Komatsu HD325-8E0 HD405-8E0 Dump Truck Shop Manual SEN06745-06 – PDF DOWNLOAD

Description

Komatsu HD325-8E0 HD405-8E0 Dump Truck Shop Manual SEN06745-06 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HD325-8E0 HD405-8E0 Dump Truck Shop Manual SEN06745-06 – PDF DOWNLOAD

SERIAL NUMBERS

HD325-55001 and up
HD405-55001 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”.
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.

TABLE OF CONTENTS:

Komatsu HD325-8E0 HD405-8E0 Dump Truck Shop Manual SEN06745-06 – 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: HD325-8E0 98
SPECIFICATION DRAWING: HD405-8E0 100
SPECIFICATIONS 102
SPECIFICATIONS: HD325-8E0 102
SPECIFICATIONS: HD405-8E0 107
WEIGHT TABLE 112
WEIGHT TABLE: HD325-8E0 112
WEIGHT TABLE: HD405-8E0 113
FUEL, COOLANT, AND LUBRICATING OIL (EU SPECIFICATION) 114
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 114
10 STRUCTURE AND FUNCTION 117
CONTENTS 118
ABBREVIATIONS 123
UREA SCR SYSTEM 128
LAYOUT DRAWING OF UREA SCR STSTEM 128
UREA SCR SYSTEM DIAGRAM 131
FUNCTION OF UREA SCR SYSTEM 132
FUNCTION OF AdBlue/DEF SYSTEM 132
INDUCEMENT STRATEGY 134
COMPONENT PARTS OF UREA SCR SYSTEM 143
AdBlue/DEF MIXING TUBE 143
SCR ASSEMBLY 144
AdBlue/DEF TANK 146
AdBlue/DEF PUMP 148
AdBlue/DEF INJECTOR 149
AdBlue/DEF HOSE 150
AdBlue/DEF TANK HEATING VALVE 151
BOOT-UP SYSTEM 152
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with KOMTRAX terminal) 152
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with KOMTRAX terminal) 154
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with gateway function controller) 156
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with gateway function controller) 158
SYSTEM OPERATING LAMP SYSTEM 160
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 160
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with KOMTRAX terminal) 160
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with gateway function controller) 161
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with gateway function controller) 161
BATTERY DISCONNECT SWITCH 162
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with KOMTRAX terminal) 162
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with gateway function controller) 163
ENGINE SHUTDOWN SECONDARY SWITCH 164
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 164
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 164
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 168
ENGINE CONTROL SYSTEM 169
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 169
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with gateway function controller) 170
FUNCTION OF ENGINE CONTROL SYSTEM 171
OPERATION OF ENGINE CONTROL SYSTEM 172
AUTOMATIC IDLE STOP SYSTEM 174
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 174
COMPONENT PARTS OF ENGINE SYSTEM 176
OUTPUT SHAFT 176
VGT 177
EGR SYSTEM 181
EGR VALVE 183
EGR COOLER 185
KCCV SYSTEM 186
KCCV VENTILATOR 188
KDPF 190
COOLING SYSTEM 194
LAYOUT DRAWING OF COOLING SYSTEM 194
SPECIFICATIONS OF COOLING SYSTEM 195
RADIATOR FAN CONTROL SYSTEM 196
RADIATOR FAN CONTROL SYSTEM DIAGRAM 196
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 196
COMPONENT PARTS OF COOLING SYSTEM 198
COOLING FAN AND HOIST PUMP 198
COOLING FAN MOTOR 206
CONTROL SYSTEM 213
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with KOMTRAX terminal) 213
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with gateway function controller) 215
RETARDER AND HOIST CONTROL SYSTEM 217
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 217
MACHINE MONITOR SYSTEM 219
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 219
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with gateway function controller) 221
FUNCTION OF MACHINE MONITOR SYSTEM 222
REARVIEW MONITOR SYSTEM 223
REARVIEW MONITOR SYSTEM DIAGRAM 223
FUNCTION OF REARVIEW MONITOR SYSTEM 223
KOMTRAX SYSTEM 224
KOMTRAX SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 224
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with KOMTRAX terminal) 224
KOMTRAX SYSTEM DIAGRAM (For machines equipped with gateway function controller) 225
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with gateway function controller) 225
PAYLOAD METER SYSTEM 226
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 226
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 227
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with gateway function controller) 228
FUNCTION OF PAYLOAD METER SYSTEM 228
COMPONENT PARTS OF CONTROL SYSTEM 238
MACHINE MONITOR 238
SWITCH PANEL 255
REARVIEW MONITOR 256
REARVIEW CAMERA 257
KOMTRAX TERMINAL 258
GATEWAY FUNCTION CONTROLLER 260
INPUT AND OUTPUT SIGNALS OF GATEWAY FUNCTION CONTROLLER 260
COMMUNICATION TERMINAL 263
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR MOBILE COMMUNICATION 263
INPUT AND OUTPUT SIGNALS OF COMMUNICATIONTERMINAL FOR IRIDIUM COMMUNICATION 264
TRANSMISSION CONTROLLER 265
RETARDER AND HOIST CONTROLLER 269
MONITOR CONTROLLER 274
ENGINE CONTROLLER 279
PAYLOAD METER CONTROLLER 285
ACCELERATOR PEDAL 289
GEAR SHIFT LEVER 290
RETARDER CONTROL LEVER 291
HYDRAULIC SYSTEM 292
LAYOUT DRAWING OF HYDRAULIC SYSTEM 292
COMPONENT PARTS OF HYDRAULIC SYSTEM 293
HYDRAULIC TANK 293
STEERING AND HOIST PUMP 294
POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 304
BRAKE COOLING DUPLEX PUMP 305
HOIST VALVE 306
POWER TRAIN SYSTEM 312
LAYOUT DRAWING OF POWER TRAIN SYSTEM 312
TRANSMISSION CONTROL SYSTEM 315
TRANSMISSION CONTROL SYSTEM DIAGRAM 315
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 317
GEAR SHIFT CONTROL SYSTEM 321
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 321
SHIFTING METHOD IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT CONTROL SYSTEM 322
GEAR SHIFT DISABLED TIME CONTROL OF GEAR SHIFT CONTROL SYSTEM 323
DIRECTION CONTROL SYSTEM 324
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 324
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 324
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 325
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 325
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 325
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 326
TRAVEL SPEED LIMITATION SYSTEM 327
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 327
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 328
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 329
COMPONENT PARTS OF POWER TRAIN SYSTEM 331
DRIVE SHAFT 331
TORQUE CONVERTER AND PTO 333
LOCKUP CLUTCH ECMV 337
TRANSMISSION 340
TRANSMISSION CONTROL VALVE 361
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 363
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 368
MAIN RELIEF VALVE 370
TORQUE CONVERTER RELIEF VALVE 372
AXLE 373
DIFFERENTIAL 375
FINAL DRIVE 377
WORK EQUIPMENT SYSTEM 378
WORK EQUIPMENT CONTROL 378
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 378
FUNCTION OF WORK EQUIPMENT CONTROL 378
HOIST CONTROL 379
HOIST CONTROL SYSTEM DIAGRAM 379
FUNCTION OF HOIST CONTROL 379
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 381
HOIST AND COOLING FAN DIRECTION SELECTOR SOLENOID VALVE 381
DUMP LEVER 382
HOIST EPC VALVE 387
STEERING SYSTEM 388
LAYOUT DRAWING OF STEERING SYSTEM 388
FUNCTION OF STEERING SYSTEM 389
STEERING COLUMN 390
STRUCTURE OF STEERING COLUMN 390
STEERING CONTROL LINKAGE 391
STRUCTURE OF STEERING CONTROL LINKAGE 391
COMPONENT PARTS OF STEERING SYSTEM 392
DEMAND VALVE 392
ORBITROL VALVE 400
STEERING PUMP SELECTOR SOLENOID VALVE 406
CROSS-OVER RELIEF VALVE 407
SECONDARY STEERING PUMP 408
SECONDARY STEERING MOTOR 409
BRAKE SYSTEM 410
LAYOUT DRAWING OF BRAKE SYSTEM 410
RETARDER CONTROL 411
RETARDER CONTROL SYSTEM DIAGRAM 411
FUNCTION OF RETARDER CONTROL 411
ARSC SYSTEM 412
ARSC SYSTEM DIAGRAM 412
FUNCTION OF ARSC SYSTEM 412
COMPONENT PARTS OF BRAKE SYSTEM 413
BRAKE CONTROL PUMP 413
