Komatsu HD465-8 HD605-8 Dump Truck Shop Manual SEN06605-19 – PDF DOWNLOAD

Description

Komatsu HD465-8 HD605-8 Dump Truck Shop Manual SEN06605-19 – PDF DOWNLOAD

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DESCRIPTION:

Komatsu HD465-8 HD605-8 Dump Truck Shop Manual SEN06605-19 – PDF DOWNLOAD

SERIAL NUMBERS
HD465-8 30001 and up
HD605-8 30001 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 HD465-8 HD605-8 Dump Truck Shop Manual SEN06605-19 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 24
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 40
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION 41
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 42
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 45
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 54
PRACTICAL USE OF KOMTRAX 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 75
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
01 SPECIFICATION 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
DIAGRAM SPECIFICATION:HD465-8 93
DIAGRAM SPECIFICATION:HD605-8 95
SPECIFICATIONS 97
SPECIFICATIONS:HD465-8 97
SPECIFICATIONS:HD605-8 102
WEIGHT TABLE 107
WEIGHT TABLE:HD465-8 107
WEIGHT TABLE:HD605-8 108
FUEL, COOLANT, LUBRICANT 109
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 109
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
BOOT-UP SYSTEM 116
BOOT UP SYSTEM DIAGRAM 116
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) 117
SYSTEM OPERATING LAMP SYSTEM 119
OPERATION LAMP SYSTEM DIAGRAM 119
FUNCTION OF OPERATION LAMP SYSTEM 119
BATTERY DISCONNECT SWITCH 120
BATTERY DISCONNECT SWITCH DIAGRAM 120
FUNCTION OF BATTERY DISCONNECT SWITCH 120
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 121
ENGINE SHUTDOWN SECONDARY SWITCH 123
ENGINE SECONDARY SHUTDOWN SWITCH DIAGRAM 123
FUNCTION OF ENGINE SECONDARY SHUTDOWN SWITCH 123
OPERATION OF ENGINE SECONDARY SHUTDOWN SWITCH 124
ENGINE SYSTEM 125
ENGINE SYSTEM DIAGRAM 125
FUNCTION OF ENGINE SYSTEM 126
ENGINE CONTROL SYSTEM 128
ENGINE CONTROL SYSTEM DIAGRAM 128
AUTOMATIC IDLE STOP SYSTEM 132
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 132
ENGINE SYSTEM 134
OUTPUT SHAFT 134
VGT 136
EGR SYSTEM 140
EGR VALVE 143
EGR COOLER 145
KCCV SYSTEM 146
KCCV VENTILATOR 148
CDR VALVE 150
KDPF 151
COOLING SYSTEM 155
COOLING SYSTEM DIAGRAM 155
SPECIFICATIONS OF COOLING SYSTEM 156
RADIATOR FAN CONTROL SYSTEM 157
RADIATOR FAN CONTROL SYSTEM DIAGRAM 157
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 157
COOLING SYSTEM 159
COOLING FAN, HOIST PUMP 159
COOLING FAN MOTOR 166
CONTROL SYSTEM 173
CONTROL SYSTEM DIAGRAM 173
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 175
RETARDER AND HOIST CONTROL SYSTEM 176
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 176
MACHINE MONITOR SYSTEM 178
MACHINE MONITOR SYSTEM DIAGRAM 178
FUNCTION OF MACHINE MONITOR SYSTEM 179
REARVIEW MONITOR SYSTEM 180
REARVIEW MONITOR SYSTEM DIAGRAM 180
FUNCTION OF REARVIEW MONITOR SYSTEM 180
KOMTRAX Plus SYSTEM 181
SYSTEM DIAGRAM OF KOMTRAX Plus SYSTEM 181
SYSTEM DIAGRAM OF KOMTRAX Plus SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 183
FUNCTION OF KOMTRAX PLUS SYSTEM 184
PAYLOAD METER SYSTEM 187
PAYLOAD METER SYSTEM DIAGRAM 187
PAYLOAD METER SYSTEM DIAGRAM 188
FUNCTION OF PAYLOAD METER SYSTEM 188
MEASUREMENT PRINCIPLE OF LOADING MASS 189
MACHINE LOCK-OUT SYSTEM 199
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM 199
FUNCTION OF MACHINE LOCK-OUT SYSTEM 200
OPERATION OF MACHINE LOCK-OUT SYSTEM 200
CONTROL SYSTEM 201
MACHINE MONITOR 201
SWITCH PANEL 221
REARVIEW MONITOR 222
REARVIEW CAMERA 224
KOMTRAX TERMINAL 225
KOMTRAX Plus CONTROLLER 227
COMMUNICATION TERMINAL 232
WIRELESS LAN UNIT 233
TRANSMISSION CONTROLLER 234
RETARDER AND HOIST CONTROLLER 238
MONITOR CONTROLLER 243
ENGINE CONTROLLER 248
ABS CONTROLLER 260
ACCELERATOR PEDAL 264
GEAR SHIFT LEVER 265
RETARDER CONTROL LEVER 266
FUEL FEED PUMP 267
FUEL FEED PUMP SWITCH 268
HYDRAULIC SYSTEM 270
HYDRAULIC SYSTEM DIAGRAM 270
HYDRAULIC SYSTEM 271
HYDRAULIC TANK 271
STEERING AND HOIST PUMP 272
LS VALVE 278
CO VALVE 279
POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 282
BRAKE COOLING, CONTROL TRIPLE PUMP 284
HOIST VALVE 286
POWER TRAIN SYSTEM 292
POWER TRAIN DIAGRAM 292
TRANSMISSION CONTROL SYSTEM 294
TRANSMISSION CONTROL SYSTEM DIAGRAM 294
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 295
GEAR SHIFT CONTROL SYSTEM 299
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 299
DIRECTION CONTROL SYSTEM 301
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 301
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 301
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 302
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 302
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 302
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 303
TRAVEL SPEED LIMITATION SYSTEM 304
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 304
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 305
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 305
POWER TRAIN SYSTEM 308
DRIVE SHAFT 308
TORQUE CONVERTER, PTO 310
LOCKUP CLUTCH ECMV 314
TRANSMISSION 317
TRANSMISSION CONTROL VALVE 338
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 340
AXLE 349
DIFFERENTIAL 351
FINAL DRIVE 353
WORK EQUIPMENT SYSTEM 354
WORK EQUIPMENT CONTROL 354
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 354
FUNCTION OF WORK EQUIPMENT CONTROL 354
HOIST CONTROL 355
HOIST CONTROL SYSTEM DIAGRAM 355
FUNCTION OF HOIST CONTROL 355
WORK EQUIPMENT SYSTEM 357
DUMP LEVER 357
HOIST EPC VALVE 362
STEERING SYSTEM 363
STEERING SYSTEM DIAGRAM 363
STEERING SYSTEM FUNCTION 364
STEERING COLUMN 365
STRUCTURE OF STEERING COLUMN 365
STEERING LINKAGE 366
STRUCTURE OF STEERING LINKAGE 366
STEERING SYSTEM 367
DEMAND VALVE 367
STEERING RELIEF VALVE 373
ORBITROL VALVE 375
STEERING PUMP SELECTOR SOLENOID VALVE 381
CROSS OVER RELIEF VALVE 382
SECONDARY STEERING PUMP 383
SECONDARY STEERING MOTOR 384
BRAKE SYSTEM 385
BRAKE SYSTEM DIAGRAM 385
RETARDER CONTROL 387
RETARDER CONTROL SYSTEM DIAGRAM 387
FUNCTION OF RETARDER CONTROL 387
ARSC SYSTEM 388
ARCS SYSTEM DIAGRAM 388
FUNCTION OF ARSC SYSTEM 388
BRAKE SYSTEM 389
BRAKE CHARGE PUMP 389
PARKING BRAKE SOLENOID VALVE 390
ACCUMULATOR CHARGE VALVE 391
BRAKE CIRCUIT ACCUMULATOR 395
BRAKE VALVE 396
SECONDARY BRAKE VALVE 400
SECONDARY BRAKE RELAY VALVE 401
PROPORTIONAL PRESSURE REDUCING VALVE 402
SLACK ADJUSTER 403
BRAKE 405
PARKING BRAKE 408
BRAKE SUB-TANK 410
ABS 411
ABS SYSTEM DIAGRAM 411
ABS SYSTEM DIAGRAM 412
FUNCTION OF ABS 413
OPERATION OF ABS 413
COMPONENT PARTS OF ABS 416
AUTO-GREASING SYSTEM 419
AUTO-GREASING SYSTEM DIAGRAM 419
AUTO-GREASING SYSTEM DIAGRAM 422
FUNCTION OF AUTO-GREASING SYSTEM 423
COMPONENT PARTS OF AUTO-GREASING SYSTEM 424
AUTO-GREASING PUMP 424
AUTO-GREASING INJECTOR 426
UNDERCARRIAGE AND FRAME 430
SUSPENSION 430
STRUCTURE OF SUSPENSION 430
FUNCTION OF SUSPENSION 430
FRONT SUSPENSION 432
STRUCTURE OF FRONT SUSPENSION 432
