Komatsu HD465-8E0 HD605-8E0 Dump Truck Shop Manual SEN06768-08 – PDF DOWNLOAD

Description

Komatsu HD465-8E0 HD605-8E0 Dump Truck Shop Manual SEN06768-08 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HD465-8E0 HD605-8E0 Dump Truck Shop Manual SEN06768-08 – PDF DOWNLOAD

SERIAL NUMBERS

HD465-35001 and up
HD605-35001 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 HD465-8E0 HD605-8E0 Dump Truck Shop Manual SEN06768-08 – 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 WHEN YOU DISCONNECT AND CONNECT PIPINGS 45
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 55
PRACTICAL USE OF KOMTRAX 56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 71
HOW TO READ ELECTRICAL WIRE CODE 72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 76
STANDARD TIGHTENING TORQUE TABLE 79
CONVERSION TABLE 86
01 SPECIFICATION 91
CONTENTS 92
SPECIFICATIONS 93
SPECIFICATION DRAWING 93
DIAGRAM SPECIFICATION:HD465-8E0 93
DIAGRAM SPECIFICATION:HD605-8E0 95
SPECIFICATIONS 97
SPECIFICATIONS:HD465-8E0 97
SPECIFICATIONS:HD605-8E0 102
WEIGHT TABLE 107
WEIGHT TABLE:HD465-8E0 107
WEIGHT TABLE:HD605-8E0 108
FUEL, COOLANT, LUBRICANT 109
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 109
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
NOx CONTROL SYSTEM 116
FUNCTION OF NOx CONTROL SYSTEM 116
BOOT-UP SYSTEM 119
BOOT UP SYSTEM DIAGRAM 119
BOOT UP SYSTEM DIAGRAM (For machines equipped with emergency engine stop switch) 120
SYSTEM OPERATING LAMP SYSTEM 122
OPERATION LAMP SYSTEM DIAGRAM 122
FUNCTION OF OPERATION LAMP SYSTEM 122
BATTERY DISCONNECT SWITCH 123
BATTERY DISCONNECT SWITCH DIAGRAM 123
FUNCTION OF BATTERY DISCONNECT SWITCH 123
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 124
ENGINE SHUTDOWN SECONDARY SWITCH 126
ENGINE SECONDARY SHUTDOWN SWITCH DIAGRAM 126
FUNCTION OF ENGINE SECONDARY SHUTDOWN SWITCH 126
OPERATION OF ENGINE SECONDARY SHUTDOWN SWITCH 127
ENGINE SYSTEM 128
ENGINE SYSTEM DIAGRAM 128
FUNCTION OF ENGINE SYSTEM 129
ENGINE CONTROL SYSTEM 131
ENGINE CONTROL SYSTEM DIAGRAM 131
AUTOMATIC IDLE STOP SYSTEM 135
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 135
ENGINE SYSTEM 137
OUTPUT SHAFT 137
VGT 139
EGR SYSTEM 143
EGR VALVE 146
EGR COOLER 147
KCCV SYSTEM 149
KCCV VENTILATOR 151
CDR VALVE 153
KDPF 154
COOLING SYSTEM 158
COOLING SYSTEM DIAGRAM 158
SPECIFICATIONS OF COOLING SYSTEM 159
RADIATOR FAN CONTROL SYSTEM 160
RADIATOR FAN CONTROL SYSTEM DIAGRAM 160
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 160
COOLING SYSTEM 162
COOLING FAN, HOIST PUMP 162
COOLING FAN MOTOR 169
CONTROL SYSTEM 176
CONTROL SYSTEM DIAGRAM 176
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 178
RETARDER AND HOIST CONTROL SYSTEM 179
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 179
MACHINE MONITOR SYSTEM 181
MACHINE MONITOR SYSTEM DIAGRAM 181
FUNCTION OF MACHINE MONITOR SYSTEM 182
REARVIEW MONITOR SYSTEM 183
REARVIEW MONITOR SYSTEM DIAGRAM 183
FUNCTION OF REARVIEW MONITOR SYSTEM 183
KOMTRAX Plus SYSTEM 184
SYSTEM DIAGRAM OF KOMTRAX Plus SYSTEM 184
SYSTEM DIAGRAM OF KOMTRAX Plus SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 186
FUNCTION OF KOMTRAX PLUS SYSTEM 187