PARKING BRAKE SOLENOID VALVE 414
ACCUMULATOR CHARGE VALVE 415
BRAKE CIRCUIT ACCUMULATOR 419
BRAKE VALVE 420
SECONDARY BRAKE VALVE 424
SECONDARY BRAKE RELAY VALVE 425
FRONT BRAKE CUT SOLENOID VALVE 426
PROPORTIONAL PRESSURE REDUCING VALVE 427
SLACK ADJUSTER 428
BRAKE COOLING OIL CONTROL VALVE 430
BRAKE 431
STRUCTURE OF REAR BRAKE 432
PARKING BRAKE 434
BRAKE SUB-TANK 435
UNDERCARRIAGE AND FRAME 436
REAR AXLE SUPPORT 436
STRUCTURE OF REAR AXLE SUPPORT 436
SUSPENSION 437
STRUCTURE OF SUSPENSION 437
FUNCTION OF SUSPENSION 438
FRONT SUSPENSION 439
STRUCTURE OF FRONT SUSPENSION 439
FUNCTION OF FRONT SUSPENSION 440
REAR SUSPENSION 441
STRUCTURE OF REAR SUSPENSION 441
FUNCTION OF REAR SUSPENSION 442
SUSPENSION CYLINDER 443
STRUCTURE OF SUSPENSION CYLINDER 443
FUNCTION OF SUSPENSION CYLINDER 443
OPERATION OF SUSPENSION CYLINDER 443
WORK EQUIPMENT 444
STRUCTURE OF WORK EQUIPMENT 444
FUNCTION OF WORK EQUIPMENT 444
CAB AND ITS ATTACHMENTS 445
ROPS CAB 445
STRUCTURE OF ROPS CAB 445
FUNCTION OF ROPS CAB 445
CAB MOUNT 446
STRUCTURE OF CAB MOUNT 446
FUNCTION OF CAB MOUNT 446
20 STANDARD VALUE TABLE 447
CONTENTS 448
ABBREVIATIONS 449
STANDARD VALUE TABLE FOR ENGINE 454
STANDARD VALUE TABLE FOR ENGINE: HD325-8E0 454
STANDARD VALUE TABLE FOR ENGINE: HD405-8E0 457
STANDARD VALUE TABLE FOR MACHINE 460
STANDARD VALUE TABLE FOR MACHINE: HD325-8E0 460
STANDARD VALUE TABLE FOR MACHINE: HD405-8E0 474
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 488
30 TESTING AND ADJUSTING 489
CONTENTS 490
ABBREVIATIONS 494
RELATED INFORMATION TO TEST AND ADJUST 499
TOOLS TO TEST AND ADJUST 499
DIAGRAM FOR TEST AND ADJUST TOOLS 509
ENGINE AND COOLING SYSTEM 511
TEST ENGINE SPEED 511
PROCEDURE TO TEST ENGINE SPEED 511
TEST BOOST PRESSURE 513
PROCEDURE TO TEST BOOST PRESSURE WITH MACHINE MONITOR 513
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 515
TEST EXHAUST GAS TEMPERATURE 517
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 517
TEST EXHAUST GAS COLOR 520
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 520
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 521
TEST AND ADJUST VALVE CLEARANCE 523
PROCEDURE TO TEST VALVE CLEARANCE 523
PROCEDURE TO ADJUST VALVE CLEARANCE 524
TEST COMPRESSION PRESSURE 526
PROCEDURE TO TEST COMPRESSION PRESSURE 526
TEST BLOWBY PRESSURE 529
PROCEDURE TO TEST BLOWBY PRESSURE 529
TEST ENGINE OIL PRESSURE 532
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH MACHINE MONITOR 532
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH TEST TOOLS 532
TEST EGR VALVE AND VGT OIL PRESSURE 534
PROCEDURE TO TEST EGR VALVE AND VGT OIL PRESSURE 534
TEST FUEL PRESSURE 535
PROCEDURE TO TEST FUEL PRESSURE 535
TEST FUEL RETURN RATE AND LEAKAGE 537
PROCEDURE TO TEST FUEL RETURN RATE AND LEAKAGE 538
BLEED AIR FROM FUEL SYSTEM 542
PROCEDURE TO BLEED AIR FROM FUEL SYSTEM 542
TEST FUEL CIRCUIT LEAK 544
PROCEDURE TO TEST FUEL CIRCUIT LEAK 544
CYLINDER CUT-OUT MODE 546
NO-INJECTION CRANKING 547
CLEAN FUEL DOSER 548
PROCEDURE TO CLEAN FUEL DOSER 548
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 551
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 552
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER 558
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 558
TEST SCR RELATED FUNCTIONS 559
TEST AdBlue/DEF PUMP RAISED PRESSURE 562
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 565
TEST AdBlue/DEF LINE HEATER RELAY 1 570
TEST AdBlue/DEF LINE HEATER RELAY 2 574
TEST AdBlue/DEF PUMP HEATER RELAY 578
TEST AdBlue/DEF TANK HEATER VALVE 582
TEST DENITRATION EFFICIENCY OF SCR 586
CLEAN AdBlue/DEF TANK 589
PROCEDURE TO CLEAN AdBlue/DEF TANK 589
CLEAN AdBlue/DEF PUMP 595
PROCEDURE TO CLEAN AdBlue/DEF PUMP 595
TEST TORQUE CONVERTER STALL SPEED 601
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED 601
TEST RADIATOR FAN SPEED 603
PROCEDURE TO TEST RADIATOR FAN SPEED 603
POWER TRAIN 605
TEST POWER TRAIN OIL PRESSURE 605
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 608
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 619
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 619
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 620
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 620
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 621
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 621
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 622
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 622
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 623
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 623
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 623
STEERING SYSTEM 628
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 628
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 628
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 628
PROCEDURE TO ADJUST STEERING CIRCUIT OIL PRESSURE 630
TEST SUPPLY PRESSURE OF ORBITROL VALVE 631
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 631
TEST STEERING CYLINDER PRESSURE 633
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 633
BLEED AIR FROM STEERING CYLINDER CIRCUIT 635
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 635
BRAKE SYSTEM 636
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 636
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 636
TEST WHEEL BRAKE OIL PRESSURE 637
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE 637
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE 638
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE 639
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE (FOR MACHINE WITH KTCS) 639
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 641
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 641
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 642
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 643
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 644
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 645
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 649
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 653
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 659
TEST BRAKE PERFORMANCE 660
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 660
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 661
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 662
BLEED AIR FROM BRAKE CIRCUIT 663
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 663
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITHOUT KTCS) 663
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 664
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 666
TEST PARKING BRAKE OIL PRESSURE 667
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 667
RELEASE PARKING BRAKE MANUALLY 669
PROCEDURE TO RELEASE PARKING BRAKE MANUALLY 669
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 670
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 670
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE PAD WEAR WITH GUAGE MEASURE 670
TEST THE AMOUNT OF REAR BRAKE DISC WEAR 671
PROCEDURE TO VISUALLY TEST THE AMOUNT OF REAR BRAKE DISC WEAR 671
TEST AND ADJUST PARKING BRAKE PAD 672
PROCEDURE TO TEST PARKING BRAKE PAD CLEARANCE 672
PROCEDURE TO ADJUST PARKING BRAKE PAD CLEARANCE 673
HYDRAULIC SYSTEM 674
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 674
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 674
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 675
TEST HOIST CYLINDER SUPPLY PRESSURE 676
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 676
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 678
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 678
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 679
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 680
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 680
TEST AND ADJUST FRONT SUSPENSION CYLINDER 682