FUNCTION OF FRONT SUSPENSION 433
REAR SUSPENSION 434
STRUCTURE OF REAR SUSPENSION 434
FUNCTION OF REAR SUSPENSION 435
SUSPENSION CYLINDER 436
STRUCTURE OF SUSPENSION CYLINDER 436
FUNCTION OF SUSPENSION CYLINDER 436
OPERATION OF SUSPENSION CYLINDER 436
WORK EQUIPMENT 438
STRUCTURE OF WORK EQUIPMENT 438
FUNCTION OF WORK EQUIPMENT 439
CAB RELATED PARTS 440
ROPS CAB 440
STRUCTURE OF ROPS CAB 440
FUNCTION OF ROPS CAB 440
CAB MOUNT 441
STRUCTURE OF CAB MOUNT 441
FUNCTION OF CAB MOUNT 441
20 STANDARD VALUE TABLE 443
CONTENTS 444
STANDARD VALUE TABLE FOR ENGINE 445
STANDARD VALUE TABLE FOR ENGINE:HD465-8 445
STANDARD VALUE TABLE FOR ENGINE:HD605-8 448
STANDARD VALUE TABLE FOR MACHINE 451
STANDARD VALUE TABLE FOR MACHINE:HD465-8 451
STANDARD VALUE TABLE FOR MACHINE:HD605-8 469
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE 487
30 TESTING AND ADJUSTING 489
CONTENTS 490
RELATED INFORMATION ON TESTING AND ADJUSTING 494
TOOLS TO TEST AND ADJUST 494
DIAGRAM FOR TEST AND ADJUST TOOLS 504
ENGINE AND COOLING SYSTEM 505
TEST ENGINE SPEED 505
PROCEDURE TO TEST ENGINE SPEED 505
TEST BOOST PRESSURE 507
BOOST PRESSURE TEST BY MACHINE MONITOR 507
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 508
TESTING EXHAUST GAS TEMPERATURE 511
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR 511
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 513
TEST EXHAUST GAS COLOR 515
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER 515
TEST EXHAUST GAS COLOR WITH SMOKE METER 516
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 518
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 518
TEST AND ADJUST VALVE CLEARANCE 521
TEST VALVE CLEARANCE 521
ADJUST VALVE CLEARANCE 522
COMPRESSION TEST 524
COMPRESSION PRESSURE TEST 524
BLOWBY PRESSURE TEST 528
BLOWBY PRESSURE TEST 528
TEST ENGINE OIL PRESSURE 531
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR 531
TEST ENGINE OIL PRESSURE 531
EGR VALVE AND VGT OIL PRESSURE TEST 533
EGR VALVE AND VGT OIL PRESSURE TEST 533
FUEL PRESSURE TEST 534
FUEL PRESSURE TEST 534
FUEL RETURN RATE AND LEAKAGE TEST 536
FUEL RETURN RATE AND LEAKAGE TEST 537
BLEEDING AIR FROM FUEL SYSTEM 540
BLEED AIR FROM FUEL SYSTEM 540
FUEL CIRCUIT LEAK TEST 542
FUEL CIRCUIT LEAK TEST 542
SUPPLY PUMP TEST 544
SUPPLY PUMP TEST 544
CYLINDER CUT-OUT MODE 547
NO-INJECTION CRANKING 548
CLEAN FUEL DOSER 549
CLEAN FUEL DOSER 549
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 552
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 552
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 559
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 559
TEST TORQUE CONVERTER STALL SPEED 560
TEST TORQUE CONVERTER STALL SPEED 560
RADIATOR FAN SPEED TEST 562
RADIATOR FAN SPEED TEST 562
POWER TRAIN 564
TEST POWER TRAIN OIL PRESSURE 564
POWER TRAIN OIL PRESSURE TEST 566
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 578
ADJUST TRANSMISSION INPUT SPEED SENSOR 578
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR 579
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR 579
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 580
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 580
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS 581
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SENSORS 581
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 582
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 582
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEM 583
STEERING SYSTEM 588
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 588
TEST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR 588
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS 588
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 590
TEST SUPPLY PRESSURE OF ORBITROL VALVE 591
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 591
TEST STEERING CYLINDER PRESSURE 593
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 593
BLEED AIR FROM STEERING CYLINDER CIRCUIT 595
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 595
BRAKE SYSTEM 596
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 596
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 596
TEST WHEEL BRAKE OIL PRESSURE 597
FRONT BRAKE ACTUATION PRESSURE TEST 597
REAR BRAKE ACTUATION PRESSURE TEST 598
RETARDER BRAKE PRESSURE TEST 599
RETARDER BRAKE ACTUATION PRESSURE TEST (FOR MACHINE WITH KTCS) 600
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 602
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR 602
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 602
ADJUST BRAKE ACCUMULATOR PRESSURE 603
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 605
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 605
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 609
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 613
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 618
TEST BRAKE PERFORMANCE 619
TEST FOOT BRAKE PERFORMANCE 619
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 619
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 620
BLEED AIR FROM BRAKE CIRCUIT 622
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 622
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT (FOR MACHINE WITH ABS) 623
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT 624
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/WITHOUT KTCS) 626
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 627
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/KTCS) 629
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 632
TEST PARKING BRAKE OIL PRESSURE 634
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 634
RELEASE PARKING BRAKE MANUALLY 635
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY 635
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 636
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 636
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE 636
TEST THE QUANTITY OF REAR BRAKE DISC WEAR 638
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR 638
HYDRAULIC SYSTEM 639
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 639
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 639
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 640
TEST HOIST CYLINDER SUPPLY PRESSURE 641
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 641
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 643
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 643
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 644
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 645
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 645
TEST AND ADJUST FRONT SUSPENSION CYLINDER 647
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 647
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 648
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 652
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 652
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 653
TEST AND ADJUST REAR SUSPENSION CYLINDER 655
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 656