PAYLOAD METER SYSTEM 190
PAYLOAD METER SYSTEM DIAGRAM 190
PAYLOAD METER SYSTEM DIAGRAM 191
FUNCTION OF PAYLOAD METER SYSTEM 191
MEASUREMENT PRINCIPLE OF LOADING MASS 192
MACHINE LOCK-OUT SYSTEM 202
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM 202
FUNCTION OF MACHINE LOCK-OUT SYSTEM 203
OPERATION OF MACHINE LOCK-OUT SYSTEM 203
CONTROL SYSTEM 204
MACHINE MONITOR 204
SWITCH PANEL 224
REARVIEW MONITOR 225
REARVIEW CAMERA 227
KOMTRAX TERMINAL 228
KOMTRAX Plus CONTROLLER 230
COMMUNICATION TERMINAL 235
WIRELESS LAN UNIT 236
TRANSMISSION CONTROLLER 237
RETARDER AND HOIST CONTROLLER 241
MONITOR CONTROLLER 246
ENGINE CONTROLLER 251
ABS CONTROLLER 263
ACCELERATOR PEDAL 267
GEAR SHIFT LEVER 268
RETARDER CONTROL LEVER 269
FUEL FEED PUMP 270
FUEL FEED PUMP SWITCH 271
HYDRAULIC SYSTEM 273
HYDRAULIC SYSTEM DIAGRAM 273
HYDRAULIC SYSTEM 274
HYDRAULIC TANK 274
STEERING AND HOIST PUMP 275
LS VALVE 281
CO VALVE 282
POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 285
BRAKE COOLING, CONTROL TRIPLE PUMP 287
HOIST VALVE 289
POWER TRAIN SYSTEM 295
POWER TRAIN DIAGRAM 295
TRANSMISSION CONTROL SYSTEM 297
TRANSMISSION CONTROL SYSTEM DIAGRAM 297
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 298
GEAR SHIFT CONTROL SYSTEM 302
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 302
DIRECTION CONTROL SYSTEM 304
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 304
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 304
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 305
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 305
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 305
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 306
TRAVEL SPEED LIMITATION SYSTEM 307
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 307
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 308
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 308
POWER TRAIN SYSTEM 311
DRIVE SHAFT 311
TORQUE CONVERTER, PTO 313
LOCKUP CLUTCH ECMV 317
TRANSMISSION 320
TRANSMISSION CONTROL VALVE 341
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 343
AXLE 352
DIFFERENTIAL 354
FINAL DRIVE 356
WORK EQUIPMENT SYSTEM 357
WORK EQUIPMENT CONTROL 357
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 357
FUNCTION OF WORK EQUIPMENT CONTROL 357
HOIST CONTROL 358
HOIST CONTROL SYSTEM DIAGRAM 358
FUNCTION OF HOIST CONTROL 358
WORK EQUIPMENT SYSTEM 360
DUMP LEVER 360
HOIST EPC VALVE 365
STEERING SYSTEM 366
STEERING SYSTEM DIAGRAM 366
STEERING SYSTEM FUNCTION 367
STEERING COLUMN 368
STRUCTURE OF STEERING COLUMN 368
STEERING LINKAGE 369
STRUCTURE OF STEERING LINKAGE 369
STEERING SYSTEM 370
DEMAND VALVE 370
STEERING RELIEF VALVE 376
ORBITROL VALVE 378
STEERING PUMP SELECTOR SOLENOID VALVE 384
CROSS OVER RELIEF VALVE 385
SECONDARY STEERING PUMP 386
SECONDARY STEERING MOTOR 387
BRAKE SYSTEM 388
BRAKE SYSTEM DIAGRAM 388
RETARDER CONTROL 390
RETARDER CONTROL SYSTEM DIAGRAM 390
FUNCTION OF RETARDER CONTROL 390
ARSC SYSTEM 391
ARCS SYSTEM DIAGRAM 391
FUNCTION OF ARSC SYSTEM 391
BRAKE SYSTEM 392
BRAKE CHARGE PUMP 392
PARKING BRAKE SOLENOID VALVE 393
ACCUMULATOR CHARGE VALVE 394
BRAKE CIRCUIT ACCUMULATOR 398
BRAKE VALVE 399