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 682
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 683
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 688
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 688
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 689
TEST AND ADJUST REAR SUSPENSION CYLINDER 690
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 690
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 691
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 696
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 696
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH TEST TOOLS 696
WORK EQUIPMENT 698
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 698
PROCEDURE TO TEST BODY POSITIONER SENSOR 698
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 698
PROCEDURE TO CALIBRATE AFTER YOU ADJUST BODY POSITION SENSOR 698
LOWER THE BODY MANUALLY 700
PROCEDURE TO LOWER THE BODY MANUALLY 700
LIFT THE BODY MANUALLY 701
PROCEDURE TO LIFT THE BODY MANUALLY 701
CAB AND ITS ATTACHMENTS 702
ADJUST STEERING WHEEL TILT LOCK LEVER 702
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 702
ADJUST RATTLING OPERATOR’S SEAT 703
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 703
ELECTRICAL SYSTEM 704
SET AND ADJUST EACH EQUIPMENT 704
SET AND OPERATE OF MACHINE MONITOR 707
OPERATOR MODE 711
SERVICE MODE 724
ABNORMALITY RECORD MENU 751
DEFAULT MENU 766
DIAGNOSTIC TESTS MENU 780
ADJUSTMENT MENU 792
PROCEDURE TO PERFORM NO-INJECTION CRANKING 813
PAYLOAD METER SETTING 815
KOMTRAX SETTINGS MENU 837
PROCEDURE TO DISPLAY SERVICE MESSAGE 842
PROCEDURE TO START UP KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 844
PROCEDURE TO FINISH KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 848
PROCEDURE TO START UP KOMTRAX SYSTEM (For machines equipped with gateway function controller) 850
PROCEDURE TO FINISH KOMTRAX SYSTEM (For machines equipped with gateway function controller) 854
ADJUST REARVIEW CAMERA ANGLE 856
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 856
ADJUST OPTICAL AXIS OF HEAD LAMP 857
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 857
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 860
BATTERY DISCONNECT SWITCH WORK (For machines equipped with KOMTRAX terminal) 861
BATTERY DISCONNECT SWITCH WORK (For machines equipped with gateway function controller) 862
TEST DIODES 863
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 863
PROCEDURE TO TEST DIODE USING ANALOG TESTER 863
Pm CLINIC 864
Pm CLINIC SERVICE 864
Pm CLINIC CHECK SHEET: HD325-8E0 867
Pm CLINIC CHECK SHEET: HD405-8E0 874
40 TROUBLESHOOTING 881
CONTENTS 882
ABBREVIATIONS 896
RELATED INFORMATION ON TROUBLESHOOTING 901
GENERAL TROUBLESHOOTING POINTS 901
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 902
SEQUENCE OF EVENTS IN TROUBLESHOOTING 914
CHECKS BEFORE TROUBLESHOOTING 916
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 919
WALK-AROUND CHECK 919
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 921
CHECK FUEL LEVEL AND TYPE 921
CHECK IMPURE INGREDIENT IN FUEL 921
CHECK AdBlue/DEF LEVEL AND TYPE 921
CHECK FUEL PREFILTER 922
CHECK MAIN FILTER 924
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 926
CHECK COOLANT LEVEL (RESERVOIR TANK) 927
CHECK CLOGGING OF AIR CLEANER 928
CHECK OF AIR CLEANER 929
OUTER ELEMENT – CLEAN 929
REPLACE ELEMENT 931
CHECK HYDRAULIC OIL LEVEL 933
CHECK HYDRAULIC OIL STRAINER 933
CHECK HYDRAULIC FILTER 934
CHECK OIL LEVEL IN TRANSMISSION CASE 934
CHECK OIL LEVEL IN DIFFERENTIAL CASE 935
CHECK OIL LEVEL IN FINAL DRIVE CASE 935
BLEED AIR FROM FUEL SYSTEM 936
BLEED AIR FROM HYDRAULIC SYSTEM 936
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 936
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 942
PROCEDURE FOR TESTING AND TROUBLESHOOTING 952
SYMPTOM AND TROUBLESHOOTING NUMBERS 954
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 959
CONNECTORS LIST AND LAYOUT 962
CONNECTOR CONTACT IDENTIFICATION 988
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1028
FUSE LOCATION TABLE (For machines equipped with KOMTRAX terminal) 1034
FUSE LOCATION TABLE (For machines equipped with gateway function controller) 1040
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1046
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1049
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1051
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135]) 1057
FAILURE CODES TABLE 1059
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1085
FAILURE CODE [1500L0] 1085
FAILURE CODE [15B0NX] 1086
FAILURE CODE [15F0KM] 1088
FAILURE CODE [15F0MB] 1089
FAILURE CODE [15F7KM] 1090
FAILURE CODE [15G0MW] 1091
FAILURE CODE [15G7KM] 1092
FAILURE CODE [15H0MW] 1093
FAILURE CODE [15J0MW] 1094
FAILURE CODE [15K0MW] 1095
FAILURE CODE [15L0MW] 1097
FAILURE CODE [15M0MW] 1099
FAILURE CODE [15N0MW] 1101
FAILURE CODE [15SBL1] 1102
FAILURE CODE [15SBMA] 1105
FAILURE CODE [15SCL1] 1106
FAILURE CODE [15SCMA] 1109
FAILURE CODE [15SDL1] 1110
FAILURE CODE [15SDMA] 1113
FAILURE CODE [15SEL1] 1114
FAILURE CODE [15SEMA] 1117
FAILURE CODE [15SFL1] 1118
FAILURE CODE [15SFMA] 1121
FAILURE CODE [15SGL1] 1122
FAILURE CODE [15SGMA] 1125
FAILURE CODE [15SHL1] 1126
FAILURE CODE [15SHMA] 1129
FAILURE CODE [15SJMA] 1130
FAILURE CODE [2C4MNX] 1131
FAILURE CODE [2F00KM] 1132
FAILURE CODE [2G42ZG] 1135
FAILURE CODE [2G43ZG] 1136
FAILURE CODE [6014NX] 1137
FAILURE CODE [879AKA] 1138
FAILURE CODE [879AKB] 1139
FAILURE CODE [879BKA] 1140
FAILURE CODE [879BKB] 1141
FAILURE CODE [879CKA] 1142
FAILURE CODE [879CKB] 1143
FAILURE CODE [879EMC] 1144
FAILURE CODE [879FMC] 1145
FAILURE CODE [879GKX] 1146
FAILURE CODE [989D00] 1147
FAILURE CODE [989L00] 1148
FAILURE CODE [989M00] 1149
FAILURE CODE [989N00] 1150
FAILURE CODE [989X00] 1151
FAILURE CODE [A1U0N3] 1152
FAILURE CODE [A1U0N4] 1153
FAILURE CODE [AA10NX] 1154
FAILURE CODE [AB00KE] 1156
FAILURE CODE [AB00KY] 1158
FAILURE CODE [AQ10N3] 1159
FAILURE CODE [AS00N3] 1160
FAILURE CODE [AS00R2] 1161
FAILURE CODE [AS00R3] 1162
FAILURE CODE [AS00R4] 1163
FAILURE CODE [AS00R5] 1164
FAILURE CODE [AS00R6] 1165
FAILURE CODE [AS00ZK] 1166
FAILURE CODE [AS10KM] 1167
FAILURE CODE [AS10NR] 1168
FAILURE CODE [AS10NT] 1169
FAILURE CODE [B@BAZG] 1170
FAILURE CODE [B@BAZK] 1171
FAILURE CODE [B@BCNS] 1172
FAILURE CODE [B@BCQA] 1173
FAILURE CODE [B@BCZK] 1175
FAILURE CODE [B@C7NS] 1177
FAILURE CODE [B@CENS] 1179
FAILURE CODE [B@JANS] 1180
FAILURE CODE [CA115] 1181
FAILURE CODE [CA122] 1182
FAILURE CODE [CA123] 1184
FAILURE CODE [CA131] 1186
FAILURE CODE [CA132] 1188
FAILURE CODE [CA135] 1190
FAILURE CODE [CA141] 1192
FAILURE CODE [CA144] 1194
FAILURE CODE [CA145] 1196
FAILURE CODE [CA153] 1198
FAILURE CODE [CA154] 1200
FAILURE CODE [CA187] 1202
FAILURE CODE [CA221] 1204
FAILURE CODE [CA222] 1206
FAILURE CODE [CA227] 1208
FAILURE CODE [CA234] 1209
FAILURE CODE [CA238] 1210
FAILURE CODE [CA239] 1212
FAILURE CODE [CA249] 1214
FAILURE CODE [CA256] 1216
FAILURE CODE [CA271] 1218
FAILURE CODE [CA272] 1220
FAILURE CODE [CA273] 1221
FAILURE CODE [CA274] 1223
FAILURE CODE [CA322] 1224
FAILURE CODE [CA323] 1226
FAILURE CODE [CA324] 1228
FAILURE CODE [CA325] 1230
FAILURE CODE [CA331] 1232
FAILURE CODE [CA332] 1234
FAILURE CODE [CA343] 1236
FAILURE CODE [CA351] 1237
FAILURE CODE [CA352] 1238
FAILURE CODE [CA356] 1240
FAILURE CODE [CA357] 1242
FAILURE CODE [CA386] 1244
FAILURE CODE [CA431] 1245
FAILURE CODE [CA432] 1248
FAILURE CODE [CA441] 1251
FAILURE CODE [CA442] 1254
FAILURE CODE [CA449] 1255
FAILURE CODE [CA451] 1256
FAILURE CODE [CA452] 1258
FAILURE CODE [CA515] 1260
FAILURE CODE [CA516] 1262
FAILURE CODE [CA553] 1264
FAILURE CODE [CA555] 1265
FAILURE CODE [CA556] 1266
FAILURE CODE [CA559] 1267
FAILURE CODE [CA595] 1271
FAILURE CODE [CA687] 1272
FAILURE CODE [CA689] 1274
FAILURE CODE [CA691] 1276
FAILURE CODE [CA692] 1278
