
SPECIFICATION DRAWING 98
SPECIFICATION DRAWING: HD325-8 98
SPECIFICATION DRAWING: HD405-8 100
SPECIFICATIONS 102
SPECIFICATIONS: HD325-8 102
SPECIFICATIONS: HD405-8 107
WEIGHT TABLE 112
WEIGHT TABLE: HD325-8 112
WEIGHT TABLE: HD405-8 113
FUEL, COOLANT, AND LUBRICATING OIL (NORTH AMERICAN SPECIFICATION) 114
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 114
FUEL, COOLANT, AND LUBRICATING OIL (EU SPECIFICATION) 116
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 116
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATIONS 125
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR STSTEM 130
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 136
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with KOMTRAX terminal) 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with KOMTRAX terminal) 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with gateway function controller) 164
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with gateway function controller) 166
SYSTEM OPERATING LAMP SYSTEM 168
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 168
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with KOMTRAX terminal) 168
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with gateway function controller) 169
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with gateway function controller) 169
BATTERY DISCONNECT SWITCH 170
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with KOMTRAX terminal) 170
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with gateway function controller) 171
ENGINE SHUTDOWN SECONDARY SWITCH 172
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 172
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 172
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 173
ENGINE SYSTEM 174
LAYOUT DRAWING OF ENGINE SYSTEM 174
FUNCTION OF ENGINE SYSTEM 176
ENGINE CONTROL SYSTEM 177
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 177
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with gateway function controller) 178
FUNCTION OF ENGINE CONTROL SYSTEM 179
OPERATION OF ENGINE CONTROL SYSTEM 180
AUTOMATIC IDLE STOP SYSTEM 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 182
COMPONENT PARTS OF ENGINE SYSTEM 184
OUTPUT SHAFT 184
VGT 185
EGR SYSTEM 189
EGR VALVE 191
EGR COOLER 193
KCCV SYSTEM 194
KCCV VENTILATOR 196
KDPF 198
COOLING SYSTEM 202
LAYOUT DRAWING OF COOLING SYSTEM 202
SPECIFICATIONS OF COOLING SYSTEM 203
RADIATOR FAN CONTROL SYSTEM 204
RADIATOR FAN CONTROL SYSTEM DIAGRAM 204
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 204
COMPONENT PARTS OF COOLING SYSTEM 206
COOLING FAN AND HOIST PUMP 206
COOLING FAN MOTOR 214
CONTROL SYSTEM 221
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with KOMTRAX terminal) 221
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with gateway function controller) 223
RETARDER AND HOIST CONTROL SYSTEM 225
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 225
MACHINE MONITOR SYSTEM 227
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 227
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with gateway function controller) 229
FUNCTION OF MACHINE MONITOR SYSTEM 230
REARVIEW MONITOR SYSTEM 231
REARVIEW MONITOR SYSTEM DIAGRAM 231
FUNCTION OF REARVIEW MONITOR SYSTEM 231
KOMTRAX SYSTEM 232
KOMTRAX SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 232
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with KOMTRAX terminal) 232
KOMTRAX SYSTEM DIAGRAM (For machines equipped with gateway function controller) 233
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with gateway function controller) 233
PAYLOAD METER SYSTEM 234
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 234
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 235
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with gateway function controller) 236
FUNCTION OF PAYLOAD METER SYSTEM 236
COMPONENT PARTS OF CONTROL SYSTEM 246
MACHINE MONITOR 246
SWITCH PANEL 263
REARVIEW MONITOR 264
REARVIEW CAMERA 265
KOMTRAX TERMINAL 266
GATEWAY FUNCTION CONTROLLER 268
INPUT AND OUTPUT SIGNALS OF GATEWAY FUNCTION CONTROLLER 268
COMMUNICATION TERMINAL 271
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR MOBILE COMMUNICATION 271
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR IRIDIUM COMMUNICATION 272
TRANSMISSION CONTROLLER 273
RETARDER AND HOIST CONTROLLER 277
MONITOR CONTROLLER 282
ENGINE CONTROLLER 287
PAYLOAD METER CONTROLLER 293
ACCELERATOR PEDAL 297
GEAR SHIFT LEVER 298
RETARDER CONTROL LEVER 299
HYDRAULIC SYSTEM 300
LAYOUT DRAWING OF HYDRAULIC SYSTEM 300
COMPONENT PARTS OF HYDRAULIC SYSTEM 301
HYDRAULIC TANK 301
STEERING AND HOIST PUMP 302
POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 312
BRAKE COOLING DUPLEX PUMP 313
HOIST VALVE 314
POWER TRAIN SYSTEM 320
LAYOUT DRAWING OF POWER TRAIN SYSTEM 320
TRANSMISSION CONTROL SYSTEM 323
TRANSMISSION CONTROL SYSTEM DIAGRAM 323
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 325
GEAR SHIFT CONTROL SYSTEM 329
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 329
SHIFTING METHOD IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT CONTROL SYSTEM 330
GEAR SHIFT DISABLED TIME CONTROL OF GEAR SHIFT CONTROL SYSTEM 331
DIRECTION CONTROL SYSTEM 332
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 332
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 332
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 333
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 333
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 333
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 334
TRAVEL SPEED LIMITATION SYSTEM 335
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 335
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 336
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 337
COMPONENT PARTS OF POWER TRAIN SYSTEM 339
DRIVE SHAFT 339
TORQUE CONVERTER AND PTO 341
LOCKUP CLUTCH ECMV 345
TRANSMISSION 348
TRANSMISSION CONTROL VALVE 369
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 371
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 376
MAIN RELIEF VALVE 378
TORQUE CONVERTER RELIEF VALVE 380
AXLE 381
DIFFERENTIAL 383
FINAL DRIVE 385
WORK EQUIPMENT SYSTEM 386
WORK EQUIPMENT CONTROL 386
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 386
FUNCTION OF WORK EQUIPMENT CONTROL 386
HOIST CONTROL 387
HOIST CONTROL SYSTEM DIAGRAM 387
FUNCTION OF HOIST CONTROL 387
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 389
HOIST AND COOLING FAN DIRECTION SELECTOR SOLENOID VALVE 389
DUMP LEVER 390
HOIST EPC VALVE 395
STEERING SYSTEM 396
LAYOUT DRAWING OF STEERING SYSTEM 396
FUNCTION OF STEERING SYSTEM 397
STEERING COLUMN 398
STRUCTURE OF STEERING COLUMN 398
STEERING CONTROL LINKAGE 399
STRUCTURE OF STEERING CONTROL LINKAGE 399
COMPONENT PARTS OF STEERING SYSTEM 400
DEMAND VALVE 400
ORBITROL VALVE 408
STEERING PUMP SELECTOR SOLENOID VALVE 414
CROSS-OVER RELIEF VALVE 415
SECONDARY STEERING PUMP 416
SECONDARY STEERING MOTOR 417
BRAKE SYSTEM 418
LAYOUT DRAWING OF BRAKE SYSTEM 418
RETARDER CONTROL 419
RETARDER CONTROL SYSTEM DIAGRAM 419
FUNCTION OF RETARDER CONTROL 419
ARSC SYSTEM 420
ARSC SYSTEM DIAGRAM 420
FUNCTION OF ARSC SYSTEM 420
COMPONENT PARTS OF BRAKE SYSTEM 421
BRAKE CONTROL PUMP 421
PARKING BRAKE SOLENOID VALVE 422
ACCUMULATOR CHARGE VALVE 423
BRAKE CIRCUIT ACCUMULATOR 427
BRAKE VALVE 428
SECONDARY BRAKE VALVE 432
SECONDARY BRAKE RELAY VALVE 433
FRONT BRAKE CUT SOLENOID VALVE 434
PROPORTIONAL PRESSURE REDUCING VALVE 435
SLACK ADJUSTER 436
BRAKE COOLING OIL CONTROL VALVE 438
BRAKE 439
STRUCTURE OF REAR BRAKE 440
PARKING BRAKE 442
BRAKE SUB-TANK 443
UNDERCARRIAGE AND FRAME 444
REAR AXLE SUPPORT 444
STRUCTURE OF REAR AXLE SUPPORT 444
SUSPENSION 445
STRUCTURE OF SUSPENSION 445
FUNCTION OF SUSPENSION 446
FRONT SUSPENSION 447