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 657
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 661
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 661
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 661
WORK EQUIPMENT 663
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 663
PROCEDURE TO TEST THE BODY POSITION SENSOR 663
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR 663
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR 663
LOWER THE BODY MANUALLY 665
PROCEDURE TO LOWER THE BODY MANUALLY 665
LIFT THE BODY MANUALLY 666
PROCEDURE TO RAISE THE BODY MANUALLY 666
CAB RELATED PARTS 667
ADJUST STEERING WHEEL TILT LOCK LEVER 667
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 667
ADJUST RATTLING OPERATOR’S SEAT 669
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 669
ELECTRICAL SYSTEM 670
SET AND ADJUST EACH EQUIPMENT 670
SET AND OPERATE OF MACHINE MONITOR 674
OPERATOR MODE 678
SERVICE MODE 691
ABNORMALITY RECORD MENU 717
DEFAULT MENU 731
DIAGNOSTIC TESTS MENU 746
ADJUSTMENT MENU 758
PROCEDURE TO CRANK WITH NO-INJECTION 781
PAYLOAD METER SETTING 784
PROCEDURE FOR MANUAL SNAP SHOT 803
KOMTRAX SETTINGS MENU 807
PROCEDURE TO DISPLAY SERVICE MESSAGE 809
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL 811
STOP USE OF KOMTRAX TERMINAL 815
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 817
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 819
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 819
SETTING DEFAULT OF WIRELESS LAN MODEM 822
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM 822
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION 823
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 825
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 825
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 829
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED 829
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 832
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED 832
SETTING OF MOBILE COMMUNICATION TERMINAL 835
SETTING OF MOBILE COMMUNICATION TERMINAL 835
ADJUST REARVIEW CAMERA ANGLE 845
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 845
ADJUST OPTICAL AXIS OF HEAD LAMP 846
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 846
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK 850
BATTERY DISCONNECT SWITCH 851
BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 853
TEST DIODES 855
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 855
PROCEDURE TO TEST DIODE USING ANALOG TESTER 855
Pm-CLINIC 856
Pm CLINIC SERVICE 856
Pm CLINIC CHECK SHEET: HD465-8 860
Pm CLINIC CHECK SHEET: HD605-8 868
PERFORMING QUICK Pm 876
PROCEDURE TO PERFORM QUICK Pm 876
40 TROUBLESHOOTING 881
CONTENTS 882
RELATED INFORMATION ON TROUBLESHOOTING 895
GENERAL TROUBLESHOOTING POINTS 895
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS 896
SEQUENCE OF EVENTS IN TROUBLESHOOTING 902
CHECKS BEFORE TROUBLESHOOTING 904
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 906
WALK-AROUND CHECK 906
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 908
CHECK FUEL LEVEL AND TYPE 908
CHECK IMPURE INGREDIENT IN FUEL 908
CHECK FUEL PREFILTER 908
CHECK MAIN FILTER 910
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 912
CHECK COOLANT LEVEL (RESERVOIR TANK) 913
CHECK CLOGGING OF AIR CLEANER 914
OUTER ELEMENT – CLEAN 915
REPLACE ELEMENT 917
CHECK HYDRAULIC OIL LEVEL 918
CHECK HYDRAULIC OIL STRAINER 919
CHECK HYDRAULIC FILTER 919
CHECK OIL LEVEL IN TRANSMISSION CASE 920
CHECK OIL LEVEL IN DIFFERENTIAL CASE 920
CHECK OIL LEVEL IN FINAL DRIVE CASE 921
BLEED AIR FROM FUEL SYSTEM 921
BLEED AIR FROM HYDRAULIC SYSTEM 921
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 921
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 927
PROCEDURE FOR TESTING AND TROUBLESHOOTING 937
SYMPTOM AND TROUBLESHOOTING NUMBERS 939
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 942
CONNECTORS LIST AND LAYOUT 944
CONNECTOR CONTACT IDENTIFICATION 974
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1016
FUSE LOCATION TABLE 1022
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1028
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1032
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1034
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135]) 1040
FAILURE CODES TABLE 1042
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1067
FAILURE CODE [1500L0] 1067
FAILURE CODE [15B0NX] 1068
FAILURE CODE [15F0KM] 1070
FAILURE CODE [15F0MB] 1071
FAILURE CODE [15F7KM] 1072
FAILURE CODE [15G0MW] 1073
FAILURE CODE [15G7KM] 1075
FAILURE CODE [15H0MW] 1076
FAILURE CODE [15J0MW] 1078
FAILURE CODE [15K0MW] 1080
FAILURE CODE [15L0MW] 1082
FAILURE CODE [15M0MW] 1084
FAILURE CODE [15N0MW] 1086
FAILURE CODE [15SBL1] 1088
FAILURE CODE [15SBMA] 1091
FAILURE CODE [15SCL1] 1093
FAILURE CODE [15SCMA] 1096
FAILURE CODE [15SDL1] 1098
FAILURE CODE [15SDMA] 1101
FAILURE CODE [15SEL1] 1103
FAILURE CODE [15SEMA] 1106
FAILURE CODE [15SFL1] 1108
FAILURE CODE [15SFMA] 1111
FAILURE CODE [15SGL1] 1113
FAILURE CODE [15SGMA] 1116
FAILURE CODE [15SHL1] 1118
FAILURE CODE [15SHMA] 1121
FAILURE CODE [15SJMA] 1123
FAILURE CODE [2C4MNX] 1124
FAILURE CODE [2F00KM] 1126
FAILURE CODE [2G42ZG] 1129
FAILURE CODE [2G43ZG] 1130
FAILURE CODE [6014NX] 1131
FAILURE CODE [879AKA] 1133
FAILURE CODE [879AKB] 1134
FAILURE CODE [879BKA] 1135
FAILURE CODE [879BKB] 1136
FAILURE CODE [879CKA] 1138
FAILURE CODE [879CKB] 1139
FAILURE CODE [879EMC] 1140
FAILURE CODE [879FMC] 1141
FAILURE CODE [879GKX] 1142
FAILURE CODE [989D00] 1143
FAILURE CODE [989L00] 1144
FAILURE CODE [989M00] 1145
FAILURE CODE [989N00] 1146
FAILURE CODE [989X00] 1147
FAILURE CODE [989Y00] 1148
FAILURE CODE [A1U0N3] 1149
FAILURE CODE [A1U0N4] 1151
FAILURE CODE [AA10NX] 1153
FAILURE CODE [AB00KE] 1155
FAILURE CODE [AB00KY] 1157
FAILURE CODE [AQ00N3] 1158
FAILURE CODE [AQ00N4] 1159
FAILURE CODE [AQ10N3] 1160
FAILURE CODE [B@BAZG] 1161
FAILURE CODE [B@BAZK] 1162
FAILURE CODE [B@BCNS] 1163
FAILURE CODE [B@BCQA] 1164
FAILURE CODE [B@BCZK] 1166
FAILURE CODE [B@C7NS] 1168
FAILURE CODE [B@CENS] 1170
FAILURE CODE [B@JANS] 1171
FAILURE CODE [CA115] 1172
FAILURE CODE [CA122] 1176
FAILURE CODE [CA123] 1178
FAILURE CODE [CA131] 1180
FAILURE CODE [CA132] 1182
FAILURE CODE [CA135] 1184
FAILURE CODE [CA141] 1186
FAILURE CODE [CA144] 1188
FAILURE CODE [CA145] 1190
FAILURE CODE [CA153] 1192
FAILURE CODE [CA154] 1194
FAILURE CODE [CA187] 1196
FAILURE CODE [CA212] 1198
FAILURE CODE [CA213] 1200
FAILURE CODE [CA221] 1202
FAILURE CODE [CA222] 1204
FAILURE CODE [CA227] 1206
FAILURE CODE [CA234] 1208
FAILURE CODE [CA238] 1209
FAILURE CODE [CA239] 1211
FAILURE CODE [CA271] 1213
FAILURE CODE [CA272] 1215
FAILURE CODE [CA273] 1216
FAILURE CODE [CA274] 1218
FAILURE CODE [CA322] 1219
FAILURE CODE [CA323] 1221
FAILURE CODE [CA324] 1223
FAILURE CODE [CA325] 1225
FAILURE CODE [CA331] 1227
FAILURE CODE [CA332] 1229
FAILURE CODE [CA343] 1231
FAILURE CODE [CA351] 1234