FAILURE CODE [CA697] 1280
FAILURE CODE [CA698] 1281
FAILURE CODE [CA731] 1282
FAILURE CODE [CA778] 1283
FAILURE CODE [CA1117] 1286
FAILURE CODE [CA1664] 1288
FAILURE CODE [CA1669] 1290
FAILURE CODE [CA1673] 1291
FAILURE CODE [CA1677] 1292
FAILURE CODE [CA1678] 1293
FAILURE CODE [CA1682] 1294
FAILURE CODE [CA1683] 1298
FAILURE CODE [CA1684] 1300
FAILURE CODE [CA1686] 1302
FAILURE CODE [CA1691] 1303
FAILURE CODE [CA1694] 1305
FAILURE CODE [CA1695] 1307
FAILURE CODE [CA1696] 1308
FAILURE CODE [CA1712] 1310
FAILURE CODE [CA1713] 1312
FAILURE CODE [CA1714] 1314
FAILURE CODE [CA1715] 1315
FAILURE CODE [CA1776] 1316
FAILURE CODE [CA1777] 1319
FAILURE CODE [CA1843] 1322
FAILURE CODE [CA1844] 1324
FAILURE CODE [CA1879] 1326
FAILURE CODE [CA1881] 1328
FAILURE CODE [CA1883] 1330
FAILURE CODE [CA1885] 1333
FAILURE CODE [CA1887] 1335
FAILURE CODE [CA1921] 1337
FAILURE CODE [CA1922] 1339
FAILURE CODE [CA1923] 1342
FAILURE CODE [CA1924] 1344
FAILURE CODE [CA1925] 1346
FAILURE CODE [CA1927] 1348
FAILURE CODE [CA1928] 1350
FAILURE CODE [CA1942] 1352
FAILURE CODE [CA1963] 1353
FAILURE CODE [CA1977] 1357
FAILURE CODE [CA1993] 1359
FAILURE CODE [CA2185] 1361
FAILURE CODE [CA2186] 1363
FAILURE CODE [CA2249] 1365
FAILURE CODE [CA2265] 1366
FAILURE CODE [CA2266] 1368
FAILURE CODE [CA2271] 1370
FAILURE CODE [CA2272] 1372
FAILURE CODE [CA2349] 1374
FAILURE CODE [CA2353] 1376
FAILURE CODE [CA2357] 1378
FAILURE CODE [CA2381] 1379
FAILURE CODE [CA2382] 1381
FAILURE CODE [CA2383] 1383
FAILURE CODE [CA2386] 1385
FAILURE CODE [CA2387] 1387
FAILURE CODE [CA2555] 1388
FAILURE CODE [CA2556] 1390
FAILURE CODE [CA2637] 1392
FAILURE CODE [CA2639] 1394
FAILURE CODE [CA2732] 1396
FAILURE CODE [CA2733] 1398
FAILURE CODE [CA2741] 1400
FAILURE CODE [CA2765] 1401
FAILURE CODE [CA2771] 1402
FAILURE CODE [CA2777] 1407
FAILURE CODE [CA2878] 1408
FAILURE CODE [CA2881] 1411
FAILURE CODE [CA2976] 1415
FAILURE CODE [CA3133] 1417
FAILURE CODE [CA3134] 1419
FAILURE CODE [CA3135] 1421
FAILURE CODE [CA3142] 1424
FAILURE CODE [CA3143] 1425
FAILURE CODE [CA3144] 1426
FAILURE CODE [CA3146] 1428
FAILURE CODE [CA3147] 1429
FAILURE CODE [CA3148] 1430
FAILURE CODE [CA3151] 1432
FAILURE CODE [CA3165] 1437
FAILURE CODE [CA3167] 1439
FAILURE CODE [CA3229] 1442
FAILURE CODE [CA3231] 1444
FAILURE CODE [CA3232] 1446
FAILURE CODE [CA3235] 1450
FAILURE CODE [CA3239] 1452
FAILURE CODE [CA3241] 1455
FAILURE CODE [CA3242] 1458
FAILURE CODE [CA3251] 1460
FAILURE CODE [CA3253] 1462
FAILURE CODE [CA3254] 1465
FAILURE CODE [CA3255] 1467
FAILURE CODE [CA3256] 1469
FAILURE CODE [CA3311] 1471
FAILURE CODE [CA3312] 1473
FAILURE CODE [CA3313] 1475
FAILURE CODE [CA3314] 1476
FAILURE CODE [CA3315] 1477
FAILURE CODE [CA3316] 1480
FAILURE CODE [CA3317] 1481
FAILURE CODE [CA3318] 1482
FAILURE CODE [CA3319] 1485
FAILURE CODE [CA3321] 1486
FAILURE CODE [CA3322] 1487
FAILURE CODE [CA3419] 1490
FAILURE CODE [CA3421] 1492
FAILURE CODE [CA3497] 1494
FAILURE CODE [CA3498] 1495
FAILURE CODE [CA3543] 1496
FAILURE CODE [CA3545] 1501
FAILURE CODE [CA3547] 1503
FAILURE CODE [CA3558] 1504
FAILURE CODE [CA3559] 1506
FAILURE CODE [CA3562] 1508
FAILURE CODE [CA3563] 1510
FAILURE CODE [CA3567] 1513
FAILURE CODE [CA3568] 1515
FAILURE CODE [CA3571] 1519
FAILURE CODE [CA3572] 1521
FAILURE CODE [CA3574] 1523
FAILURE CODE [CA3575] 1525
FAILURE CODE [CA3577] 1527
FAILURE CODE [CA3578] 1529
FAILURE CODE [CA3582] 1531
FAILURE CODE [CA3583] 1537
FAILURE CODE [CA3596] 1539
FAILURE CODE [CA3649] 1543
FAILURE CODE [CA3681] 1545
FAILURE CODE [CA3682] 1549
FAILURE CODE [CA3713] 1553
FAILURE CODE [CA3717] 1556
FAILURE CODE [CA3718] 1557
FAILURE CODE [CA3725] 1558
FAILURE CODE [CA3748] 1561
FAILURE CODE [CA3751] 1563
FAILURE CODE [CA3755] 1564
FAILURE CODE [CA3866] 1566
FAILURE CODE [CA3867] 1569
FAILURE CODE [CA3868] 1572
FAILURE CODE [CA3899] 1576
FAILURE CODE [CA3911] 1578
FAILURE CODE [CA3912] 1582
FAILURE CODE [CA3932] 1584
FAILURE CODE [CA3933] 1586
FAILURE CODE [CA3934] 1588
FAILURE CODE [CA3935] 1591
FAILURE CODE [CA3936] 1593
FAILURE CODE [CA4151] 1595
FAILURE CODE [CA4152] 1599
FAILURE CODE [CA4155] 1603
FAILURE CODE [CA4156] 1605
FAILURE CODE [CA4157] 1607
FAILURE CODE [CA4158] 1609
FAILURE CODE [CA4159] 1611
FAILURE CODE [CA4161] 1612
FAILURE CODE [CA4162] 1614
FAILURE CODE [CA4163] 1616
FAILURE CODE [CA4164] 1618
FAILURE CODE [CA4165] 1620
FAILURE CODE [CA4166] 1622
FAILURE CODE [CA4168] 1623
FAILURE CODE [CA4169] 1628
FAILURE CODE [CA4171] 1631
FAILURE CODE [CA4249] 1634
FAILURE CODE [CA4251] 1637
FAILURE CODE [CA4259] 1640
FAILURE CODE [CA4261] 1643
FAILURE CODE [CA4277] 1645
FAILURE CODE [CA4281] 1647
FAILURE CODE [CA4459] 1650
FAILURE CODE [CA4461] 1652
FAILURE CODE [CA4658] 1655
FAILURE CODE [CA4731] 1658
FAILURE CODE [CA4732] 1659
FAILURE CODE [CA4739] 1660
FAILURE CODE [CA4768] 1661
FAILURE CODE [CA4769] 1663
FAILURE CODE [CA4842] 1665
FAILURE CODE [CA4952] (For machines equipped with KOMTRAX terminal) 1668
FAILURE CODE [CA4952] (For machines equipped with gateway function controller) 1670
FAILURE CODE [CA5115] 1672
FAILURE CODE [CA5179] 1675
FAILURE CODE [CA5181] 1677
FAILURE CODE [CA5383] 1679
FAILURE CODE [D150KB] 1680
FAILURE CODE [D150KZ] 1681
FAILURE CODE [D164KY] 1682
FAILURE CODE [D19HKZ] 1683
FAILURE CODE [D19JKZ] 1685
FAILURE CODE [D19QKZ] 1686
FAILURE CODE [D1EHKA] 1688
FAILURE CODE [D1EHKB] 1689
FAILURE CODE [D1EHKY] 1690
FAILURE CODE [D1EMKA] 1691
FAILURE CODE [D1EMKB] 1692
FAILURE CODE [D1EMKY] 1693
FAILURE CODE [D1FBKB] 1694
FAILURE CODE [D5ZHL6] 1695
FAILURE CODE [D5ZKKZ] 1697
FAILURE CODE [D811MC] (For machines equipped with KOMTRAX terminal) 1699
FAILURE CODE [D811MC] (For machines equipped with gateway function controller) 1700
FAILURE CODE [D862KA] (For machines equipped with KOMTRAX terminal) 1701
FAILURE CODE [D862KA] (For machines equipped with gateway function controller) 1702
FAILURE CODE [D8ALKA] (For machines equipped with KOMTRAX terminal) 1703
FAILURE CODE [D8ALKA] (For machines equipped with gateway function controller) 1705
FAILURE CODE [D8ALKB] (For machines equipped with KOMTRAX terminal) 1707
FAILURE CODE [D8ALKB] (For machines equipped with gateway function controller) 1709
FAILURE CODE [D8AQK4] (For machines equipped with KOMTRAX terminal) 1711
FAILURE CODE [D8AQK4] (For machines equipped with gateway function controller) 1712
FAILURE CODE [D8AQKR] (For machines equipped with KOMTRAX terminal) 1713
FAILURE CODE [D8AQKR] (For machines equipped with gateway function controller) 1714
FAILURE CODE [D8G1KT] 1715
FAILURE CODE [D8G6KT] 1716
FAILURE CODE [DAF0KT] 1717
FAILURE CODE [DAF0MB] 1718
FAILURE CODE [DAF0MC] 1719
FAILURE CODE [DAF3KK] 1720
FAILURE CODE [DAF8KB] 1722
FAILURE CODE [DAFDKB] 1723
FAILURE CODE [DAFGMC] (For machines equipped with KOMTRAX terminal) 1725
FAILURE CODE [DAFGMC] (For machines equipped with gateway function controller) 1726
FAILURE CODE [DAFLKA] (For machines equipped with KOMTRAX terminal) 1727
FAILURE CODE [DAFLKA] (For machines equipped with gateway function controller) 1729
FAILURE CODE [DAFLKB] (For machines equipped with KOMTRAX terminal) 1731
FAILURE CODE [DAFLKB] (For machines equipped with gateway function controller) 1733
FAILURE CODE [DAFQKR] (For machines equipped with KOMTRAX terminal) 1735
FAILURE CODE [DAFQKR] (For machines equipped with gateway function controller) 1736
FAILURE CODE [DAQ0KK] 1737
FAILURE CODE [DAQ0KT] 1740
FAILURE CODE [DAQ0MC] 1741
FAILURE CODE [DAQ1KA] 1742
FAILURE CODE [DAQ2KK] 1745
FAILURE CODE [DAQ9KQ] 1748
FAILURE CODE [DAQLKA] (For machines equipped with KOMTRAX terminal) 1749
FAILURE CODE [DAQLKA] (For machines equipped with gateway function controller) 1751
FAILURE CODE [DAQLKB] (For machines equipped with KOMTRAX terminal) 1753
FAILURE CODE [DAQLKB] (For machines equipped with gateway function controller) 1755
FAILURE CODE [DAQQKR] 1757
FAILURE CODE [DAQRKR] 1758