STRUCTURE OF FRONT SUSPENSION 447
FUNCTION OF FRONT SUSPENSION 448
REAR SUSPENSION 449
STRUCTURE OF REAR SUSPENSION 449
FUNCTION OF REAR SUSPENSION 450
SUSPENSION CYLINDER 451
STRUCTURE OF SUSPENSION CYLINDER 451
FUNCTION OF SUSPENSION CYLINDER 451
OPERATION OF SUSPENSION CYLINDER 451
WORK EQUIPMENT 452
STRUCTURE OF WORK EQUIPMENT 452
FUNCTION OF WORK EQUIPMENT 452
CAB AND ITS ATTACHMENTS 453
ROPS CAB 453
STRUCTURE OF ROPS CAB 453
FUNCTION OF ROPS CAB 453
CAB MOUNT 454
STRUCTURE OF CAB MOUNT 454
FUNCTION OF CAB MOUNT 454
20 STANDARD VALUE TABLE 455
CONTENTS 456
ABBREVIATIONS 457
STANDARD VALUE TABLE FOR ENGINE 462
STANDARD VALUE TABLE FOR ENGINE: HD325-8 462
STANDARD VALUE TABLE FOR ENGINE: HD405-8 465
STANDARD VALUE TABLE FOR MACHINE 468
STANDARD VALUE TABLE FOR MACHINE: HD325-8 468
STANDARD VALUE TABLE FOR MACHINE: HD405-8 482
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 496
30 TESTING AND ADJUSTING 497
CONTENTS 498
ABBREVIATIONS 502
RELATED INFORMATION TO TEST AND ADJUST 507
TOOLS TO TEST AND ADJUST 507
DIAGRAM FOR TEST AND ADJUST TOOLS 517
ENGINE AND COOLING SYSTEM 519
TEST ENGINE SPEED 519
PROCEDURE TO TEST ENGINE SPEED 519
TEST BOOST PRESSURE 521
PROCEDURE TO TEST BOOST PRESSURE WITH MACHINE MONITOR 521
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 523
TEST EXHAUST GAS TEMPERATURE 525
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 525
TEST EXHAUST GAS COLOR 528
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 528
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 529
TEST AND ADJUST VALVE CLEARANCE 531
PROCEDURE TO TEST VALVE CLEARANCE 531
PROCEDURE TO ADJUST VALVE CLEARANCE 532
TEST COMPRESSION PRESSURE 534
PROCEDURE TO TEST COMPRESSION PRESSURE 534
TEST BLOWBY PRESSURE 537
PROCEDURE TO TEST BLOWBY PRESSURE 537
TEST ENGINE OIL PRESSURE 540
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH MACHINE MONITOR 540
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH TEST TOOLS 540
TEST EGR VALVE AND VGT OIL PRESSURE 542
PROCEDURE TO TEST EGR VALVE AND VGT OIL PRESSURE 542
TEST FUEL PRESSURE 543
PROCEDURE TO TEST FUEL PRESSURE 543
TEST FUEL RETURN RATE AND LEAKAGE 545
PROCEDURE TO TEST FUEL RETURN RATE AND LEAKAGE 546
BLEED AIR FROM FUEL SYSTEM 550
PROCEDURE TO BLEED AIR FROM FUEL SYSTEM 550
TEST FUEL CIRCUIT LEAK 552
PROCEDURE TO TEST FUEL CIRCUIT LEAK 552
CYLINDER CUT-OUT MODE 554
NO-INJECTION CRANKING 555
CLEAN FUEL DOSER 556
PROCEDURE TO CLEAN FUEL DOSER 556
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 559
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 560
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER 566
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 566
TEST SCR RELATED FUNCTIONS 567
TEST AdBlue/DEF PUMP RAISED PRESSURE 570
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 573
TEST AdBlue/DEF LINE HEATER RELAY 1 578
TEST AdBlue/DEF LINE HEATER RELAY 2 582
TEST AdBlue/DEF PUMP HEATER RELAY 586
TEST AdBlue/DEF TANK HEATER VALVE 590
TEST DENITRATION EFFICIENCY OF SCR 594
CLEAN AdBlue/DEF TANK 597
PROCEDURE TO CLEAN AdBlue/DEF TANK 597
CLEAN AdBlue/DEF PUMP 603
PROCEDURE TO CLEAN AdBlue/DEF PUMP 603
TEST TORQUE CONVERTER STALL SPEED 609
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED 609
TEST RADIATOR FAN SPEED 611
PROCEDURE TO TEST RADIATOR FAN SPEED 611
POWER TRAIN 613
TEST POWER TRAIN OIL PRESSURE 613
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 616
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 627
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 627
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 628
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 628
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 629
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 629
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 630
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 630
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 631
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 631
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 631
STEERING SYSTEM 636
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 636
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 636
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 636
PROCEDURE TO ADJUST STEERING CIRCUIT OIL PRESSURE 638
TEST SUPPLY PRESSURE OF ORBITROL VALVE 639
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 639
TEST STEERING CYLINDER PRESSURE 641
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 641
BLEED AIR FROM STEERING CYLINDER CIRCUIT 643
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 643
BRAKE SYSTEM 644
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 644
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 644
TEST WHEEL BRAKE OIL PRESSURE 645
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE 645
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE 646
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE 647
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE (FOR MACHINE WITH KTCS) 647
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 649
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 649
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 650
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 651
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 652
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 653
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 657
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 661
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 667
TEST BRAKE PERFORMANCE 668
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 668
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 669
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 670
BLEED AIR FROM BRAKE CIRCUIT 671
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 671
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITHOUT KTCS) 671
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 672
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 674
TEST PARKING BRAKE OIL PRESSURE 675
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 675
RELEASE PARKING BRAKE MANUALLY 677
PROCEDURE TO RELEASE PARKING BRAKE MANUALLY 677
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 678
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 678
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE PAD WEAR WITH GUAGE MEASURE 678
TEST THE AMOUNT OF REAR BRAKE DISC WEAR 679
PROCEDURE TO VISUALLY TEST THE AMOUNT OF REAR BRAKE DISC WEAR 679
TEST AND ADJUST PARKING BRAKE PAD 680
PROCEDURE TO TEST PARKING BRAKE PAD CLEARANCE 680
PROCEDURE TO ADJUST PARKING BRAKE PAD CLEARANCE 681
HYDRAULIC SYSTEM 682
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 682
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 682
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 683
TEST HOIST CYLINDER SUPPLY PRESSURE 684
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 684
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 686
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 686
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 687
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 688
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 688
TEST AND ADJUST FRONT SUSPENSION CYLINDER 690
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 690
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 691
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 696
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 696
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 697
TEST AND ADJUST REAR SUSPENSION CYLINDER 698
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 698
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 699