FAILURE CODE [CA352] 1237
FAILURE CODE [CA356] 1239
FAILURE CODE [CA357] 1241
FAILURE CODE [CA386] 1243
FAILURE CODE [CA431] 1245
FAILURE CODE [CA432] 1248
FAILURE CODE [CA441] 1251
FAILURE CODE [CA442] 1254
FAILURE CODE [CA449] 1257
FAILURE CODE [CA451] 1258
FAILURE CODE [CA452] 1260
FAILURE CODE [CA515] 1262
FAILURE CODE [CA516] 1264
FAILURE CODE [CA553] 1266
FAILURE CODE [CA555] 1267
FAILURE CODE [CA556] 1269
FAILURE CODE [CA559] 1271
FAILURE CODE [CA595] 1276
FAILURE CODE [CA687] 1278
FAILURE CODE [CA689] 1280
FAILURE CODE [CA691] 1282
FAILURE CODE [CA692] 1284
FAILURE CODE [CA697] 1286
FAILURE CODE [CA698] 1287
FAILURE CODE [CA731] 1288
FAILURE CODE [CA778] 1291
FAILURE CODE [CA1117] 1294
FAILURE CODE [CA1135] 1297
FAILURE CODE [CA1257] 1300
FAILURE CODE [CA1664] 1301
FAILURE CODE [CA1691] 1303
FAILURE CODE [CA1695] 1306
FAILURE CODE [CA1696] 1308
FAILURE CODE [CA1843] 1310
FAILURE CODE [CA1844] 1312
FAILURE CODE [CA1879] 1314
FAILURE CODE [CA1881] 1316
FAILURE CODE [CA1883] 1318
FAILURE CODE [CA1921] 1321
FAILURE CODE [CA1922] 1323
FAILURE CODE [CA1923] 1326
FAILURE CODE [CA1924] 1328
FAILURE CODE [CA1925] 1333
FAILURE CODE [CA1927] 1337
FAILURE CODE [CA1928] 1339
FAILURE CODE [CA1942] 1341
FAILURE CODE [CA1963] 1343
FAILURE CODE [CA1977] 1351
FAILURE CODE [CA1993] 1353
FAILURE CODE [CA2185] 1356
FAILURE CODE [CA2186] 1358
FAILURE CODE [CA2249] 1360
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] 1381
FAILURE CODE [CA2382] 1383
FAILURE CODE [CA2383] 1385
FAILURE CODE [CA2386] 1387
FAILURE CODE [CA2387] 1389
TROUBLESHOOTING FLOWCHART 1393
FAILURE CODE [CA2555] 1394
FAILURE CODE [CA2556] 1396
FAILURE CODE [CA2637] 1398
FAILURE CODE [CA2639] 1400
FAILURE CODE [CA2732] 1402
FAILURE CODE [CA2733] 1404
FAILURE CODE [CA2741] 1406
FAILURE CODE [CA2765] 1410
FAILURE CODE [CA2777] 1411
FAILURE CODE [CA2878] 1413
FAILURE CODE [CA2881] 1418
FAILURE CODE [CA3133] 1424
FAILURE CODE [CA3134] 1426
FAILURE CODE [CA3135] 1428
FAILURE CODE [CA3167] 1431
FAILURE CODE [CA3251] 1436
FAILURE CODE [CA3253] 1438
FAILURE CODE [CA3254] 1442
FAILURE CODE [CA3255] 1445
FAILURE CODE [CA3256] 1447
FAILURE CODE [CA3311] 1449
FAILURE CODE [CA3312] 1451
FAILURE CODE [CA3313] 1453
FAILURE CODE [CA3314] 1454
FAILURE CODE [CA3315] 1455
FAILURE CODE [CA3316] 1458
FAILURE CODE [CA3317] 1459
FAILURE CODE [CA3318] 1460
FAILURE CODE [CA3319] 1463
FAILURE CODE [CA3321] 1464
FAILURE CODE [CA3322] 1465
FAILURE CODE [CA3419] 1468
FAILURE CODE [CA3421] 1470
FAILURE CODE [CA4151] 1472
FAILURE CODE [CA4158] 1475
FAILURE CODE [CA4161] 1477
FAILURE CODE [CA4162] 1479
FAILURE CODE [CA4163] 1481
FAILURE CODE [CA4259] 1483
FAILURE CODE [CA4952] 1485
FAILURE CODE [CA5383] 1488
FAILURE CODE [CB115] 1489
FAILURE CODE [CB187] 1493
FAILURE CODE [CB227] 1494
FAILURE CODE [CB238] 1495
FAILURE CODE [CB239] 1497
FAILURE CODE [CB271] 1499
FAILURE CODE [CB272] 1501
FAILURE CODE [CB273] 1502
FAILURE CODE [CB274] 1504
FAILURE CODE [CB343] 1505
FAILURE CODE [CB352] 1508
FAILURE CODE [CB386] 1510
FAILURE CODE [CB441] 1512
FAILURE CODE [CB442] 1515
FAILURE CODE [CB689] 1518
FAILURE CODE [CB697] 1520
FAILURE CODE [CB698] 1521
FAILURE CODE [CB731] 1522
FAILURE CODE [CB778] 1526
FAILURE CODE [CB1117] 1528
FAILURE CODE [CB1257] 1531
FAILURE CODE [CB1664] 1532
FAILURE CODE [CB1691] 1534
FAILURE CODE [CB1695] 1537
FAILURE CODE [CB1696] 1539
FAILURE CODE [CB1879] 1541
FAILURE CODE [CB1881] 1543
FAILURE CODE [CB1883] 1545
FAILURE CODE [CB1921] 1548
FAILURE CODE [CB1922] 1550
FAILURE CODE [CB1923] 1553
FAILURE CODE [CB1924] 1555
FAILURE CODE [CB1925] 1560
FAILURE CODE [CB1927] 1564
FAILURE CODE [CB1928] 1566
FAILURE CODE [CB1963] 1568
FAILURE CODE [CB1977] 1576
FAILURE CODE [CB1993] 1578
FAILURE CODE [CB2265] 1581
FAILURE CODE [CB2266] 1583
FAILURE CODE [CB2637] 1585
FAILURE CODE [CB2639] 1588
FAILURE CODE [CB2732] 1590
FAILURE CODE [CB2733] 1592
FAILURE CODE [CB2741] 1594
FAILURE CODE [CB2777] 1598
FAILURE CODE [CB2878] 1600
FAILURE CODE [CB2881] 1605
FAILURE CODE [CB3133] 1611
FAILURE CODE [CB3134] 1613
FAILURE CODE [CB3135] 1615
FAILURE CODE [CB3167] 1618
FAILURE CODE [CB3251] 1623
FAILURE CODE [CB3253] 1625
FAILURE CODE [CB3254] 1629
FAILURE CODE [CB3255] 1632
FAILURE CODE [CB3256] 1634
FAILURE CODE [CB3311] 1636
FAILURE CODE [CB3312] 1638
FAILURE CODE [CB3313] 1640
FAILURE CODE [CB3314] 1641
FAILURE CODE [CB3315] 1642
FAILURE CODE [CB3316] 1645
FAILURE CODE [CB3317] 1646
FAILURE CODE [CB3318] 1647
FAILURE CODE [CB3319] 1650
FAILURE CODE [CB3321] 1651
FAILURE CODE [CB3322] 1652
FAILURE CODE [CB4151] 1655
FAILURE CODE [CB4158] 1658
FAILURE CODE [CB4161] 1659
FAILURE CODE [CB4162] 1661
FAILURE CODE [CB4163] 1663
FAILURE CODE [CB4259] 1665
FAILURE CODE [CB4952] 1667
FAILURE CODE [CB5383] 1670
FAILURE CODE [D150KB] 1671
FAILURE CODE [D150KZ] 1673
FAILURE CODE [D164KY] 1675
FAILURE CODE [D19HKZ] 1676
FAILURE CODE [D19JKZ] 1678
FAILURE CODE [D19QKZ] 1680
FAILURE CODE [D1EHKA] 1682
FAILURE CODE [D1EHKB] 1684
FAILURE CODE [D1EHKY] 1686
FAILURE CODE [D1EMKA] 1687
FAILURE CODE [D1EMKB] 1688
FAILURE CODE [D1EMKY] 1689
FAILURE CODE [D1FBKB] 1690
FAILURE CODE [D5ZHL6] 1692
FAILURE CODE [D5ZKKZ] 1694
FAILURE CODE [D862KA] 1696
FAILURE CODE [DAF0KT] 1697
FAILURE CODE [DAF0MB] 1698
FAILURE CODE [DAF0MC] 1699
FAILURE CODE [DAF3KK] 1700
FAILURE CODE [DAF8KB] 1702
FAILURE CODE [DAFDKB] 1704
FAILURE CODE [DAFGMC] 1706
FAILURE CODE [DAFLKA] 1707
FAILURE CODE [DAFLKB] 1710
FAILURE CODE [DAFQKR] 1713
FAILURE CODE [DAQ0KK] 1714
FAILURE CODE [DAQ0KT] 1717
FAILURE CODE [DAQ0MC] 1718
FAILURE CODE [DAQ1KA] 1719
FAILURE CODE [DAQ2KK] 1722
FAILURE CODE [DAQ9KQ] 1725
FAILURE CODE [DAQLKA] 1726
FAILURE CODE [DAQLKB] 1729
FAILURE CODE [DAQQKR] 1732
FAILURE CODE [DAQRKR] 1733
FAILURE CODE [DAQRMA] 1734
FAILURE CODE [DAQV00] 1735
FAILURE CODE [DAQW00] 1736
FAILURE CODE [DAZ9KQ] 1737
FAILURE CODE [DAZQKR] 1738
FAILURE CODE [DB10KT] 1740
FAILURE CODE [DB10MC] 1741
FAILURE CODE [DB11KA] 1742
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) 1745
FAILURE CODE [DB12KK] 1748
FAILURE CODE [DB13KK] 1751
FAILURE CODE [DB19KQ] 1754
FAILURE CODE [DB1LKA] 1755
FAILURE CODE [DB1LKB] 1758
FAILURE CODE [DB1QKR] 1761
FAILURE CODE [DB1QMA] 1762
FAILURE CODE [DB1RKR] 1763
FAILURE CODE [DB2QKR] 1764
FAILURE CODE [DB2QKR] 1771
FAILURE CODE [DB2RKR] 1779
FAILURE CODE [DB2RKR] 1786
FAILURE CODE [DBC0KT] 1794
FAILURE CODE [DBC0MC] 1795
FAILURE CODE [DBC1KA] 1796
FAILURE CODE [DBC2KK] 1799
FAILURE CODE [DBC3KK] 1801
FAILURE CODE [DBC9KQ] 1804
FAILURE CODE [DBCLKA] 1805
FAILURE CODE [DBCLKB] 1807
FAILURE CODE [DBCQKR] 1809
FAILURE CODE [DBCQMA] 1810
FAILURE CODE [DBCRKR] 1811
FAILURE CODE [DBV0MC] 1812
FAILURE CODE [DBV1KK] 1813
FAILURE CODE [DBV6KB] 1815
FAILURE CODE [DBV7KB] 1817
FAILURE CODE [DBVLKA] 1818
FAILURE CODE [DBVLKB] 1821
FAILURE CODE [DBVQKR] 1824
FAILURE CODE [DBVRKR] 1825
FAILURE CODE [DBVVKR] 1826
FAILURE CODE [DBVWKR] 1827
FAILURE CODE [DDAAL6] 1828
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) 1830
FAILURE CODE [DDACL4] 1833