FAILURE CODE [DAQRMA] 1759
FAILURE CODE [DAQV00] 1760
FAILURE CODE [DAQW00] 1761
FAILURE CODE [DAZ9KQ] 1762
FAILURE CODE [DAZQKR] 1763
FAILURE CODE [DB10KT] 1764
FAILURE CODE [DB10MC] 1765
FAILURE CODE [DB11KA] 1766
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) 1769
FAILURE CODE [DB12KK] 1772
FAILURE CODE [DB13KK] 1775
FAILURE CODE [DB19KQ] 1778
FAILURE CODE [DB1LKA] (For machines equipped with KOMTRAX terminal) 1779
FAILURE CODE [DB1LKA] (For machines equipped with gateway function controller) 1781
FAILURE CODE [DB1LKB] (For machines equipped with KOMTRAX terminal) 1783
FAILURE CODE [DB1LKB] (For machines equipped with gateway function controller) 1785
FAILURE CODE [DB1QKR] 1787
FAILURE CODE [DB1QMA] 1788
FAILURE CODE [DB1RKR] 1789
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal) 1790
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller) 1796
FAILURE CODE [DB2RKR] 1802
FAILURE CODE [DBS0KK] 1807
FAILURE CODE [DBS6KP] 1810
FAILURE CODE [DBSQKQ] 1812
FAILURE CODE [DBSQKR] 1813
FAILURE CODE [DBSRKR] 1814
FAILURE CODE [DDAAL6] 1815
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) 1817
FAILURE CODE [DDD7KX] 1819
FAILURE CODE [DDTHKA] 1821
FAILURE CODE [DDTJKA] 1823
FAILURE CODE [DDTKKA] 1825
FAILURE CODE [DDTLKA] 1827
FAILURE CODE [DDTMKA] 1829
FAILURE CODE [DDTNKA] 1831
FAILURE CODE [DDTPKA] 1833
FAILURE CODE [DF10KA] 1835
FAILURE CODE [DF10KB] 1839
FAILURE CODE [DGF1KX] 1844
FAILURE CODE [DGR2KB] 1846
FAILURE CODE [DGR6KB] 1848
FAILURE CODE [DGR6L8] 1849
FAILURE CODE [DGT1KX] 1851
FAILURE CODE [DHA4KA] 1853
FAILURE CODE [DHAAMA] 1855
FAILURE CODE [DHACMA] 1856
FAILURE CODE [DHP4KY] 1857
FAILURE CODE [DHP4KZ] 1859
FAILURE CODE [DHP5KY] 1861
FAILURE CODE [DHP5KZ] 1863
FAILURE CODE [DHP6KA] 1865
FAILURE CODE [DHP6KX] 1867
FAILURE CODE [DHP6KY] 1869
FAILURE CODE [DHP6KZ] 1871
FAILURE CODE [DHP7KA] 1873
FAILURE CODE [DHP7KX] 1875
FAILURE CODE [DHP7KY] 1877
FAILURE CODE [DHP7KZ] 1879
FAILURE CODE [DHQ4KX] 1881
FAILURE CODE [DHT5KX] 1883
FAILURE CODE [DHT5L6] 1885
FAILURE CODE [DHT8KX] 1887
FAILURE CODE [DHT8ZG] 1889
FAILURE CODE [DHU2KX] 1890
FAILURE CODE [DHU3KX] 1892
FAILURE CODE [DHUCKX] 1894
FAILURE CODE [DHUDKX] 1897
FAILURE CODE [DHUHKX] 1899
FAILURE CODE [DHULKX] 1901
FAILURE CODE [DHUMKX] 1903
FAILURE CODE [DHUPKX] 1905
FAILURE CODE [DJF1KA] 1907
FAILURE CODE [DK30KX] 1909
FAILURE CODE [DK51L5] 1911
FAILURE CODE [DK52KX] 1914
FAILURE CODE [DK53L8] 1916
FAILURE CODE [DK54KX] 1918
FAILURE CODE [DK60KX] 1920
FAILURE CODE [DKD0L6] 1922
FAILURE CODE [DKH0KX] 1924
FAILURE CODE [DKH1KX] 1927
FAILURE CODE [DLF1KA] 1929
FAILURE CODE [DLF1LC] 1930
FAILURE CODE [DLF2KA] 1932
FAILURE CODE [DLF2LC] 1933
FAILURE CODE [DLF8KA] 1935
FAILURE CODE [DLF8LC] 1937
FAILURE CODE [DLF9KA] 1939
FAILURE CODE [DLF9LC] 1941
FAILURE CODE [DLM3KA] 1943
FAILURE CODE [DLM3LC] 1944
FAILURE CODE [DLM3MB] 1946
FAILURE CODE [DLT3KA] 1947
FAILURE CODE [DLT3LC] 1948
FAILURE CODE [DPQ1KR] 1950
FAILURE CODE [DPQ2KR] 1953
FAILURE CODE [DPQ3KR] 1956
FAILURE CODE [DSJ0KR] 1960
FAILURE CODE [DV00KB] 1961
FAILURE CODE [DW2AKA] 1963
FAILURE CODE [DW2AKB] 1964
FAILURE CODE [DW2AKY] 1966
FAILURE CODE [DW2AL1] 1967
FAILURE CODE [DW2ALH] 1968
FAILURE CODE [DW35KZ] 1969
FAILURE CODE [DW36KZ] 1971
FAILURE CODE [DW4BK4] 1973
FAILURE CODE [DW4BMA] 1976
FAILURE CODE [DW72KZ] 1979
FAILURE CODE [DW73KA] 1981
FAILURE CODE [DW73KB] 1983
FAILURE CODE [DW73KY] 1985
FAILURE CODE [DW78KZ] 1986
FAILURE CODE [DW7BKB] 1988
FAILURE CODE [DW7BKY] 1989
FAILURE CODE [DW7BKZ] 1990
FAILURE CODE [DW7MKB] 1991
FAILURE CODE [DW7MKY] 1993
FAILURE CODE [DW7MKZ] 1994
FAILURE CODE [DW7NKZ] 1996
FAILURE CODE [DWNMKZ] 1998
FAILURE CODE [DX11K4] 2000
FAILURE CODE [DX11KA] 2002
FAILURE CODE [DX11KB] 2004
FAILURE CODE [DX11KY] 2006
FAILURE CODE [DX11MA] 2007
FAILURE CODE [DX13KA] 2009
FAILURE CODE [DX13KB] 2011
FAILURE CODE [DX13KY] 2013
FAILURE CODE [DX16KA] 2014
FAILURE CODE [DX16KB] 2015
FAILURE CODE [DX16KY] 2017
FAILURE CODE [DX37K4] 2018
FAILURE CODE [DX37KA] 2020
FAILURE CODE [DX37KB] 2022
FAILURE CODE [DX37KY] 2024
FAILURE CODE [DX37MA] 2025
FAILURE CODE [DX38K4] 2027
FAILURE CODE [DX38KA] 2029
FAILURE CODE [DX38KB] 2031
FAILURE CODE [DX38KY] 2033
FAILURE CODE [DX38MA] 2034
FAILURE CODE [DXH1KA] 2036
FAILURE CODE [DXH1KB] 2038
FAILURE CODE [DXH1KY] 2040
FAILURE CODE [DXH2KA] 2042
FAILURE CODE [DXH2KB] 2044
FAILURE CODE [DXH2KY] 2046
FAILURE CODE [DXH3KA] 2049
FAILURE CODE [DXH3KB] 2051
FAILURE CODE [DXH3KY] 2053
FAILURE CODE [DXH4KA] 2056
FAILURE CODE [DXH4KB] 2058
FAILURE CODE [DXH4KY] 2060
FAILURE CODE [DXH5KA] 2063
FAILURE CODE [DXH5KB] 2065
FAILURE CODE [DXH5KY] 2067
FAILURE CODE [DXH6KA] 2070
FAILURE CODE [DXH6KB] 2072
FAILURE CODE [DXH6KY] 2074
FAILURE CODE [DXH7KA] 2077
FAILURE CODE [DXH7KB] 2079
FAILURE CODE [DXH7KY] 2081
FAILURE CODE [DXHHKA] 2083
FAILURE CODE [DXHHKB] 2085
FAILURE CODE [DXHHKY] 2087
FAILURE CODE [DY30MA] 2089
FAILURE CODE [DY30MC] 2091
FAILURE CODE [DY30ME] 2094
FAILURE CODE [F313KA] 2096
FAILURE CODE [F313KB] 2098
FAILURE CODE [F318KB] 2099
FAILURE CODE [F318KY] 2100
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2101
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2101
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2108
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2111
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2113
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2114
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch) 2117
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2120
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2122
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2124
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2126
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2129
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2132
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2135
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2137
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2139
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2141
E-17 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2142
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2145
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2149
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2153
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2156
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2158
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2161
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2163
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2165
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2167
E-27 ALARM BUZZER DOES NOT SOUND 2168
E-28 ALARM BUZZER DOES NOT STOP SOUNDING 2170
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY 2172
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY 2174
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY 2176
E-32 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2178
E-33 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2181
E-34 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2185
E-35 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2188
E-36 TAIL LAMP DOES NOT LIGHT UP 2191
E-37 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2194
E-38 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2196
E-39 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2198
E-40 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2200
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with KOMTRAX terminal) 2202
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with gateway function controller) 2204
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2206
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2206
FAILURE MODE AND CAUSE TABLE 2207
H-1 MACHINE DOES NOT START 2215
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2219