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 704
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 704
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH TEST TOOLS 704
WORK EQUIPMENT 706
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 706
PROCEDURE TO TEST BODY POSITIONER SENSOR 706
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 706
PROCEDURE TO CALIBRATE AFTER YOU ADJUST BODY POSITION SENSOR 706
LOWER THE BODY MANUALLY 708
PROCEDURE TO LOWER THE BODY MANUALLY 708
LIFT THE BODY MANUALLY 709
PROCEDURE TO LIFT THE BODY MANUALLY 709
CAB AND ITS ATTACHMENTS 710
ADJUST STEERING WHEEL TILT LOCK LEVER 710
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 710
ADJUST RATTLING OPERATOR’S SEAT 711
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 711
ELECTRICAL SYSTEM 712
SET AND ADJUST EACH EQUIPMENT 712
SET AND OPERATE OF MACHINE MONITOR 715
OPERATOR MODE 719
SERVICE MODE 732
ABNORMALITY RECORD MENU 759
DEFAULT MENU 774
DIAGNOSTIC TESTS MENU 788
ADJUSTMENT MENU 800
PROCEDURE TO PERFORM NO-INJECTION CRANKING 821
PAYLOAD METER SETTING 823
KOMTRAX SETTINGS MENU 845
PROCEDURE TO DISPLAY SERVICE MESSAGE 850
PROCEDURE TO START UP KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 852
PROCEDURE TO FINISH KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 856
PROCEDURE TO START UP KOMTRAX SYSTEM (For machines equipped with gateway function controller) 858
PROCEDURE TO FINISH KOMTRAX SYSTEM(For machines equipped with gateway function controller) 862
ADJUST REARVIEW CAMERA ANGLE 864
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 864
ADJUST OPTICAL AXIS OF HEAD LAMP 865
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 865
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 868
BATTERY DISCONNECT SWITCH WORK (For machines equipped with KOMTRAX terminal) 869
BATTERY DISCONNECT SWITCH WORK (For machines equipped with gateway function controller) 870
TEST DIODES 871
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 871
PROCEDURE TO TEST DIODE USING ANALOG TESTER 871
Pm CLINIC 872
Pm CLINIC SERVICE 872
Pm CLINIC CHECK SHEET: HD325-8 875
Pm CLINIC CHECK SHEET: HD405-8 882
40 TROUBLESHOOTING 889
CONTENTS 890
ABBREVIATIONS 904
RELATED INFORMATION ON TROUBLESHOOTING 909
GENERAL TROUBLESHOOTING POINTS 909
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 910
SEQUENCE OF EVENTS IN TROUBLESHOOTING 922
CHECKS BEFORE TROUBLESHOOTING 924
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 927
WALK-AROUND CHECK 927
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 929
CHECK FUEL LEVEL AND TYPE 929
CHECK IMPURE INGREDIENT IN FUEL 929
CHECK AdBlue/DEF LEVEL AND TYPE 929
CHECK FUEL PREFILTER 930
CHECK MAIN FILTER 932
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 934
CHECK COOLANT LEVEL (RESERVOIR TANK) 935
CHECK CLOGGING OF AIR CLEANER 936
CHECK OF AIR CLEANER 937
OUTER ELEMENT – CLEAN 937
REPLACE ELEMENT 939
CHECK HYDRAULIC OIL LEVEL 941
CHECK HYDRAULIC OIL STRAINER 941
CHECK HYDRAULIC FILTER 942
CHECK OIL LEVEL IN TRANSMISSION CASE 942
CHECK OIL LEVEL IN DIFFERENTIAL CASE 943
CHECK OIL LEVEL IN FINAL DRIVE CASE 943
BLEED AIR FROM FUEL SYSTEM 944
BLEED AIR FROM HYDRAULIC SYSTEM 944
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 944
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 950
PROCEDURE FOR TESTING AND TROUBLESHOOTING 960
SYMPTOM AND TROUBLESHOOTING NUMBERS 962
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 967
CONNECTORS LIST AND LAYOUT 970
CONNECTOR CONTACT IDENTIFICATION 996
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1036
FUSE LOCATION TABLE (For machines equipped with KOMTRAX terminal) 1042
FUSE LOCATION TABLE (For machines equipped with gateway function controller) 1049
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1055
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1058
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1060
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135]) 1066
FAILURE CODES TABLE 1068
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1094
FAILURE CODE [1500L0] 1094
FAILURE CODE [15B0NX] 1095
FAILURE CODE [15F0KM] 1097
FAILURE CODE [15F0MB] 1098
FAILURE CODE [15F7KM] 1099
FAILURE CODE [15G0MW] 1100
FAILURE CODE [15G7KM] 1101
FAILURE CODE [15H0MW] 1102
FAILURE CODE [15J0MW] 1103
FAILURE CODE [15K0MW] 1104
FAILURE CODE [15L0MW] 1106
FAILURE CODE [15M0MW] 1108
FAILURE CODE [15N0MW] 1110
FAILURE CODE [15SBL1] 1111
FAILURE CODE [15SBMA] 1114
FAILURE CODE [15SCL1] 1115
FAILURE CODE [15SCMA] 1118
FAILURE CODE [15SDL1] 1119
FAILURE CODE [15SDMA] 1122
FAILURE CODE [15SEL1] 1123
FAILURE CODE [15SEMA] 1126
FAILURE CODE [15SFL1] 1127
FAILURE CODE [15SFMA] 1130
FAILURE CODE [15SGL1] 1131
FAILURE CODE [15SGMA] 1134
FAILURE CODE [15SHL1] 1135
FAILURE CODE [15SHMA] 1138
FAILURE CODE [15SJMA] 1139
FAILURE CODE [2C4MNX] 1140
FAILURE CODE [2F00KM] 1141
FAILURE CODE [2G42ZG] 1144
FAILURE CODE [2G43ZG] 1145
FAILURE CODE [6014NX] 1146
FAILURE CODE [879AKA] 1147
FAILURE CODE [879AKB] 1148
FAILURE CODE [879BKA] 1149
FAILURE CODE [879BKB] 1150
FAILURE CODE [879CKA] 1151
FAILURE CODE [879CKB] 1152
FAILURE CODE [879EMC] 1153
FAILURE CODE [879FMC] 1154
FAILURE CODE [879GKX] 1155
FAILURE CODE [989D00] 1156
FAILURE CODE [989L00] 1157
FAILURE CODE [989M00] 1158
FAILURE CODE [989N00] 1159
FAILURE CODE [989X00] 1160
FAILURE CODE [A1U0N3] 1161
FAILURE CODE [A1U0N4] 1162
FAILURE CODE [AA10NX] 1163
FAILURE CODE [AB00KE] 1165
FAILURE CODE [AB00KY] 1167
FAILURE CODE [AQ10N3] 1168
FAILURE CODE [AS00N3] 1169
FAILURE CODE [AS00R2] 1170
FAILURE CODE [AS00R3] 1171
FAILURE CODE [AS00R4] 1172
FAILURE CODE [AS00R5] 1173
FAILURE CODE [AS00R6] 1174
FAILURE CODE [AS00ZK] 1175
FAILURE CODE [AS10KM] 1176
FAILURE CODE [AS10NR] 1177
FAILURE CODE [AS10NT] 1178
FAILURE CODE [B@BAZG] 1179
FAILURE CODE [B@BAZK] 1180
FAILURE CODE [B@BCNS] 1181
FAILURE CODE [B@BCQA] 1182
FAILURE CODE [B@BCZK] 1184
FAILURE CODE [B@C7NS] 1186
FAILURE CODE [B@CENS] 1188
FAILURE CODE [B@JANS] 1189
FAILURE CODE [CA115] 1190
FAILURE CODE [CA122] 1191
FAILURE CODE [CA123] 1193
FAILURE CODE [CA131] 1195
FAILURE CODE [CA132] 1197
FAILURE CODE [CA135] 1199
FAILURE CODE [CA141] 1201
FAILURE CODE [CA144] 1203
FAILURE CODE [CA145] 1205
FAILURE CODE [CA153] 1207
FAILURE CODE [CA154] 1209
FAILURE CODE [CA187] 1211
FAILURE CODE [CA221] 1213
FAILURE CODE [CA222] 1215
FAILURE CODE [CA227] 1217
FAILURE CODE [CA234] 1218
FAILURE CODE [CA238] 1219
FAILURE CODE [CA239] 1221
FAILURE CODE [CA249] 1223
FAILURE CODE [CA256] 1225
FAILURE CODE [CA271] 1227
FAILURE CODE [CA272] 1229
FAILURE CODE [CA273] 1230
FAILURE CODE [CA274] 1232
FAILURE CODE [CA322] 1233
FAILURE CODE [CA323] 1235
FAILURE CODE [CA324] 1237
FAILURE CODE [CA325] 1239
FAILURE CODE [CA331] 1241
FAILURE CODE [CA332] 1243
FAILURE CODE [CA343] 1245
FAILURE CODE [CA351] 1246
FAILURE CODE [CA352] 1247
FAILURE CODE [CA356] 1249
FAILURE CODE [CA357] 1251
FAILURE CODE [CA386] 1253
FAILURE CODE [CA431] 1254
FAILURE CODE [CA432] 1257
FAILURE CODE [CA441] 1260
FAILURE CODE [CA442] 1263
FAILURE CODE [CA449] 1264
FAILURE CODE [CA451] 1265
FAILURE CODE [CA452] 1267
FAILURE CODE [CA515] 1269
FAILURE CODE [CA516] 1271
FAILURE CODE [CA553] 1273
FAILURE CODE [CA555] 1274
FAILURE CODE [CA556] 1275
FAILURE CODE [CA559] 1276
FAILURE CODE [CA595] 1280
FAILURE CODE [CA687] 1281
FAILURE CODE [CA689] 1283
FAILURE CODE [CA691] 1285
FAILURE CODE [CA692] 1287
FAILURE CODE [CA697] 1289
FAILURE CODE [CA698] 1290
FAILURE CODE [CA731] 1291
FAILURE CODE [CA778] 1292
FAILURE CODE [CA1117] 1295
FAILURE CODE [CA1664] 1297
FAILURE CODE [CA1669] 1299
FAILURE CODE [CA1673] 1300
FAILURE CODE [CA1677] 1301
FAILURE CODE [CA1678] 1302
FAILURE CODE [CA1682] 1303
FAILURE CODE [CA1683] 1307
FAILURE CODE [CA1684] 1309
FAILURE CODE [CA1686] 1311
FAILURE CODE [CA1691] 1312