SECONDARY BRAKE VALVE 403
SECONDARY BRAKE RELAY VALVE 404
PROPORTIONAL PRESSURE REDUCING VALVE 405
SLACK ADJUSTER 406
BRAKE 408
PARKING BRAKE 411
BRAKE SUB-TANK 413
ABS 414
ABS SYSTEM DIAGRAM 414
ABS SYSTEM DIAGRAM 415
FUNCTION OF ABS 416
OPERATION OF ABS 416
COMPONENT PARTS OF ABS 419
AUTO-GREASING SYSTEM 422
AUTO-GREASING SYSTEM DIAGRAM 422
AUTO-GREASING SYSTEM DIAGRAM 425
FUNCTION OF AUTO-GREASING SYSTEM 426
COMPONENT PARTS OF AUTO-GREASING SYSTEM 427
AUTO-GREASING PUMP 427
AUTO-GREASING INJECTOR 429
UNDERCARRIAGE AND FRAME 433
SUSPENSION 433
STRUCTURE OF SUSPENSION 433
FUNCTION OF SUSPENSION 433
FRONT SUSPENSION 435
STRUCTURE OF FRONT SUSPENSION 435
FUNCTION OF FRONT SUSPENSION 436
REAR SUSPENSION 437
STRUCTURE OF REAR SUSPENSION 437
FUNCTION OF REAR SUSPENSION 438
SUSPENSION CYLINDER 439
STRUCTURE OF SUSPENSION CYLINDER 439
FUNCTION OF SUSPENSION CYLINDER 439
OPERATION OF SUSPENSION CYLINDER 439
WORK EQUIPMENT 441
STRUCTURE OF WORK EQUIPMENT 441
FUNCTION OF WORK EQUIPMENT 442
CAB RELATED PARTS 443
ROPS CAB 443
STRUCTURE OF ROPS CAB 443
FUNCTION OF ROPS CAB 443
CAB MOUNT 444
STRUCTURE OF CAB MOUNT 444
FUNCTION OF CAB MOUNT 444
20 STANDARD VALUE TABLE 445
CONTENTS 446
STANDARD VALUE TABLE FOR ENGINE 447
STANDARD VALUE TABLE FOR ENGINE:HD465-8E0 447
STANDARD VALUE TABLE FOR ENGINE:HD605-8E0 450
STANDARD VALUE TABLE FOR MACHINE 453
STANDARD VALUE TABLE FOR MACHINE:HD465-8E0 453
STANDARD VALUE TABLE FOR MACHINE:HD605-8E0 471
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE 489
30 TESTING AND ADJUSTING 491
CONTENTS 492
RELATED INFORMATION ON TESTING AND ADJUSTING 496
TOOLS TO TEST AND ADJUST 496
DIAGRAM FOR TEST AND ADJUST TOOLS 506
ENGINE AND COOLING SYSTEM 507
TEST ENGINE SPEED 507
PROCEDURE TO TEST ENGINE SPEED 507
TEST BOOST PRESSURE 509
BOOST PRESSURE TEST BY MACHINE MONITOR 509
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 510
TESTING EXHAUST GAS TEMPERATURE 513
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR 513
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 515
TEST EXHAUST GAS COLOR 517
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER 517
TEST EXHAUST GAS COLOR WITH SMOKE METER 518
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 520
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 520
TEST AND ADJUST VALVE CLEARANCE 523
TEST VALVE CLEARANCE 523
ADJUST VALVE CLEARANCE 524
COMPRESSION TEST 526
COMPRESSION PRESSURE TEST 526
BLOWBY PRESSURE TEST 530
BLOWBY PRESSURE TEST 530
TEST ENGINE OIL PRESSURE 533
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR 533
TEST ENGINE OIL PRESSURE 533
EGR VALVE AND VGT OIL PRESSURE TEST 535
EGR VALVE AND VGT OIL PRESSURE TEST 535
FUEL PRESSURE TEST 536
FUEL PRESSURE TEST 536
FUEL RETURN RATE AND LEAKAGE TEST 538
FUEL RETURN RATE AND LEAKAGE TEST 539
BLEEDING AIR FROM FUEL SYSTEM 542
BLEED AIR FROM FUEL SYSTEM 542
FUEL CIRCUIT LEAK TEST 544
FUEL CIRCUIT LEAK TEST 544
SUPPLY PUMP TEST 546
SUPPLY PUMP TEST 546
CYLINDER CUT-OUT MODE 549
NO-INJECTION CRANKING 550
CLEAN FUEL DOSER 551
CLEAN FUEL DOSER 551
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 554
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 554