H-3 LOCKUP IS NOT RELEASED 2220
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2221
H-5 GEAR IS NOT SHIFTED UP 2223
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2226
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2227
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2228
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2230
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2233
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 2234
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2235
H-13 STEERING WHEEL CANNOT BE OPERATED 2236
H-14 STEERING WHEEL WAGGLES 2237
H-15 FRONT BRAKE DOES NOT WORK ENOUGH 2238
H-16 REAR BRAKE DOES NOT WORK ENOUGH 2239
H-17 DUMP BODY RISING SPEED IS LOW 2240
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2242
H-19 DUMP BODY DOES NOT MOVE 2243
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2245
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN 2246
TROUBLESHOOTING OF ENGINE (S-MODE) 2247
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2247
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2248
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2249
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2250
S-4 ENGINE STARTABILITY IS POOR 2251
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2253
S-6 ENGINE STOPS DURING OPERATION 2255
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2257
S-8 ENGINE LACKS POWER 2258
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2260
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2262
S-11 OIL BECOMES CONTAMINATED QUICKLY 2263
S-12 FUEL CONSUMPTION IS EXCESSIVE 2264
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2265
S-14 OIL PRESSURE DROPS 2266
S-15 FUEL MIXES INTO ENGINE OIL 2267
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2268
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2269
S-18 UNUSUAL NOISE IS HEARD 2270
S-19 VIBRATION IS EXCESSIVE 2271
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2272
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2273
S-22 ACTIVE REGENERATION TAKES TIME 2275
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2276
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2277
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2279
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2280
50 DISASSEMBLY AND ASSEMBLY 2281
CONTENTS 2282
ABBREVIATIONS 2288
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION 2293
HOW TO READ THIS MANUAL 2293
COATING MATERIALS LIST 2295
SPECIAL TOOL LIST 2298
DIAGRAMS OF SPECIAL TOOLS 2314
ENGINE AND COOLING SYSTEM 2319
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2319
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY 2319
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY 2320
REMOVE AND INSTALL INJECTOR ASSEMBLY 2324
PROCEDURE TO REMOVE INJECTOR ASSEMBLY 2324
PROCEDURE TO INSTALL INJECTOR ASSEMBLY 2338
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2356
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY 2356
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY 2358
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2360
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY 2361
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY 2376
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2399
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY 2399
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY 2402
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2405
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY 2405
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY 2411
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2417
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY 2417
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY 2418
REMOVE AND INSTALL ALTERNATOR BELT 2419
PROCEDURE TO REMOVE ALTERNATOR BELT 2419
PROCEDURE TO INSTALL ALTERNATOR BELT 2420
REMOVE AND INSTALL RADIATOR 2423
PROCEDURE TO REMOVE RADIATOR 2424
PROCEDURE TO INSTALL RADIATOR 2428
REMOVE AND INSTALL COOLER ASSEMBLY 2432
PROCEDURE TO REMOVE COOLER ASSEMBLY 2432
PROCEDURE TO INSTALL COOLER ASSEMBLY 2443
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2455
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2455
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2459
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2464
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY 2464
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY 2465
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY 2467
PROCEDURE TO REMOVE GRILLE GUARD ASSEMBLY 2467
PROCEDURE TO INSTALL GRILLE GUARD ASSEMBLY 2471
REMOVE AND INSTALL ENGINE ASSEMBLY 2475
PROCEDURE TO REMOVE ENGINE ASSEMBLY 2476
PROCEDURE TO INSTALL ENGINE ASSEMBLY 2485
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2500
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL 2500
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL 2501
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2503
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL 2503
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL 2505
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY 2511
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY 2511
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY 2512
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY 2514
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY 2514
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY 2515
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2517
PROCEDURE TO REMOVE AdBlue/DEF TANK ASSEMBLY 2518
PROCEDURE TO INSTALL AdBlue/DEF TANK ASSEMBLY 2525
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2530
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2531
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2538
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2543
PROCEDURE TO REMOVE AdBlue/DEF TANK SENSOR 2543
PROCEDURE TO INSTALL AdBlue/DEF TANK SENSOR 2544
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2546
PROCEDURE TO REMOVE AdBlue/DEF TANK STRAINER 2546
PROCEDURE TO INSTALL AdBlue/DEF TANK STRAINER 2546
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2547
PROCEDURE TO REMOVE KDPF, SCR ASSEMBLY 2548
PROCEDURE TO INSTALL KDPF, SCR ASSEMBLY 2558
REMOVE AND INSTALL KDPF ASSEMBLY 2568
PROCEDURE TO REMOVE KDPF ASSEMBLY 2569
PROCEDURE TO INSTALL KDPF ASSEMBLY 2573
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2578
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY 2579
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY 2584
REMOVE AND INSTALL SCR ASSEMBLY 2589
PROCEDURE TO REMOVE SCR ASSEMBLY 2589
PROCEDURE TO INSTALL SCR ASSEMBLY 2592
REMOVE AND INSTALL KCCV ASSEMBLY 2597
PROCEDURE TO REMOVE KCCV ASSEMBLY 2597
PROCEDURE TO INSTALL KCCV ASSEMBLY 2601
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2605
PROCEDURE TO REMOVE AdBlue/DEF MIXING TUBE 2606
PROCEDURE TO INSTALL AdBlue/DEF MIXING TUBE 2614
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2625
PROCEDURE TO REMOVE AdBlue/DEF INJECTOR 2626
PROCEDURE TO INSTALL AdBlue/DEF INJECTOR 2632
REMOVE AND INSTALL AdBlue/DEF PUMP 2637
PROCEDURE TO REMOVE AdBlue/DEF PUMP 2637
PROCEDURE TO INSTALL AdBlue/DEF PUMP 2642
REMOVE AND INSTALL AdBlue/DEF HOSE 2646
PROCEDURE TO REMOVE AdBlue/DEF HOSE 2647
PROCEDURE TO INSTALL AdBlue/DEF HOSE 2658
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2669
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY 2669
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY 2671
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2674
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2674
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2675
POWER TRAIN 2676
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2676