FAILURE CODE [CA1694] 1314
FAILURE CODE [CA1695] 1316
FAILURE CODE [CA1696] 1317
FAILURE CODE [CA1712] 1319
FAILURE CODE [CA1713] 1321
FAILURE CODE [CA1714] 1323
FAILURE CODE [CA1715] 1324
FAILURE CODE [CA1776] 1325
FAILURE CODE [CA1777] 1328
FAILURE CODE [CA1843] 1331
FAILURE CODE [CA1844] 1333
FAILURE CODE [CA1879] 1335
FAILURE CODE [CA1881] 1337
FAILURE CODE [CA1883] 1339
FAILURE CODE [CA1885] 1342
FAILURE CODE [CA1887] 1344
FAILURE CODE [CA1921] 1346
FAILURE CODE [CA1922] 1348
FAILURE CODE [CA1923] 1351
FAILURE CODE [CA1924] 1353
FAILURE CODE [CA1925] 1355
FAILURE CODE [CA1927] 1357
FAILURE CODE [CA1928] 1359
FAILURE CODE [CA1942] 1361
FAILURE CODE [CA1963] 1362
FAILURE CODE [CA1977] 1366
FAILURE CODE [CA1993] 1368
FAILURE CODE [CA2185] 1370
FAILURE CODE [CA2186] 1372
FAILURE CODE [CA2249] 1374
FAILURE CODE [CA2265] 1375
FAILURE CODE [CA2266] 1377
FAILURE CODE [CA2271] 1379
FAILURE CODE [CA2272] 1381
FAILURE CODE [CA2349] 1383
FAILURE CODE [CA2353] 1385
FAILURE CODE [CA2357] 1387
FAILURE CODE [CA2381] 1388
FAILURE CODE [CA2382] 1390
FAILURE CODE [CA2383] 1392
FAILURE CODE [CA2386] 1394
FAILURE CODE [CA2387] 1396
FAILURE CODE [CA2555] 1397
FAILURE CODE [CA2556] 1399
FAILURE CODE [CA2637] 1401
FAILURE CODE [CA2639] 1403
FAILURE CODE [CA2732] 1405
FAILURE CODE [CA2733] 1407
FAILURE CODE [CA2741] 1409
FAILURE CODE [CA2765] 1410
FAILURE CODE [CA2771] 1411
FAILURE CODE [CA2777] 1416
FAILURE CODE [CA2878] 1417
FAILURE CODE [CA2881] 1420
FAILURE CODE [CA2976] 1424
FAILURE CODE [CA3133] 1426
FAILURE CODE [CA3134] 1428
FAILURE CODE [CA3135] 1430
FAILURE CODE [CA3142] 1433
FAILURE CODE [CA3143] 1434
FAILURE CODE [CA3144] 1435
FAILURE CODE [CA3146] 1437
FAILURE CODE [CA3147] 1438
FAILURE CODE [CA3148] 1439
FAILURE CODE [CA3151] 1441
FAILURE CODE [CA3165] 1446
FAILURE CODE [CA3167] 1448
FAILURE CODE [CA3229] 1451
FAILURE CODE [CA3231] 1453
FAILURE CODE [CA3232] 1455
FAILURE CODE [CA3235] 1459
FAILURE CODE [CA3239] 1461
FAILURE CODE [CA3241] 1464
FAILURE CODE [CA3242] 1467
FAILURE CODE [CA3251] 1469
FAILURE CODE [CA3253] 1471
FAILURE CODE [CA3254] 1474
FAILURE CODE [CA3255] 1476
FAILURE CODE [CA3256] 1478
FAILURE CODE [CA3311] 1480
FAILURE CODE [CA3312] 1482
FAILURE CODE [CA3313] 1484
FAILURE CODE [CA3314] 1485
FAILURE CODE [CA3315] 1486
FAILURE CODE [CA3316] 1489
FAILURE CODE [CA3317] 1490
FAILURE CODE [CA3318] 1491
FAILURE CODE [CA3319] 1494
FAILURE CODE [CA3321] 1495
FAILURE CODE [CA3322] 1496
FAILURE CODE [CA3419] 1499
FAILURE CODE [CA3421] 1501
FAILURE CODE [CA3497] 1503
FAILURE CODE [CA3498] 1504
FAILURE CODE [CA3543] 1505
FAILURE CODE [CA3545] 1510
FAILURE CODE [CA3547] 1512
FAILURE CODE [CA3558] 1513
FAILURE CODE [CA3559] 1515
FAILURE CODE [CA3562] 1517
FAILURE CODE [CA3563] 1519
FAILURE CODE [CA3567] 1522
FAILURE CODE [CA3568] 1524
FAILURE CODE [CA3571] 1528
FAILURE CODE [CA3572] 1530
FAILURE CODE [CA3574] 1532
FAILURE CODE [CA3575] 1534
FAILURE CODE [CA3577] 1536
FAILURE CODE [CA3578] 1538
FAILURE CODE [CA3582] 1540
FAILURE CODE [CA3583] 1546
FAILURE CODE [CA3596] 1548
FAILURE CODE [CA3649] 1552
FAILURE CODE [CA3681] 1554
FAILURE CODE [CA3682] 1558
FAILURE CODE [CA3713] 1562
FAILURE CODE [CA3717] 1565
FAILURE CODE [CA3718] 1566
FAILURE CODE [CA3725] 1567
FAILURE CODE [CA3748] 1570
FAILURE CODE [CA3751] 1572
FAILURE CODE [CA3755] 1573
FAILURE CODE [CA3866] 1575
FAILURE CODE [CA3867] 1578
FAILURE CODE [CA3868] 1581
FAILURE CODE [CA3899] 1585
FAILURE CODE [CA3911] 1587
FAILURE CODE [CA3912] 1591
FAILURE CODE [CA3932] 1593
FAILURE CODE [CA3933] 1595
FAILURE CODE [CA3934] 1597
FAILURE CODE [CA3935] 1600
FAILURE CODE [CA3936] 1602
FAILURE CODE [CA4151] 1604
FAILURE CODE [CA4152] 1608
FAILURE CODE [CA4155] 1612
FAILURE CODE [CA4156] 1614
FAILURE CODE [CA4157] 1616
FAILURE CODE [CA4158] 1618
FAILURE CODE [CA4159] 1620
FAILURE CODE [CA4161] 1621
FAILURE CODE [CA4162] 1623
FAILURE CODE [CA4163] 1625
FAILURE CODE [CA4164] 1627
FAILURE CODE [CA4165] 1629
FAILURE CODE [CA4166] 1631
FAILURE CODE [CA4168] 1632
FAILURE CODE [CA4169] 1637
FAILURE CODE [CA4171] 1640
FAILURE CODE [CA4249] 1643
FAILURE CODE [CA4251] 1646
FAILURE CODE [CA4259] 1649
FAILURE CODE [CA4261] 1652
FAILURE CODE [CA4277] 1654
FAILURE CODE [CA4281] 1656
FAILURE CODE [CA4459] 1659
FAILURE CODE [CA4461] 1661
FAILURE CODE [CA4658] 1664
FAILURE CODE [CA4731] 1667
FAILURE CODE [CA4732] 1668
FAILURE CODE [CA4739] 1669
FAILURE CODE [CA4768] 1670
FAILURE CODE [CA4769] 1672
FAILURE CODE [CA4842] 1674
FAILURE CODE [CA4952] (For machines equipped with KOMTRAX terminal) 1677
FAILURE CODE [CA4952] (For machines equipped with gateway function controller) 1679
FAILURE CODE [CA5115] 1681
FAILURE CODE [CA5179] 1684
FAILURE CODE [CA5181] 1686
FAILURE CODE [CA5383] 1688
FAILURE CODE [D150KB] 1689
FAILURE CODE [D150KZ] 1690
FAILURE CODE [D164KY] 1691
FAILURE CODE [D19HKZ] 1692
FAILURE CODE [D19JKZ] 1694
FAILURE CODE [D19QKZ] 1695
FAILURE CODE [D1EHKA] 1697
FAILURE CODE [D1EHKB] 1698
FAILURE CODE [D1EHKY] 1699
FAILURE CODE [D1EMKA] 1700
FAILURE CODE [D1EMKB] 1701
FAILURE CODE [D1EMKY] 1702
FAILURE CODE [D1FBKB] 1703
FAILURE CODE [D5ZHL6] 1704
FAILURE CODE [D5ZKKZ] 1706
FAILURE CODE [D811MC] (For machines equipped with KOMTRAX terminal) 1708
FAILURE CODE [D811MC] (For machines equipped with gateway function controller) 1709
FAILURE CODE [D862KA] (For machines equipped with KOMTRAX terminal) 1710
FAILURE CODE [D862KA] (For machines equipped with gateway function controller) 1711
FAILURE CODE [D8ALKA] (For machines equipped with KOMTRAX terminal) 1712
FAILURE CODE [D8ALKA] (For machines equipped with gateway function controller) 1714
FAILURE CODE [D8ALKB] (For machines equipped with KOMTRAX terminal) 1716
FAILURE CODE [D8ALKB] (For machines equipped with gateway function controller) 1718
FAILURE CODE [D8AQK4] (For machines equipped with KOMTRAX terminal) 1720
FAILURE CODE [D8AQK4] (For machines equipped with gateway function controller) 1721
FAILURE CODE [D8AQKR] (For machines equipped with KOMTRAX terminal) 1722
FAILURE CODE [D8AQKR] (For machines equipped with gateway function controller) 1723
FAILURE CODE [D8G1KT] 1724
FAILURE CODE [D8G6KT] 1725
FAILURE CODE [DAF0KT] 1726
FAILURE CODE [DAF0MB] 1727
FAILURE CODE [DAF0MC] 1728
FAILURE CODE [DAF3KK] 1729
FAILURE CODE [DAF8KB] 1731
FAILURE CODE [DAFDKB] 1732
FAILURE CODE [DAFGMC] (For machines equipped with KOMTRAX terminal) 1734
FAILURE CODE [DAFGMC] (For machines equipped with gateway function controller) 1735
FAILURE CODE [DAFLKA] (For machines equipped with KOMTRAX terminal) 1736
FAILURE CODE [DAFLKA] (For machines equipped with gateway function controller) 1738
FAILURE CODE [DAFLKB] (For machines equipped with KOMTRAX terminal) 1740
FAILURE CODE [DAFLKB] (For machines equipped with gateway function controller) 1742
FAILURE CODE [DAFQKR] (For machines equipped with KOMTRAX terminal) 1744
FAILURE CODE [DAFQKR] (For machines equipped with gateway function controller) 1745
FAILURE CODE [DAQ0KK] 1746
FAILURE CODE [DAQ0KT] 1749
FAILURE CODE [DAQ0MC] 1750
FAILURE CODE [DAQ1KA] 1751
FAILURE CODE [DAQ2KK] 1754
FAILURE CODE [DAQ9KQ] 1757
FAILURE CODE [DAQLKA] (For machines equipped with KOMTRAX terminal) 1758
FAILURE CODE [DAQLKA] (For machines equipped with gateway function controller) 1760
FAILURE CODE [DAQLKB] (For machines equipped with KOMTRAX terminal) 1762
FAILURE CODE [DAQLKB] (For machines equipped with gateway function controller) 1764
FAILURE CODE [DAQQKR] 1766
FAILURE CODE [DAQRKR] 1767
FAILURE CODE [DAQRMA] 1768
FAILURE CODE [DAQV00] 1769
FAILURE CODE [DAQW00] 1770
FAILURE CODE [DAZ9KQ] 1771
FAILURE CODE [DAZQKR] 1772
FAILURE CODE [DB10KT] 1773
FAILURE CODE [DB10MC] 1774
FAILURE CODE [DB11KA] 1775
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) 1778
FAILURE CODE [DB12KK] 1781
FAILURE CODE [DB13KK] 1784
FAILURE CODE [DB19KQ] 1787