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 561
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 561
TEST TORQUE CONVERTER STALL SPEED 562
TEST TORQUE CONVERTER STALL SPEED 562
RADIATOR FAN SPEED TEST 564
RADIATOR FAN SPEED TEST 564
POWER TRAIN 566
TEST POWER TRAIN OIL PRESSURE 566
POWER TRAIN OIL PRESSURE TEST 568
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 580
ADJUST TRANSMISSION INPUT SPEED SENSOR 580
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR 581
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR 581
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 582
ADJUST TRANSMISSION OUTPUT SPEED SENSOR 582
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS 583
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SENSORS 583
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 584
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 584
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEM 585
STEERING SYSTEM 590
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 590
TEST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR 590
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS 590
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 592
TEST SUPPLY PRESSURE OF ORBITROL VALVE 593
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 593
TEST STEERING CYLINDER PRESSURE 595
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 595
BLEED AIR FROM STEERING CYLINDER CIRCUIT 597
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 597
BRAKE SYSTEM 598
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 598
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 598
TEST WHEEL BRAKE OIL PRESSURE 599
FRONT BRAKE ACTUATION PRESSURE TEST 599
REAR BRAKE ACTUATION PRESSURE TEST 600
RETARDER BRAKE PRESSURE TEST 601
RETARDER BRAKE ACTUATION PRESSURE TEST (FOR MACHINE WITH KTCS) 602
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 604
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR 604
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 604
ADJUST BRAKE ACCUMULATOR PRESSURE 605
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 607
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 607
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 611
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 615
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 620
TEST BRAKE PERFORMANCE 621
TEST FOOT BRAKE PERFORMANCE 621
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 621
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 622
BLEED AIR FROM BRAKE CIRCUIT 624
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 624
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT (FOR MACHINE WITH ABS) 625
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT 626
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/WITHOUT KTCS) 628
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 629
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH ABS/KTCS) 631
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 634
TEST PARKING BRAKE OIL PRESSURE 636
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 636