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2677
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2689
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2704
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2704
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2716
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY 2730
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY 2731
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY 2737
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 2747
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY 2748
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY 2765
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 2786
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY 2786
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY 2788
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 2790
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY 2791
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY 2796
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD 2807
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD 2807
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD 2807
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY 2808
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY 2808
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY 2808
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2810
PROCEDURE TO DISASSEMBLE FRONT BRAKE CALIPER ASSEMBLY 2810
PROCEDURE TO ASSEMBLE FRONT BRAKE CALIPER ASSEMBLY 2811
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2813
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2813
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2814
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY 2816
PROCEDURE TO REMOVE PARKING BRAKE PAD ASSEMBLY 2816
PROCEDURE TO INSTALL PARKING BRAKE PAD ASSEMBLY 2817
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY 2819
PROCEDURE TO REMOVE PARKING BRAKE CALIPER ASSEMBLY 2819
PROCEDURE TO INSTALL PARKING BRAKE CALIPER ASSEMBLY 2819
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 2820
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2820
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2821
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY 2823
PROCEDURE TO DISASSEMBLE FINAL DRIVE ASSEMBLY 2823
PROCEDURE TO ASSEMBLE FINAL DRIVE ASSEMBLY 2827
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY 2832
PROCEDURE TO REMOVE SLACK ADJUSTER ASSEMBLY 2832
PROCEDURE TO INSTALL SLACK ADJUSTER ASSEMBLY 2833
STEERING SYSTEM 2835
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 2835
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY 2835
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY 2838
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 2841
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY 2841
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY 2843
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY 2846
PROCEDURE TO REMOVE SECONDARY STEERING MOTOR PUMP ASSEMBLY 2846
PROCEDURE TO INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY 2849
UNDERCARRIAGE AND FRAME 2852
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 2852
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY 2852
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY 2853
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 2855
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY 2855
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY 2857
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2859
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY 2859
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2860
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2863
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 2863
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 2865
REMOVE AND INSTALL KING PIN 2867
PROCEDURE TO REMOVE KING PIN 2867
PROCEDURE TO INSTALL KING PIN 2868
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2869
PROCEDURE TO DISASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2871
PROCEDURE TO ASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY 2871
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2873
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY 2873
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2873
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING) 2874
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 2874
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 2876
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY 2879
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY 2879
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY 2880
HYDRAULIC SYSTEM 2884
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 2884
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY 2884
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY 2887
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 2891
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY 2892
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY 2895
WORK EQUIPMENT 2902
REMOVE AND INSTALL DUMP BODY ASSEMBLY 2902
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY 2902
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY 2903
CAB AND ITS ATTACHMENTS 2906
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 2906
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY 2906
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY 2914
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 2921
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY 2921
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY 2923
REMOVE AND INSTALL SEAT BELT 2926
PROCEDURE TO REMOVE SEAT BELT 2926
PROCEDURE TO INSTALL SEAT BELT 2927
ELECTRICAL SYSTEM 2928
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2928
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY 2928
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY 2929
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2932
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY 2932
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 2933
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2934
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY 2934
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY 2935
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2936
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY 2936
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY 2938
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 2941
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY 2941
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY 2942
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2943
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 2943
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2944
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2946
PROCEDURE TO REMOVE SCR TEMPERATURE SENSOR 2946
PROCEDURE TO INSTALL SCR TEMPERATURE SENSOR 2948
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY 2950
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY 2950
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY 2951
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2952
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 2952
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2956
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2960
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 2960
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 2968
REMOVE AND INSTALL COMMUNICATION TERMINAL 2975
METHOD FOR REMOVING COMMUNICATION TERMINAL 2975
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2983
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2990
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR 2990