FAILURE CODE [DDADKA] 1835
FAILURE CODE [DDADKY] 1837
FAILURE CODE [DDD7KX] 1839
FAILURE CODE [DDP6L4] 1841
FAILURE CODE [DDTHKA] 1843
FAILURE CODE [DDTJKA] 1845
FAILURE CODE [DDTKKA] 1847
FAILURE CODE [DDTLKA] 1849
FAILURE CODE [DDTMKA] 1851
FAILURE CODE [DDTNKA] 1853
FAILURE CODE [DDTPKA] 1855
FAILURE CODE [DF10KA] 1857
FAILURE CODE [DF10KB] 1861
FAILURE CODE [DGE5KX] 1866
FAILURE CODE [DGF1KX] 1868
FAILURE CODE [DGR2KB] 1870
FAILURE CODE [DGR6KB] 1872
FAILURE CODE [DGR6L8] 1873
FAILURE CODE [DGT1KX] 1875
FAILURE CODE [DGT4KA] 1877
FAILURE CODE [DGT4KB] 1879
FAILURE CODE [DGT4KY] 1881
FAILURE CODE [DHA4KA] 1883
FAILURE CODE [DHAAMA] 1885
FAILURE CODE [DHABMA] 1886
FAILURE CODE [DHACMA] 1887
FAILURE CODE [DHADMA] 1888
FAILURE CODE [DHP4KY] 1889
FAILURE CODE [DHP4KZ] 1891
FAILURE CODE [DHP5KY] 1893
FAILURE CODE [DHP5KZ] 1895
FAILURE CODE [DHP6KA] 1897
FAILURE CODE [DHP6KX] 1899
FAILURE CODE [DHP6KY] 1901
FAILURE CODE [DHP6KZ] 1903
FAILURE CODE [DHP7KA] 1905
FAILURE CODE [DHP7KX] 1907
FAILURE CODE [DHP7KY] 1909
FAILURE CODE [DHP7KZ] 1911
FAILURE CODE [DHQ2KX] 1913
FAILURE CODE [DHQ4KX] 1915
FAILURE CODE [DHT5KX] 1917
FAILURE CODE [DHT5L6] 1919
FAILURE CODE [DHT8KX] 1921
FAILURE CODE [DHT8ZG] 1923
FAILURE CODE [DHU2KX] 1925
FAILURE CODE [DHU3KX] 1927
FAILURE CODE [DHU6KX] 1929
FAILURE CODE [DHU7KX] 1931
FAILURE CODE [DHU8KX] 1933
FAILURE CODE [DHU9KX] 1935
FAILURE CODE [DHUCKX] 1937
FAILURE CODE [DHUDKX] 1940
FAILURE CODE [DHUHKX] 1942
FAILURE CODE [DHULKX] 1944
FAILURE CODE [DHUMKX] 1947
FAILURE CODE [DHUPKX] 1950
FAILURE CODE [DHUTKX] 1952
FAILURE CODE [DHY9KX] 1954
FAILURE CODE [DJF1KA] 1956
FAILURE CODE [DK30KX] 1958
FAILURE CODE [DK51L5] 1960
FAILURE CODE [DK52KX] 1963
FAILURE CODE [DK53L8] 1965
FAILURE CODE [DK54KX] 1967
FAILURE CODE [DK60KX] 1969
FAILURE CODE [DKD0L6] 1971
FAILURE CODE [DKH0KX] 1973
FAILURE CODE [DKH1KX] 1975
FAILURE CODE [DLF1KA] 1977
FAILURE CODE [DLF1LC] 1978
FAILURE CODE [DLF2KA] 1980
FAILURE CODE [DLF2LC] 1982
FAILURE CODE [DLF6KA] 1984
FAILURE CODE [DLF6L3] 1985
FAILURE CODE [DLF7KA] 1987
FAILURE CODE [DLF7L3] 1988
FAILURE CODE [DLF8KA] 1990
FAILURE CODE [DLF8L3] 1991
FAILURE CODE [DLF8LC] 1992
FAILURE CODE [DLF8MA] 1994
FAILURE CODE [DLF9KA] 1995
FAILURE CODE [DLF9L3] 1996
FAILURE CODE [DLF9LC] 1997
FAILURE CODE [DLF9MA] 1999
FAILURE CODE [DLM3KA] 2000
FAILURE CODE [DLM3LC] 2001
FAILURE CODE [DLM3MB] 2003
FAILURE CODE [DLT3KA] 2004
FAILURE CODE [DLT3LC] 2005
FAILURE CODE [DPQ1KR] 2007
FAILURE CODE [DPQ2KR] 2010
FAILURE CODE [DPQ3KR] 2013
FAILURE CODE [DSJ0KR] 2017
FAILURE CODE [DV00KB] 2018
FAILURE CODE [DW2AKA] 2020
FAILURE CODE [DW2AKB] 2021
FAILURE CODE [DW2AKY] 2023
FAILURE CODE [DW2AL1] 2024
FAILURE CODE [DW2ALH] 2025
FAILURE CODE [DW2BKA] 2026
FAILURE CODE [DW2BKB] 2027
FAILURE CODE [DW2BKY] 2028
FAILURE CODE [DW2BL1] 2029
FAILURE CODE [DW2BLH] 2030
FAILURE CODE [DW35KZ] 2031
FAILURE CODE [DW36KZ] 2033
FAILURE CODE [DW4BK4] 2035
FAILURE CODE [DW4BMA] 2039
FAILURE CODE [DW72KZ] 2043
FAILURE CODE [DW73KA] 2045
FAILURE CODE [DW73KB] 2047
FAILURE CODE [DW73KY] 2049
FAILURE CODE [DW78KZ] 2050
FAILURE CODE [DW7BKB] 2052
FAILURE CODE [DW7BKY] 2054
FAILURE CODE [DW7BKZ] 2055
FAILURE CODE [DW7NKZ] 2057
FAILURE CODE [DWD6KA] 2059
FAILURE CODE [DWD6KB] 2061
FAILURE CODE [DWD6KY] 2063
FAILURE CODE [DWD6MA] 2064
FAILURE CODE [DWD7K4] 2066
FAILURE CODE [DWD7KA] 2067
FAILURE CODE [DWD7KB] 2069
FAILURE CODE [DWD7KY] 2071
FAILURE CODE [DWD7MA] 2072
FAILURE CODE [DWNDKZ] 2073
FAILURE CODE [DWNDMA] 2075
FAILURE CODE [DWNEKZ] 2077
FAILURE CODE [DWNEMA] 2079
FAILURE CODE [DWNMKZ] 2081
FAILURE CODE [DX11K4] 2083
FAILURE CODE [DX11KA] 2085
FAILURE CODE [DX11KB] 2087
FAILURE CODE [DX11KY] 2089
FAILURE CODE [DX11MA] 2090
FAILURE CODE [DX13KA] 2092
FAILURE CODE [DX13KB] 2094
FAILURE CODE [DX13KY] 2096
FAILURE CODE [DX16KA] 2097
FAILURE CODE [DX16KB] 2098
FAILURE CODE [DX16KY] 2100
FAILURE CODE [DX21KA] 2101
FAILURE CODE [DX21KB] 2102
FAILURE CODE [DX21KY] 2104
FAILURE CODE [DX21MA] 2105
FAILURE CODE [DX22KA] 2107
FAILURE CODE [DX22KB] 2108
FAILURE CODE [DX22KY] 2110
FAILURE CODE [DX22MA] 2111
FAILURE CODE [DX23KA] 2113
FAILURE CODE [DX23KB] 2114
FAILURE CODE [DX23KY] 2116
FAILURE CODE [DX23MA] 2117
FAILURE CODE [DX24KA] 2119
FAILURE CODE [DX24KB] 2120
FAILURE CODE [DX24KY] 2122
FAILURE CODE [DX24MA] 2123
FAILURE CODE [DX25MA] 2125
FAILURE CODE [DX26MA] 2126
FAILURE CODE [DX37K4] 2127
FAILURE CODE [DX37KA] 2129
FAILURE CODE [DX37KB] 2130
FAILURE CODE [DX37KY] 2132
FAILURE CODE [DX37MA] 2133
FAILURE CODE [DX38K4] 2135
FAILURE CODE [DX38KA] 2137
FAILURE CODE [DX38KB] 2138
FAILURE CODE [DX38KY] 2140
FAILURE CODE [DX38MA] 2141
FAILURE CODE [DXH1KA] 2143
FAILURE CODE [DXH1KB] 2145
FAILURE CODE [DXH1KY] 2147
FAILURE CODE [DXH2KA] 2148
FAILURE CODE [DXH2KB] 2150
FAILURE CODE [DXH2KY] 2152
FAILURE CODE [DXH3KA] 2155
FAILURE CODE [DXH3KB] 2157
FAILURE CODE [DXH3KY] 2159
FAILURE CODE [DXH4KA] 2162
FAILURE CODE [DXH4KB] 2164
FAILURE CODE [DXH4KY] 2166
FAILURE CODE [DXH5KA] 2169
FAILURE CODE [DXH5KB] 2171
FAILURE CODE [DXH5KY] 2173
FAILURE CODE [DXH6KA] 2176
FAILURE CODE [DXH6KB] 2178
FAILURE CODE [DXH6KY] 2180
FAILURE CODE [DXH7KA] 2183
FAILURE CODE [DXH7KB] 2185
FAILURE CODE [DXH7KY] 2187
FAILURE CODE [DXHHKA] 2189
FAILURE CODE [DXHHKB] 2191
FAILURE CODE [DXHHKY] 2193
FAILURE CODE [DY30MA] 2195
FAILURE CODE [DY30MC] 2197
FAILURE CODE [DY30ME] 2200
FAILURE CODE [F@BYNR] 2202
FAILURE CODE [F@BYNS] 2203
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2204
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2204
MANUAL PREHEATING SYSTEM DOES NOT WORK 2212
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2215
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2217
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2219
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch) 2222
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2225
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2227
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2229
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2231
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2234
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2238
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2240
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2242
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2244
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2246
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2247
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2251
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2255
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2259
REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2261
GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2264
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2266
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2268
MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2270
ALARM BUZZER DOES NOT SOUND 2271
ALARM BUZZER DOES NOT STOP SOUNDING 2273