RELEASE PARKING BRAKE MANUALLY 637
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY 637
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 638
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 638
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE 638
TEST THE QUANTITY OF REAR BRAKE DISC WEAR 640
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR 640
HYDRAULIC SYSTEM 641
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 641
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 641
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 642
TEST HOIST CYLINDER SUPPLY PRESSURE 643
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 643
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 645
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 645
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 646
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 647
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 647
TEST AND ADJUST FRONT SUSPENSION CYLINDER 649
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 649
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 650
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 654
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 654
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 655
TEST AND ADJUST REAR SUSPENSION CYLINDER 657
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 658
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 659
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 663
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 663
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS 663
WORK EQUIPMENT 665
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 665
PROCEDURE TO TEST THE BODY POSITION SENSOR 665
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR 665
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR 665
LOWER THE BODY MANUALLY 667
PROCEDURE TO LOWER THE BODY MANUALLY 667
LIFT THE BODY MANUALLY 668
PROCEDURE TO RAISE THE BODY MANUALLY 668
CAB RELATED PARTS 669
ADJUST STEERING WHEEL TILT LOCK LEVER 669
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 669
ADJUST RATTLING OPERATOR’S SEAT 671
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 671
ELECTRICAL SYSTEM 672
SET AND ADJUST EACH EQUIPMENT 672
SET AND OPERATE OF MACHINE MONITOR 676
OPERATOR MODE 680
SERVICE MODE 693
ABNORMALITY RECORD MENU 719
DEFAULT MENU 733
DIAGNOSTIC TESTS MENU 748
ADJUSTMENT MENU 760
PROCEDURE TO CRANK WITH NO-INJECTION 783
PAYLOAD METER SETTING 786
PROCEDURE FOR MANUAL SNAP SHOT 805
KOMTRAX SETTINGS MENU 809
PROCEDURE TO DISPLAY SERVICE MESSAGE 811
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL 813
STOP USE OF KOMTRAX TERMINAL 817
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 819
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 821
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 821
SETTING DEFAULT OF WIRELESS LAN MODEM 824
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM 824
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION 825
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 827
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA 827