FAILURE CODE [DB1LKA] (For machines equipped with KOMTRAX terminal) 1788
FAILURE CODE [DB1LKA] (For machines equipped with gateway function controller) 1790
FAILURE CODE [DB1LKB] (For machines equipped with KOMTRAX terminal) 1792
FAILURE CODE [DB1LKB] (For machines equipped with gateway function controller) 1794
FAILURE CODE [DB1QKR] 1796
FAILURE CODE [DB1QMA] 1797
FAILURE CODE [DB1RKR] 1798
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal) 1799
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller) 1805
FAILURE CODE [DB2RKR] 1811
FAILURE CODE [DBS0KK] 1816
FAILURE CODE [DBS6KP] 1819
FAILURE CODE [DBSQKQ] 1821
FAILURE CODE [DBSQKR] 1822
FAILURE CODE [DBSRKR] 1823
FAILURE CODE [DDAAL6] 1824
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) 1826
FAILURE CODE [DDD7KX] 1828
FAILURE CODE [DDTHKA] 1830
FAILURE CODE [DDTJKA] 1832
FAILURE CODE [DDTKKA] 1834
FAILURE CODE [DDTLKA] 1836
FAILURE CODE [DDTMKA] 1838
FAILURE CODE [DDTNKA] 1840
FAILURE CODE [DDTPKA] 1842
FAILURE CODE [DF10KA] 1844
FAILURE CODE [DF10KB] 1848
FAILURE CODE [DGF1KX] 1853
FAILURE CODE [DGR2KB] 1855
FAILURE CODE [DGR6KB] 1857
FAILURE CODE [DGR6L8] 1858
FAILURE CODE [DGT1KX] 1860
FAILURE CODE [DHA4KA] 1862
FAILURE CODE [DHAAMA] 1864
FAILURE CODE [DHACMA] 1865
FAILURE CODE [DHP4KY] 1866
FAILURE CODE [DHP4KZ] 1868
FAILURE CODE [DHP5KY] 1870
FAILURE CODE [DHP5KZ] 1872
FAILURE CODE [DHP6KA] 1874
FAILURE CODE [DHP6KX] 1876
FAILURE CODE [DHP6KY] 1878
FAILURE CODE [DHP6KZ] 1880
FAILURE CODE [DHP7KA] 1882
FAILURE CODE [DHP7KX] 1884
FAILURE CODE [DHP7KY] 1886
FAILURE CODE [DHP7KZ] 1888
FAILURE CODE [DHQ4KX] 1890
FAILURE CODE [DHT5KX] 1892
FAILURE CODE [DHT5L6] 1894
FAILURE CODE [DHT8KX] 1896
FAILURE CODE [DHT8ZG] 1898
FAILURE CODE [DHU2KX] 1899
FAILURE CODE [DHU3KX] 1901
FAILURE CODE [DHUCKX] 1903
FAILURE CODE [DHUDKX] 1906
FAILURE CODE [DHUHKX] 1908
FAILURE CODE [DHULKX] 1910
FAILURE CODE [DHUMKX] 1912
FAILURE CODE [DHUPKX] 1914
FAILURE CODE [DJF1KA] 1916
FAILURE CODE [DK30KX] 1918
FAILURE CODE [DK51L5] 1920
FAILURE CODE [DK52KX] 1923
FAILURE CODE [DK53L8] 1925
FAILURE CODE [DK54KX] 1927
FAILURE CODE [DK60KX] 1929
FAILURE CODE [DKD0L6] 1931
FAILURE CODE [DKH0KX] 1933
FAILURE CODE [DKH1KX] 1936
FAILURE CODE [DLF1KA] 1938
FAILURE CODE [DLF1LC] 1939
FAILURE CODE [DLF2KA] 1941
FAILURE CODE [DLF2LC] 1942
FAILURE CODE [DLF8KA] 1944
FAILURE CODE [DLF8LC] 1946
FAILURE CODE [DLF9KA] 1948
FAILURE CODE [DLF9LC] 1950
FAILURE CODE [DLM3KA] 1952
FAILURE CODE [DLM3LC] 1953
FAILURE CODE [DLM3MB] 1955
FAILURE CODE [DLT3KA] 1956
FAILURE CODE [DLT3LC] 1957
FAILURE CODE [DPQ1KR] 1959
FAILURE CODE [DPQ2KR] 1962
FAILURE CODE [DPQ3KR] 1965
FAILURE CODE [DSJ0KR] 1969
FAILURE CODE [DV00KB] 1970
FAILURE CODE [DW2AKA] 1972
FAILURE CODE [DW2AKB] 1973
FAILURE CODE [DW2AKY] 1975
FAILURE CODE [DW2AL1] 1976
FAILURE CODE [DW2ALH] 1977
FAILURE CODE [DW35KZ] 1978
FAILURE CODE [DW36KZ] 1980
FAILURE CODE [DW4BK4] 1982
FAILURE CODE [DW4BMA] 1985
FAILURE CODE [DW72KZ] 1988
FAILURE CODE [DW73KA] 1990
FAILURE CODE [DW73KB] 1992
FAILURE CODE [DW73KY] 1994
FAILURE CODE [DW78KZ] 1995
FAILURE CODE [DW7BKB] 1997
FAILURE CODE [DW7BKY] 1998
FAILURE CODE [DW7BKZ] 1999
FAILURE CODE [DW7MKB] 2000
FAILURE CODE [DW7MKY] 2002
FAILURE CODE [DW7MKZ] 2003
FAILURE CODE [DW7NKZ] 2005
FAILURE CODE [DWNMKZ] 2007
FAILURE CODE [DX11K4] 2009
FAILURE CODE [DX11KA] 2011
FAILURE CODE [DX11KB] 2013
FAILURE CODE [DX11KY] 2015
FAILURE CODE [DX11MA] 2016
FAILURE CODE [DX13KA] 2018
FAILURE CODE [DX13KB] 2020
FAILURE CODE [DX13KY] 2022
FAILURE CODE [DX16KA] 2023
FAILURE CODE [DX16KB] 2024
FAILURE CODE [DX16KY] 2026
FAILURE CODE [DX37K4] 2027
FAILURE CODE [DX37KA] 2029
FAILURE CODE [DX37KB] 2031
FAILURE CODE [DX37KY] 2033
FAILURE CODE [DX37MA] 2034
FAILURE CODE [DX38K4] 2036
FAILURE CODE [DX38KA] 2038
FAILURE CODE [DX38KB] 2040
FAILURE CODE [DX38KY] 2042
FAILURE CODE [DX38MA] 2043
FAILURE CODE [DXH1KA] 2045
FAILURE CODE [DXH1KB] 2047
FAILURE CODE [DXH1KY] 2049
FAILURE CODE [DXH2KA] 2051
FAILURE CODE [DXH2KB] 2053
FAILURE CODE [DXH2KY] 2055
FAILURE CODE [DXH3KA] 2058
FAILURE CODE [DXH3KB] 2060
FAILURE CODE [DXH3KY] 2062
FAILURE CODE [DXH4KA] 2065
FAILURE CODE [DXH4KB] 2067
FAILURE CODE [DXH4KY] 2069
FAILURE CODE [DXH5KA] 2072
FAILURE CODE [DXH5KB] 2074
FAILURE CODE [DXH5KY] 2076
FAILURE CODE [DXH6KA] 2079
FAILURE CODE [DXH6KB] 2081
FAILURE CODE [DXH6KY] 2083
FAILURE CODE [DXH7KA] 2086
FAILURE CODE [DXH7KB] 2088
FAILURE CODE [DXH7KY] 2090
FAILURE CODE [DXHHKA] 2092
FAILURE CODE [DXHHKB] 2094
FAILURE CODE [DXHHKY] 2096
FAILURE CODE [DY30MA] 2098
FAILURE CODE [DY30MC] 2100
FAILURE CODE [DY30ME] 2103
FAILURE CODE [F313KA] 2105
FAILURE CODE [F313KB] 2107
FAILURE CODE [F318KB] 2108
FAILURE CODE [F318KY] 2109
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2110
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2110
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2117
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2120
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2122
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2123
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch) 2126
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2129
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2131
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2133
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2135
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2138
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2141
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2144
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2146
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2148
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2150
E-17 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2151
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2154
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2158
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2162
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2165
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2167
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2170
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2172
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2174
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2176
E-27 ALARM BUZZER DOES NOT SOUND 2177
E-28 ALARM BUZZER DOES NOT STOP SOUNDING 2179
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY 2181
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY 2183
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY 2185
E-32 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2187
E-33 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2190
E-34 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2194
E-35 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2197
E-36 TAIL LAMP DOES NOT LIGHT UP 2200
E-37 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2203
E-38 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2205
E-39 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2207
E-40 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2209
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with KOMTRAX terminal) 2211
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with gateway function controller) 2213
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2215
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2215
FAILURE MODE AND CAUSE TABLE 2216
H-1 MACHINE DOES NOT START 2224
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2228
H-3 LOCKUP IS NOT RELEASED 2229
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2230
H-5 GEAR IS NOT SHIFTED UP 2232
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2235
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2236