AISS FUNCTION DOES NOT OPERATE PROPERLY 2275
HOIST LEVER DOES NOT OPERATE PROPERLY 2277
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2279
TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2284
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2288
SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2291
TAIL LAMP DOES NOT LIGHT UP 2294
(LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2297
(HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2299
NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2301
HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2303
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2305
DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 2307
CANNOT ACCESS TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL 2308
CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL BECAUSE THE LOG IN PASSWORD IS UNKNOWN 2315
KOMTRAX Plus CONTROLLER IS NOT DETECTED 2317
KOMTRAX Plus CONTROLLER DOES NOT BECOME ACTIVE 2319
COMMUNICATION BETWEEN MOBILE COMMUNICATION TERMINAL AND KOMTRAX Plus SERVER FAILS 2320
RESTRICTIONS ON RADIO RECEPTION 2322
DATA IS NOT SENT TO KOMTRAX Plus SERVER 2323
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2325
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2325
FAILURE MODE AND CAUSE TABLE 2326
MACHINE DOES NOT START 2336
MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2339
LOCKUP IS NOT RELEASED 2340
ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2341
GEAR IS NOT SHIFTED UP 2343
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2346
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2347
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2348
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2350
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2353
OIL PRESSURE OF TORQUE CONVERTER IS LOW 2354
STEERING WHEEL IS HEAVY TO OPERATE 2355
STEERING WHEEL CANNOT BE OPERATED 2356
STEERING WHEEL WAGGLES 2357
FRONT BRAKE DOES NOT WORK ENOUGH 2358
REAR BRAKE DOES NOT WORK ENOUGH 2359
DUMP BODY RISING SPEED IS LOW 2360
HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2362
DUMP BODY DOES NOT MOVE 2363
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2364
UNUSUAL NOISE IS HEARD FROM AROUND FAN 2365
TROUBLESHOOTING OF ENGINE (S-MODE) 2366
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2366
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2367
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2368
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING:ENGINE CRANKS BUT DOES NOT START) 2369
ENGINE STARTABILITY IS POOR 2370
ENGINE DOES NOT PICK UP SMOOTHLY 2372
ENGINE STOPS DURING OPERATION 2374
ENGINE RUNS ROUGH OR IS UNSTABLE 2376
ENGINE LACKS POWER 2377
KDPF GETS CLOGGED IN A SHORT TIME 2379
ENGINE OIL CONSUMPTION IS EXCESSIVE 2381
OIL BECOMES CONTAMINATED QUICKLY 2382
FUEL CONSUMPTION IS EXCESSIVE 2383
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2384
OIL PRESSURE DROPS 2385
FUEL MIXES INTO ENGINE OIL 2387
WATER MIXES INTO ENGINE OIL (MILKY) 2388
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2389
UNUSUAL NOISE IS HEARD 2390
VIBRATION IS EXCESSIVE 2391
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2392
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2393
ACTIVE REGENERATION TAKES TIME 2394
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2395
50 DISASSEMBLY AND ASSEMBLY 2397
CONTENTS 2398
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2402
HOW TO READ THIS MANUAL 2402
COATING MATERIALS LIST 2404
SPECIAL TOOLS LIST 2408
SKETCHES OF SPECIAL TOOLS 2416
ENGINE AND COOLING SYSTEM 2419
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2419
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY 2420
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY 2431
REMOVE AND INSTALL INJECTOR ASSEMBLY 2447
PROCEDURE TO REMOVE INJECTOR ASSEMBLY 2449
PROCEDURE TO INSTALL INJECTOR ASSEMBLY 2470
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2500
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY 2501
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY 2502
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2505
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY 2507
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY 2552
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2614
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY 2615
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY 2617
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2620
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY 2621
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY 2630
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2640
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY 2640
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY 2641
REMOVE AND INSTALL ALTERNATOR BELT 2643
PROCEDURE TO REMOVE ALTERNATOR BELT 2643
PROCEDURE TO INSTALL ALTERNATOR BELT 2644
REMOVE AND INSTALL COOLER ASSEMBLY 2646
PROCEDURE TO REMOVE COOLER ASSEMBLY 2647
PROCEDURE TO INSTALL COOLER ASSEMBLY 2662
REMOVE AND INSTALL RADIATOR 2676
PROCEDURE TO REMOVE RADIATOR 2677
PROCEDURE TO INSTALL RADIATOR 2683
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2690
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2691
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2693
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2696
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY 2697
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY 2703
REMOVE AND INSTALL ENGINE ASSEMBLY 2710
PROCEDURE TO REMOVE ENGINE ASSEMBLY 2712
PROCEDURE TO INSTALL ENGINE ASSEMBLY 2725
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2738
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL 2738
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL 2740
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2742
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL 2742
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL 2743
REMOVE AND INSTALL DAMPER ASSEMBLY 2748
PROCEDURE TO REMOVE DAMPER ASSEMBLY 2748
PROCEDURE TO INSTALL DAMPER ASSEMBLY 2752
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 2757
PROCEDURE TO DISASSEMBLE DAMPER ASSEMBLY 2758
PROCEDURE TO ASSEMBLE DAMPER ASSEMBLY 2759
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET) 2762
PROCEDURE TO REMOVE KDPF ASSEMBLY 2763
PROCEDURE TO INSTALL KDPF ASSEMBLY 2767
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET) 2773
PROCEDURE TO REMOVE KDPF ASSEMBLY 2774
PROCEDURE TO INSTALL KDPF ASSEMBLY 2780
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2788
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY 2789
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY 2794
REMOVE AND INSTALL KCCV ASSEMBLY 2801
PROCEDURE TO REMOVE KCCV ASSEMBLY 2802
PROCEDURE TO INSTALL KCCV ASSEMBLY 2804
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2807
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY 2807
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY 2808