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 831
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED 831
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 834
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED 834
SETTING OF MOBILE COMMUNICATION TERMINAL 837
SETTING OF MOBILE COMMUNICATION TERMINAL 837
ADJUST REARVIEW CAMERA ANGLE 847
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 847
ADJUST OPTICAL AXIS OF HEAD LAMP 848
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 848
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK 852
BATTERY DISCONNECT SWITCH 853
BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 855
TEST DIODES 857
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 857
PROCEDURE TO TEST DIODE USING ANALOG TESTER 857
Pm-CLINIC 858
Pm CLINIC SERVICE 858
Pm CLINIC CHECK SHEET: HD465-8E0 862
Pm CLINIC CHECK SHEET: HD605-8E0 870
PERFORMING QUICK Pm 878
PROCEDURE TO PERFORM QUICK Pm 878
40 TROUBLESHOOTING 883
CONTENTS 884
RELATED INFORMATION ON TROUBLESHOOTING 897
GENERAL TROUBLESHOOTING POINTS 897
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS 898
SEQUENCE OF EVENTS IN TROUBLESHOOTING 906
CHECKS BEFORE TROUBLESHOOTING 908
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 910
WALK-AROUND CHECK 910
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 912
CHECK FUEL LEVEL AND TYPE 912
CHECK IMPURE INGREDIENT IN FUEL 912
CHECK FUEL PREFILTER 912
CHECK MAIN FILTER 914
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 916
CHECK COOLANT LEVEL (RESERVOIR TANK) 917
CHECK CLOGGING OF AIR CLEANER 918
OUTER ELEMENT – CLEAN 919
REPLACE ELEMENT 921
CHECK HYDRAULIC OIL LEVEL 922
CHECK HYDRAULIC OIL STRAINER 923
CHECK HYDRAULIC FILTER 923
CHECK OIL LEVEL IN TRANSMISSION CASE 924
CHECK OIL LEVEL IN DIFFERENTIAL CASE 924
CHECK OIL LEVEL IN FINAL DRIVE CASE 925
BLEED AIR FROM FUEL SYSTEM 925
BLEED AIR FROM HYDRAULIC SYSTEM 925
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 925
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 931
PROCEDURE FOR TESTING AND TROUBLESHOOTING 941
SYMPTOM AND TROUBLESHOOTING NUMBERS 943
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 946
CONNECTORS LIST AND LAYOUT 948
CONNECTOR CONTACT IDENTIFICATION 978
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1020
FUSE LOCATION TABLE 1026
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1032
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1036
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1038
PREPARATION OF SHORT SOCKET ADAPTER (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135]) 1044
FAILURE CODES TABLE 1046
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1071
FAILURE CODE [1500L0] 1071
FAILURE CODE [15B0NX] 1072
FAILURE CODE [15F0KM] 1074
FAILURE CODE [15F0MB] 1075
FAILURE CODE [15F7KM] 1076
FAILURE CODE [15G0MW] 1077
FAILURE CODE [15G7KM] 1079
FAILURE CODE [15H0MW] 1080
FAILURE CODE [15J0MW] 1082
FAILURE CODE [15K0MW] 1084
FAILURE CODE [15L0MW] 1086
FAILURE CODE [15M0MW] 1088
FAILURE CODE [15N0MW] 1090
FAILURE CODE [15SBL1] 1092
FAILURE CODE [15SBMA] 1095
FAILURE CODE [15SCL1] 1097
FAILURE CODE [15SCMA] 1100