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR 2991
60 MAINTENANCE STANDARD 2993
CONTENTS 2994
ABBREVIATIONS 2995
ENGINE AND COOLING SYSTEM 3000
MAINTENANCE STANDARD OF ENGINE MOUNT 3000
MAINTENANCE STANDARD OF OUTPUT SHAFT 3001
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP 3003
MAINTENANCE STANDARD OF SERVO VALVE OF COOLING FAN AND HOIST PUMP 3004
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3005
POWER TRAIN 3007
MAINTENANCE STANDARD OF DRIVE SHAFT 3007
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 3008
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3009
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE 3012
MAINTENANCE STANDARD OF TRANSMISSION 3013
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3018
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3019
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3020
MAINTENANCE STANDARD OF FRONT AXLE 3021
MAINTENANCE STANDARD OF REAR AXLE 3022
MAINTENANCE STANDARD OF DIFFERENTIAL 3023
MAINTENANCE STANDARD OF FINAL DRIVE 3024
STEERING SYSTEM 3025
MAINTENANCE STANDARD OF STEERING COLUMN 3025
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE 3026
MAINTENANCE STANDARD OF DEMAND VALVE 3029
MAINTENANCE STANDARD OF STEERING CYLINDER 3031
BRAKE SYSTEM 3032
MAINTENANCE STANDARD OF SLACK ADJUSTER 3032
MAINTENANCE STANDARD OF FRONT BRAKE 3033
MAINTENANCE STANDARD OF REAR BRAKE 3034
MAINTENANCE STANDARD OF PARKING BRAKE 3035
UNDERCARRIAGE AND FRAME 3037
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 3037
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 3039
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 3041
HYDRAULIC SYSTEM 3042
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP 3042
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP 3043
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 3045
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP 3047
MAINTENANCE STANDARD OF HOIST VALVE 3049
WORK EQUIPMENT 3051
MAINTENANCE STANDARD OF HOIST CYLINDER 3051
CAB AND ITS ATTACHMENTS 3052
MAINTENANCE STANDARD OF CAB MOUNT 3052
80 THE OTHER INFORMATION 3053
CONTENTS 3054
ABBREVIATIONS 3056
AIR CONDITIONER SYSTEM 3061
PRECAUTIONS FOR REFRIGERANT 3061
AIR CONDITIONER COMPONENT 3062
SPECIFICATIONS OF AIR CONDITIONER 3064
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3065
OUTLINE OF REFRIGERATION CYCLE 3066
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3068
AIR CONDITIONER UNIT 3068
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3068
FUNCTION OF AIR CONDITIONER UNIT 3069
COMPONENT PARTS OF AIR CONDITIONER UNIT 3071
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3071
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3072
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3072
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3072
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3073
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3073
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3073
FUNCTION OF DUAL PRESSURE SWITCH 3074
AIR CONDITIONER CONTROLLER 3075
STRUCTURE OF AIR CONDITIONER CONTROLLER 3075
COMPRESSOR 3076
STRUCTURE OF COMPRESSOR 3076
SPECIFICATIONS OF COMPRESSOR 3076
FUNCTION OF COMPRESSOR 3076
CONDENSER 3077
STRUCTURE OF CONDENSER 3077
SPECIFICATIONS OF CONDENSER 3077
FUNCTION OF CONDENSER 3077
SENSORS FOR AIR CONDITIONER SYSTEM 3079
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3079
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3079
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3080
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3082
AIR CONDITIONER SYSTEM DIAGRAM 3084
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3085
FUNCTION OF AIR CONDITIONER CONTROLLER 3086
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3087
TESTING AIR LEAKAGE (DUCT) 3090
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3090
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3093
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3095
TEST VENT (MODE) CHANGEOVER 3097
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3097
TESTING FRESH/RECIRC AIR CHANGEOVER 3098
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3098
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3099
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3099
TEST RELAYS 3100
METHOD FOR TESTING RELAYS 3100
AIR CONDITIONER TROUBLESHOOTING CHART 1 3101
AIR CONDITIONER TROUBLESHOOTING CHART 2 3102
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3105
FAILURE CODE [879AKA] 3106
FAILURE CODE [879AKB] 3107
FAILURE CODE [879BKA] 3108
FAILURE CODE [879BKB] 3109
FAILURE CODE [879CKA] 3110
FAILURE CODE [879CKB] 3111
FAILURE CODE [879EMC] 3112
FAILURE CODE [879FMC] 3113
FAILURE CODE [879GKX] 3114
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3115
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3117
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3120
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3122
TROUBLESHOOTING USING GAUGE PRESSURE 3124
CONNECTION OF SERVICE TOOL 3127
METHOD FOR CONNECTING SERVICE TOOL 3127
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3128
HANDLE COMPRESSOR OIL 3130
METHOD FOR REPLACING DESICCANT 3132
90 CIRCUIT DIAGRAMS 3135
CONTENTS 3136
ABBREVIATIONS 3137
HYDRAULIC CIRCUIT DIAGRAM 3142
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3142
HYDRAULIC CIRCUIT DIAGRAM 3147
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3149
ELECTRICAL CIRCUIT DIAGRAM 3151
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3151
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/9) 3155
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/9) 3157
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/9) 3159
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/9) 3161
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/9) 3163
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/9) 3165
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/9) 3167
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/9) 3169
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (9/9) 3171
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/10) 3173
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/10) 3175
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/10) 3177
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/10) 3179
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/10) 3181
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/10) 3183
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/10) 3185
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/10) 3187
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (9/10) 3189
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (10/10) 3191
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/8) 3193
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/8) 3195
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/8) 3197
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/8) 3199
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/8) 3201
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/8) 3203
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/8) 3205
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/8) 3207
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/8) 3209
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/8) 3211
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/8) 3213
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/8) 3215
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/8) 3217
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/8) 3219
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/8) 3221
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/8) 3223
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE 3225
INDEX 3227

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