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2810
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2810
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2811
POWER TRAIN 2813
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2813
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2814
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2819
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2824
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2825
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2833
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY 2851
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY 2852
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY 2858
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 2869
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY 2871
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY 2890
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 2918
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY 2919
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY 2922
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 2925
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY 2926
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY 2932
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD 2942
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD 2942
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD 2943
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY 2944
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY 2944
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY 2945
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2946
DISASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2946
ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2946
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2949
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2950
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2953
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2957
PROCEDURE TO REMOVE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2957
PROCEDURE TO INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2960
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2964
PROCEDURE TO DISASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2965
PROCEDURE TO ASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2970
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 2978
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY 2978
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY 2980
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 2982
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2982
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2982
STEERING SYSTEM 2983
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 2983
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY 2984
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY 2985
UNDERCARRIAGE AND FRAME 2988
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 2988
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY 2988
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY 2989
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 2991
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY 2991
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY 2993
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2995
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY 2995
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2996
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFERRING) 2999
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 2999
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 3001
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 3005
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY 3005
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 3006
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFERRING) 3007
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 3008
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 3009
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY 3013
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY 3013
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY 3015
HYDRAULIC SYSTEM 3019
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 3019
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY 3020
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY 3022
WORK EQUIPMENT 3028
REMOVE AND INSTALL DUMP BODY ASSEMBLY 3028
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY 3028
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY 3029
CAB RELATED PARTS 3032
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 3032
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY 3033
PROCEDURE TO INSTALL AIR CONDITIONER ASSEMBLY 3040
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3048
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY 3048
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY 3050
REMOVE AND INSTALL SEATBELT 3053
PROCEDURE TO REMOVE SEAT BELT 3053
PROCEDURE TO INSTALL SEAT BELT 3054
ELECTRICAL SYSTEM 3056
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3056
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY 3056
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY 3058
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3061
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY 3061
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3062
REMOVE AND INSTALL ABS CONTROLLER ASSEMBLY 3064
PROCEDURE TO REMOVE ABS CONTROLLER ASSEMBLY 3064
PROCEDURE TO INSTALL ABS CONTROLLER ASSEMBLY 3065
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3066
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY 3066
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3067
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3068
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY 3069
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY 3071
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3074
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY 3074
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY 3075
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3076
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 3076
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3077
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3079
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR 3079
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR 3080
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 3082
PROCEDURE TO REMOVE KOMTRAX PLUS CONTROLLER ASSEMBLY 3082
PROCEDURE TO INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 3083
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL 3085
REMOVE MOBILE COMMUNICATION TERMINAL 3085
INSTALL MOBILE COMMUNICATION TERMINAL 3086
REMOVE AND INSTALL DC-DC CONVERTER 3088
REMOVE DC-DC CONVERTER 3088
INSTALL DC-DC CONVERTER 3089
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3090