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2237
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2239
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2242
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 2243
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2244
H-13 STEERING WHEEL CANNOT BE OPERATED 2245
H-14 STEERING WHEEL WAGGLES 2246
H-15 FRONT BRAKE DOES NOT WORK ENOUGH 2247
H-16 REAR BRAKE DOES NOT WORK ENOUGH 2248
H-17 DUMP BODY RISING SPEED IS LOW 2249
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2251
H-19 DUMP BODY DOES NOT MOVE 2252
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2254
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN 2255
TROUBLESHOOTING OF ENGINE (S-MODE) 2256
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2256
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2257
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2258
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2259
S-4 ENGINE STARTABILITY IS POOR 2260
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2262
S-6 ENGINE STOPS DURING OPERATION 2264
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2266
S-8 ENGINE LACKS POWER 2267
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2269
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2271
S-11 OIL BECOMES CONTAMINATED QUICKLY 2272
S-12 FUEL CONSUMPTION IS EXCESSIVE 2273
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2274
S-14 OIL PRESSURE DROPS 2275
S-15 FUEL MIXES INTO ENGINE OIL 2276
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2277
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2278
S-18 UNUSUAL NOISE IS HEARD 2279
S-19 VIBRATION IS EXCESSIVE 2280
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2281
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2282
S-22 ACTIVE REGENERATION TAKES TIME 2284
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2285
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2286
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2288
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2289
50 DISASSEMBLY AND ASSEMBLY 2291
CONTENTS 2292
ABBREVIATIONS 2298
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION 2303
HOW TO READ THIS MANUAL 2303
COATING MATERIALS LIST 2305
SPECIAL TOOL LIST 2308
DIAGRAMS OF SPECIAL TOOLS 2324
ENGINE AND COOLING SYSTEM 2329
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2329
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY 2329
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY 2330
REMOVE AND INSTALL INJECTOR ASSEMBLY 2334
PROCEDURE TO REMOVE INJECTOR ASSEMBLY 2334
PROCEDURE TO INSTALL INJECTOR ASSEMBLY 2348
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2366
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY 2366
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY 2368
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2370
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY 2371
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY 2386
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2409
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY 2409
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY 2412
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2415
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY 2415
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY 2421
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2427
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY 2427
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY 2428
REMOVE AND INSTALL ALTERNATOR BELT 2429
PROCEDURE TO REMOVE ALTERNATOR BELT 2429
PROCEDURE TO INSTALL ALTERNATOR BELT 2430
REMOVE AND INSTALL RADIATOR 2433
PROCEDURE TO REMOVE RADIATOR 2434
PROCEDURE TO INSTALL RADIATOR 2438
REMOVE AND INSTALL COOLER ASSEMBLY 2442
PROCEDURE TO REMOVE COOLER ASSEMBLY 2442
PROCEDURE TO INSTALL COOLER ASSEMBLY 2453
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2465
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2465
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2469
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2474
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY 2474
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY 2475
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY 2477
PROCEDURE TO REMOVE GRILLE GUARD ASSEMBLY 2477
PROCEDURE TO INSTALL GRILLE GUARD ASSEMBLY 2481
REMOVE AND INSTALL ENGINE ASSEMBLY 2485
PROCEDURE TO REMOVE ENGINE ASSEMBLY 2486
PROCEDURE TO INSTALL ENGINE ASSEMBLY 2495
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2510
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL 2510
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL 2511
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2513
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL 2513
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL 2515
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY 2521
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY 2521
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY 2522
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY 2524
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY 2524
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY 2525
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2527
PROCEDURE TO REMOVE AdBlue/DEF TANK ASSEMBLY 2528
PROCEDURE TO INSTALL AdBlue/DEF TANK ASSEMBLY 2535
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2540
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2541
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2548
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2553
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR 2553
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR 2554
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2556
PROCEDURE TO REMOVE AdBlue/DEF TANK STRAINER 2556
PROCEDURE TO INSTALL AdBlue/DEF TANK STRAINER 2556
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2557
PROCEDURE TO REMOVE KDPF, SCR ASSEMBLY 2558
PROCEDURE TO INSTALL KDPF, SCR ASSEMBLY 2568
REMOVE AND INSTALL KDPF ASSEMBLY 2578
PROCEDURE TO REMOVE KDPF ASSEMBLY 2579
PROCEDURE TO INSTALL KDPF ASSEMBLY 2583
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2588
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY 2589
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY 2594
REMOVE AND INSTALL SCR ASSEMBLY 2599
PROCEDURE TO REMOVE SCR ASSEMBLY 2599
PROCEDURE TO INSTALL SCR ASSEMBLY 2602
REMOVE AND INSTALL KCCV ASSEMBLY 2607
PROCEDURE TO REMOVE KCCV ASSEMBLY 2607
PROCEDURE TO INSTALL KCCV ASSEMBLY 2611
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2615
PROCEDURE TO REMOVE AdBlue/DEF MIXING TUBE 2616
PROCEDURE TO INSTALL AdBlue/DEF MIXING TUBE 2624
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2635
PROCEDURE TO REMOVE AdBlue/DEF INJECTOR 2636
PROCEDURE TO INSTALL AdBlue/DEF INJECTOR 2642
REMOVE AND INSTALL AdBlue/DEF PUMP 2647
PROCEDURE TO REMOVE AdBlue/DEF PUMP 2647
PROCEDURE TO INSTALL AdBlue/DEF PUMP 2652
REMOVE AND INSTALL AdBlue/DEF HOSE 2656
PROCEDURE TO REMOVE AdBlue/DEF HOSE 2657
PROCEDURE TO INSTALL AdBlue/DEF HOSE 2668
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2679
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY 2679
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY 2681
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2684
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2684
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2685
POWER TRAIN 2686
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2686
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2687
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2699
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2714
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2714