FAILURE CODE [15SDL1] 1102
FAILURE CODE [15SDMA] 1105
FAILURE CODE [15SEL1] 1107
FAILURE CODE [15SEMA] 1110
FAILURE CODE [15SFL1] 1112
FAILURE CODE [15SFMA] 1115
FAILURE CODE [15SGL1] 1117
FAILURE CODE [15SGMA] 1120
FAILURE CODE [15SHL1] 1122
FAILURE CODE [15SHMA] 1125
FAILURE CODE [15SJMA] 1127
FAILURE CODE [2C4MNX] 1128
FAILURE CODE [2F00KM] 1130
FAILURE CODE [2G42ZG] 1133
FAILURE CODE [2G43ZG] 1134
FAILURE CODE [6014NX] 1135
FAILURE CODE [879AKA] 1137
FAILURE CODE [879AKB] 1138
FAILURE CODE [879BKA] 1139
FAILURE CODE [879BKB] 1140
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 [989Y00] 1152
FAILURE CODE [A1U0N3] 1153
FAILURE CODE [A1U0N4] 1155
FAILURE CODE [AA10NX] 1157
FAILURE CODE [AB00KE] 1159
FAILURE CODE [AB00KY] 1161
FAILURE CODE [AQ00N3] 1162
FAILURE CODE [AQ00N4] 1163
FAILURE CODE [AQ10N3] 1164
FAILURE CODE [AS00R2] 1165
FAILURE CODE [AS00R3] 1166
FAILURE CODE [AS00R4] 1167
FAILURE CODE [AS00R6] 1168
FAILURE CODE [B@BAZG] 1169
FAILURE CODE [B@BAZK] 1170
FAILURE CODE [B@BCNS] 1171
FAILURE CODE [B@BCQA] 1172
FAILURE CODE [B@BCZK] 1174
FAILURE CODE [B@C7NS] 1176
FAILURE CODE [B@CENS] 1178
FAILURE CODE [B@JANS] 1179
FAILURE CODE [CA115] 1180
FAILURE CODE [CA122] 1184
FAILURE CODE [CA123] 1186
FAILURE CODE [CA131] 1188
FAILURE CODE [CA132] 1190
FAILURE CODE [CA135] 1192
FAILURE CODE [CA141] 1194
FAILURE CODE [CA144] 1196
FAILURE CODE [CA145] 1198
FAILURE CODE [CA153] 1200
FAILURE CODE [CA154] 1202
FAILURE CODE [CA187] 1204
FAILURE CODE [CA212] 1206
FAILURE CODE [CA213] 1208
FAILURE CODE [CA221] 1210
FAILURE CODE [CA222] 1212
FAILURE CODE [CA227] 1214
FAILURE CODE [CA234] 1216
FAILURE CODE [CA238] 1217
FAILURE CODE [CA239] 1219
FAILURE CODE [CA271] 1221
FAILURE CODE [CA272] 1223
FAILURE CODE [CA273] 1224
FAILURE CODE [CA274] 1226
FAILURE CODE [CA322] 1227
FAILURE CODE [CA323] 1229
FAILURE CODE [CA324] 1231
FAILURE CODE [CA325] 1233
FAILURE CODE [CA331] 1235
FAILURE CODE [CA332] 1237
FAILURE CODE [CA343] 1239
FAILURE CODE [CA351] 1242
FAILURE CODE [CA352] 1245
FAILURE CODE [CA356] 1247
FAILURE CODE [CA357] 1249
FAILURE CODE [CA386] 1251
FAILURE CODE [CA431] 1253
FAILURE CODE [CA432] 1256
FAILURE CODE [CA441] 1259
FAILURE CODE [CA442] 1262
FAILURE CODE [CA449] 1265
FAILURE CODE [CA451] 1266
FAILURE CODE [CA452] 1268
FAILURE CODE [CA515] 1270
FAILURE CODE [CA516] 1272
FAILURE CODE [CA553] 1274
FAILURE CODE [CA555] 1275
FAILURE CODE [CA556] 1277
FAILURE CODE [CA559] 1279
FAILURE CODE [CA595] 1284
FAILURE CODE [CA687] 1286
FAILURE CODE [CA689] 1288
FAILURE CODE [CA691] 1290
FAILURE CODE [CA692] 1292
FAILURE CODE [CA697] 1294
FAILURE CODE [CA698] 1295
FAILURE CODE [CA731] 1296
FAILURE CODE [CA778] 1299
FAILURE CODE [CA1117] 1302
FAILURE CODE [CA1135] 1305
FAILURE CODE [CA1257] 1308
FAILURE CODE [CA1664] 1309
FAILURE CODE [CA1691] 1311
FAILURE CODE [CA1695] 1314
FAILURE CODE [CA1696] 1316
FAILURE CODE [CA1843] 1318
FAILURE CODE [CA1844] 1320
FAILURE CODE [CA1879] 1322
FAILURE CODE [CA1881] 1324
FAILURE CODE [CA1883] 1326
FAILURE CODE [CA1921] 1329
FAILURE CODE [CA1922] 1331
FAILURE CODE [CA1923] 1334
FAILURE CODE [CA1924] 1336
FAILURE CODE [CA1925] 1341
FAILURE CODE [CA1927] 1345