REMOVE MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3090
INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3095
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY 3101
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY 3101
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY 3103
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 3104
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY 3104
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY 3105
60 MAINTENANCE STANDARD 3109
CONTENTS 3110
ENGINE AND COOLING SYSTEM 3111
MAINTENANCE STANDARD FOR ENGINE MOUNT 3111
MAINTENANCE STANDARD FOR OUTPUT SHAFT 3112
MAINTENANCE STANDARD FOR COOLING FAN PUMP 3114
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP 3116
MAINTENANCE STANDARD FOR COOLING FAN MOTOR 3117
POWER TRAIN 3119
MAINTENANCE STANDARD FOR DRIVE SHAFT 3119
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT 3120
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO 3121
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE 3125
MAINTENANCE STANDARD FOR TRANSMISSION 3127
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE 3133
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV 3134
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV 3135
MAINTENANCE STANDARD FOR FRONT AXLE 3136
MAINTENANCE STANDARD FOR REAR AXLE 3137
MAINTENANCE STANDARD FOR DIFFERENTIAL 3138
MAINTENANCE STANDARD FOR FINAL DRIVE 3139
STEERING SYSTEM 3140
MAINTENANCE STANDARD FOR STEERING COLUMN 3140
MAINTENANCE STANDARD FOR STEERING LINKAGE 3141
MAINTENANCE STANDARD FOR DEMAND VALVE 3144
MAINTENANCE STANDARD FOR STEERING CYLINDER 3147
BRAKE SYSTEM 3148
MAINTENANCE STANDARD FOR SLACK ADJUSTER 3148
MAINTENANCE STANDARD FOR FRONT BRAKE 3149
MAINTENANCE STANDARD FOR REAR BRAKE 3150
UNDERCARRIAGE AND FRAME 3152
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER 3152
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER 3155
HYDRAULIC SYSTEM 3157
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP 3157
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP 3158
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 3160
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP 3161
MAINTENANCE STANDARD FOR HOIST VALVE 3163
WORK EQUIPMENT 3165
MAINTENANCE STANDARD FOR HOIST CYLINDER 3165
CAB RELATED PARTS 3166
MAINTENANCE STANDARD FOR CAB MOUNT 3166
80 OTHERS 3167
CONTENTS 3168
AIR CONDITIONER SYSTEM 3170
PRECAUTIONS FOR REFRIGERANT 3170
AIR CONDITIONER COMPONENT 3171
SPECIFICATIONS OF AIR CONDITIONER 3173
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3174
OUTLINE OF REFRIGERATION CYCLE 3175
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3177
AIR CONDITIONER UNIT 3177
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3177
FUNCTION OF AIR CONDITIONER UNIT 3178
COMPONENT PARTS OF AIR CONDITIONER UNIT 3181
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3182
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3182
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3182
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3182
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3183
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3183
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3183
FUNCTION OF DUAL PRESSURE SWITCH 3184
AIR CONDITIONER CONTROLLER 3185
STRUCTURE OF AIR CONDITIONER CONTROLLER 3185
COMPRESSOR 3186
STRUCTURE OF COMPRESSOR 3186
SPECIFICATIONS OF COMPRESSOR 3186
FUNCTION OF COMPRESSOR 3186
CONDENSER 3187
STRUCTURE OF CONDENSER 3187
SPECIFICATIONS OF CONDENSER 3187
FUNCTION OF CONDENSER 3187
AIR CONDITIONER RELATED SENSORS 3189
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3189
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3189
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3190
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3193
AIR CONDITIONER SYSTEM DIAGRAM 3195
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3196
FUNCTION OF AIR CONDITIONER CONTROLLER 3197
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3198
TESTING AIR LEAKAGE (DUCT) 3201
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3201
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3204
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3205
TEST VENT (MODE) CHANGEOVER 3207
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3207
TESTING FRESH/RECIRC AIR CHANGEOVER 3208
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3208
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3209
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3209
TEST RELAYS 3210
METHOD FOR TESTING RELAYS 3210
AIR CONDITIONER TROUBLESHOOTING CHART 1 3212
AIR CONDITIONER TROUBLESHOOTING CHART 2 3213
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3216
FAILURE CODE [879AKA] 3218
FAILURE CODE [879AKB] 3219
FAILURE CODE [879BKA] 3220
FAILURE CODE [879BKB] 3221
FAILURE CODE [879CKA] 3223
FAILURE CODE [879CKB] 3224
FAILURE CODE [879EMC] 3225
FAILURE CODE [879FMC] 3226
FAILURE CODE [879GKX] 3227
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3228
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3230
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3233
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3235
TROUBLESHOOTING USING GAUGE PRESSURE 3237
CONNECTION OF SERVICE TOOL 3239
METHOD FOR CONNECTING SERVICE TOOL 3239
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3241
HANDLE COMPRESSOR OIL 3243
METHOD FOR REPLACING DESICCANT 3245
90 CIRCUIT DIAGRAMS 3247
CONTENTS 3248
ABBREVIATION LIST 3249
HYDRAULIC CIRCUIT DIAGRAM 3255
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3255
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3259
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3261
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3263
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3265
ELECTRICAL CIRCUIT DIAGRAM 3267
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 3267
INTERNAL CAB ELECTRICAL DIAGRAM (1/11) 3271
INTERNAL CAB ELECTRICAL DIAGRAM (2/11) 3273
INTERNAL CAB ELECTRICAL DIAGRAM (3/11) 3275
INTERNAL CAB ELECTRICAL DIAGRAM (4/11) 3277
INTERNAL CAB ELECTRICAL DIAGRAM (5/11) 3279
INTERNAL CAB ELECTRICAL DIAGRAM (6/11) 3281
INTERNAL CAB ELECTRICAL DIAGRAM (7/11) 3283
INTERNAL CAB ELECTRICAL DIAGRAM (8/11) 3285
INTERNAL CAB ELECTRICAL DIAGRAM (9/11) 3287
INTERNAL CAB ELECTRICAL DIAGRAM (10/11) 3289
INTERNAL CAB ELECTRICAL DIAGRAM(11/11) 3291
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8) 3293
EXTERNAL CAB ELECTRICAL DIAGRAM (2/8) 3295
EXTERNAL CAB ELECTRICAL DIAGRAM (3/8) 3297
EXTERNAL CAB ELECTRICAL DIAGRAM (4/8) 3299
EXTERNAL CAB ELECTRICAL DIAGRAM (5/8) 3301
EXTERNAL CAB ELECTRICAL DIAGRAM (6/8) 3303
EXTERNAL CAB ELECTRICAL DIAGRAM (7/8) 3305
EXTERNAL CAB ELECTRICAL DIAGRAM (8/8) 3307
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2) 3309
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2) 3311
INDEX 3313

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