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2726
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY 2740
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY 2741
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY 2747
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 2757
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY 2758
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY 2775
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 2796
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY 2796
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY 2798
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 2800
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY 2801
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY 2806
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD 2817
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD 2817
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD 2817
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY 2818
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY 2818
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY 2818
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2820
PROCEDURE TO DISASSEMBLE FRONT BRAKE CALIPER ASSEMBLY 2820
PROCEDURE TO ASSEMBLE FRONT BRAKE CALIPER ASSEMBLY 2821
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2823
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2823
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2824
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY 2826
PROCEDURE TO REMOVE PARKING BRAKE PAD ASSEMBLY 2826
PROCEDURE TO INSTALL PARKING BRAKE PAD ASSEMBLY 2827
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY 2829
PROCEDURE TO REMOVE PARKING BRAKE CALIPER ASSEMBLY 2829
PROCEDURE TO INSTALL PARKING BRAKE CALIPER ASSEMBLY 2829
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 2830
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2830
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2831
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY 2833
PROCEDURE TO DISASSEMBLE FINAL DRIVE ASSEMBLY 2833
PROCEDURE TO ASSEMBLE FINAL DRIVE ASSEMBLY 2837
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY 2842
PROCEDURE TO REMOVE SLACK ADJUSTER ASSEMBLY 2842
PROCEDURE TO INSTALL SLACK ADJUSTER ASSEMBLY 2843
STEERING SYSTEM 2845
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 2845
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY 2845
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY 2848
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 2851
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY 2851
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY 2853
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY 2856
PROCEDURE TO REMOVE SECONDARY STEERING MOTOR PUMP ASSEMBLY 2856
PROCEDURE TO INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY 2859
UNDERCARRIAGE AND FRAME 2862
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 2862
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY 2862
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY 2863
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 2865
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY 2865
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY 2867
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2869
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY 2869
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2870
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2873
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 2873
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 2875
REMOVE AND INSTALL KING PIN 2877
PROCEDURE TO REMOVE KING PIN 2877
PROCEDURE TO INSTALL KING PIN 2878
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2879
PROCEDURE TO DISASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2881
PROCEDURE TO ASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2881
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2883
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY 2883
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2883
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2884
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 2884
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 2886
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY 2889
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY 2889
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY 2890
HYDRAULIC SYSTEM 2894
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 2894
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY 2894
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY 2897
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 2901
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY 2902
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY 2905
WORK EQUIPMENT 2912
REMOVE AND INSTALL DUMP BODY ASSEMBLY 2912
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY 2912
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY 2913
CAB AND ITS ATTACHMENTS 2916
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 2916
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY 2916
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY 2924
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 2931
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY 2931
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY 2933
REMOVE AND INSTALL SEAT BELT 2936
PROCEDURE TO REMOVE SEAT BELT 2936
PROCEDURE TO INSTALL SEAT BELT 2937
ELECTRICAL SYSTEM 2938
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2938
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY 2938
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY 2939
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2942
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY 2942
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2943
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2944
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY 2944
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2945
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2946
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY 2946
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY 2948
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 2951
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY 2951
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY 2952
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2953
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 2953
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2954
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2956
PROCEDURE TO REMOVE SCR TEMPERATURE SENSOR 2956
PROCEDURE TO INSTALL SCR TEMPERATURE SENSOR 2958
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY 2960
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY 2960
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY 2961
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2962
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2962
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2966
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2970
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 2970
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 2978
REMOVE AND INSTALL COMMUNICATION TERMINAL 2985
METHOD FOR REMOVING COMMUNICATION TERMINAL 2985
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2993
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3000
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR 3000
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR 3001
60 MAINTENANCE STANDARD 3003
CONTENTS 3004
ABBREVIATIONS 3005
ENGINE AND COOLING SYSTEM 3010
MAINTENANCE STANDARD OF ENGINE MOUNT 3010
MAINTENANCE STANDARD OF OUTPUT SHAFT 3011
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP 3013
MAINTENANCE STANDARD OF SERVO VALVE OF COOLING FAN AND HOIST PUMP 3014
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3015
POWER TRAIN 3017
MAINTENANCE STANDARD OF DRIVE SHAFT 3017
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 3018
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3019
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE 3022
MAINTENANCE STANDARD OF TRANSMISSION 3023
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3028
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3029
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3030
MAINTENANCE STANDARD OF FRONT AXLE 3031
MAINTENANCE STANDARD OF REAR AXLE 3032
MAINTENANCE STANDARD OF DIFFERENTIAL 3033
MAINTENANCE STANDARD OF FINAL DRIVE 3034
STEERING SYSTEM 3035
MAINTENANCE STANDARD OF STEERING COLUMN 3035
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE 3036
MAINTENANCE STANDARD OF DEMAND VALVE 3039
MAINTENANCE STANDARD OF STEERING CYLINDER 3041
BRAKE SYSTEM 3042
MAINTENANCE STANDARD OF SLACK ADJUSTER 3042
MAINTENANCE STANDARD OF FRONT BRAKE 3043
MAINTENANCE STANDARD OF REAR BRAKE 3044
MAINTENANCE STANDARD OF PARKING BRAKE 3045
UNDERCARRIAGE AND FRAME 3047
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 3047
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 3049
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 3051
HYDRAULIC SYSTEM 3052
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP 3052
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP 3053
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 3055
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP 3057
MAINTENANCE STANDARD OF HOIST VALVE 3059
WORK EQUIPMENT 3061
MAINTENANCE STANDARD OF HOIST CYLINDER 3061
CAB AND ITS ATTACHMENTS 3062
MAINTENANCE STANDARD OF CAB MOUNT 3062
80 THE OTHER INFORMATION 3063
CONTENTS 3064
ABBREVIATIONS 3066
AIR CONDITIONER SYSTEM 3071
PRECAUTIONS FOR REFRIGERANT 3071
AIR CONDITIONER COMPONENT 3072
SPECIFICATIONS OF AIR CONDITIONER 3074
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3075
OUTLINE OF REFRIGERATION CYCLE 3076
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3078
AIR CONDITIONER UNIT 3078
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3078
FUNCTION OF AIR CONDITIONER UNIT 3079
COMPONENT PARTS OF AIR CONDITIONER UNIT 3081
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3081
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3082
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3082
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3082
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3083
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3083
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3083
FUNCTION OF DUAL PRESSURE SWITCH 3084
AIR CONDITIONER CONTROLLER 3085
STRUCTURE OF AIR CONDITIONER CONTROLLER 3085
COMPRESSOR 3086
STRUCTURE OF COMPRESSOR 3086
SPECIFICATIONS OF COMPRESSOR 3086
FUNCTION OF COMPRESSOR 3086
CONDENSER 3087
STRUCTURE OF CONDENSER 3087
SPECIFICATIONS OF CONDENSER 3087
FUNCTION OF CONDENSER 3087
SENSORS FOR AIR CONDITIONER SYSTEM 3089
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3089
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3089
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3090
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3092
AIR CONDITIONER SYSTEM DIAGRAM 3094
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3095
FUNCTION OF AIR CONDITIONER CONTROLLER 3096
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3097
TESTING AIR LEAKAGE (DUCT) 3100
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3100
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3103
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3105
TEST VENT (MODE) CHANGEOVER 3107
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3107
TESTING FRESH/RECIRC AIR CHANGEOVER 3108
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3108
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3109
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3109
TEST RELAYS 3110
METHOD FOR TESTING RELAYS 3110
AIR CONDITIONER TROUBLESHOOTING CHART 1 3111
AIR CONDITIONER TROUBLESHOOTING CHART 2 3112
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3115
FAILURE CODE [879AKA] 3116
FAILURE CODE [879AKB] 3117
FAILURE CODE [879BKA] 3118
FAILURE CODE [879BKB] 3119
FAILURE CODE [879CKA] 3120
FAILURE CODE [879CKB] 3121
FAILURE CODE [879EMC] 3122
FAILURE CODE [879FMC] 3123
FAILURE CODE [879GKX] 3124
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3125
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3127
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3130
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3132
TROUBLESHOOTING USING GAUGE PRESSURE 3134
CONNECTION OF SERVICE TOOL 3137
METHOD FOR CONNECTING SERVICE TOOL 3137
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3138
HANDLE COMPRESSOR OIL 3140
METHOD FOR REPLACING DESICCANT 3142
90 CIRCUIT DIAGRAMS 3145
CONTENTS 3146
ABBREVIATIONS 3147
HYDRAULIC CIRCUIT DIAGRAM 3152
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3152
HYDRAULIC CIRCUIT DIAGRAM 3157
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3159
ELECTRICAL CIRCUIT DIAGRAM 3161
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3161
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/9) 3165
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/9) 3167
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/9) 3169
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/9) 3171
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/9) 3173
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/9) 3175
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/9) 3177
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/9) 3179
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (9/9) 3181
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/10) 3183
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/10) 3185
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/10) 3187
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/10) 3189
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/10) 3191
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/10) 3193
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/10) 3195
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/10) 3197
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (9/10) 3199
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (10/10) 3201
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/8) 3203
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/8) 3205
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/8) 3207
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/8) 3209
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/8) 3211
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/8) 3213
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/8) 3215
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/8) 3217
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/8) 3219
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/8) 3221
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/8) 3223
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/8) 3225
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/8) 3227
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/8) 3229
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/8) 3231
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/8) 3233
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE 3235
INDEX 3237

Need help? Contact: [email protected]

https://vimeo.com/742911643

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

S.V