FAILURE CODE [CA1928] 1347
FAILURE CODE [CA1942] 1349
FAILURE CODE [CA1963] 1351
FAILURE CODE [CA1977] 1359
FAILURE CODE [CA1993] 1361
FAILURE CODE [CA2185] 1364
FAILURE CODE [CA2186] 1366
FAILURE CODE [CA2249] 1368
FAILURE CODE [CA2265] 1374
FAILURE CODE [CA2266] 1376
FAILURE CODE [CA2271] 1378
FAILURE CODE [CA2272] 1380
FAILURE CODE [CA2349] 1382
FAILURE CODE [CA2353] 1384
FAILURE CODE [CA2357] 1386
FAILURE CODE [CA2381] 1389
FAILURE CODE [CA2382] 1391
FAILURE CODE [CA2383] 1393
FAILURE CODE [CA2386] 1395
FAILURE CODE [CA2387] 1397
TROUBLESHOOTING FLOWCHART 1401
FAILURE CODE [CA2555] 1402
FAILURE CODE [CA2556] 1404
FAILURE CODE [CA2637] 1406
FAILURE CODE [CA2639] 1408
FAILURE CODE [CA2732] 1410
FAILURE CODE [CA2733] 1412
FAILURE CODE [CA2741] 1414
FAILURE CODE [CA2765] 1418
FAILURE CODE [CA2777] 1419
FAILURE CODE [CA2878] 1421
FAILURE CODE [CA2881] 1426
FAILURE CODE [CA3133] 1432
FAILURE CODE [CA3134] 1434
FAILURE CODE [CA3135] 1436
FAILURE CODE [CA3167] 1439
FAILURE CODE [CA3251] 1444
FAILURE CODE [CA3253] 1446
FAILURE CODE [CA3254] 1450
FAILURE CODE [CA3255] 1453
FAILURE CODE [CA3256] 1455
FAILURE CODE [CA3311] 1457
FAILURE CODE [CA3312] 1459
FAILURE CODE [CA3313] 1461
FAILURE CODE [CA3314] 1462
FAILURE CODE [CA3315] 1463
FAILURE CODE [CA3316] 1466
FAILURE CODE [CA3317] 1467
FAILURE CODE [CA3318] 1468
FAILURE CODE [CA3319] 1471
FAILURE CODE [CA3321] 1472
FAILURE CODE [CA3322] 1473
FAILURE CODE [CA3419] 1476
FAILURE CODE [CA3421] 1478
FAILURE CODE [CA4151] 1480
FAILURE CODE [CA4158] 1483
FAILURE CODE [CA4161] 1485
FAILURE CODE [CA4162] 1487
FAILURE CODE [CA4163] 1489
FAILURE CODE [CA4259] 1491
FAILURE CODE [CA4952] 1493
FAILURE CODE [CA5383] 1496
FAILURE CODE [CB115] 1497
FAILURE CODE [CB187] 1501
FAILURE CODE [CB227] 1502
FAILURE CODE [CB238] 1503
FAILURE CODE [CB239] 1505
FAILURE CODE [CB271] 1507
FAILURE CODE [CB272] 1509
FAILURE CODE [CB273] 1510
FAILURE CODE [CB274] 1512
FAILURE CODE [CB343] 1513
FAILURE CODE [CB352] 1516
FAILURE CODE [CB386] 1518
FAILURE CODE [CB441] 1520
FAILURE CODE [CB442] 1523
FAILURE CODE [CB689] 1526
FAILURE CODE [CB697] 1528
FAILURE CODE [CB698] 1529
FAILURE CODE [CB731] 1530
FAILURE CODE [CB778] 1534
FAILURE CODE [CB1117] 1536
FAILURE CODE [CB1257] 1539
FAILURE CODE [CB1664] 1540
FAILURE CODE [CB1691] 1542
FAILURE CODE [CB1695] 1545
FAILURE CODE [CB1696] 1547
FAILURE CODE [CB1879] 1549
FAILURE CODE [CB1881] 1551
FAILURE CODE [CB1883] 1553
FAILURE CODE [CB1921] 1556
FAILURE CODE [CB1922] 1558
FAILURE CODE [CB1923] 1561
FAILURE CODE [CB1924] 1563
FAILURE CODE [CB1925] 1568
FAILURE CODE [CB1927] 1572
FAILURE CODE [CB1928] 1574
FAILURE CODE [CB1963] 1576
FAILURE CODE [CB1977] 1584
FAILURE CODE [CB1993] 1586
FAILURE CODE [CB2265] 1589
FAILURE CODE [CB2266] 1591
FAILURE CODE [CB2637] 1593
FAILURE CODE [CB2639] 1596
FAILURE CODE [CB2732] 1598
FAILURE CODE [CB2733] 1600
FAILURE CODE [CB2741] 1602
FAILURE CODE [CB2777] 1606
FAILURE CODE [CB2878] 1608
FAILURE CODE [CB2881] 1613
FAILURE CODE [CB3133] 1619
FAILURE CODE [CB3134] 1621
FAILURE CODE [CB3135] 1623
FAILURE CODE [CB3167] 1626
FAILURE CODE [CB3251] 1631
FAILURE CODE [CB3253] 1633
FAILURE CODE [CB3254] 1637
FAILURE CODE [CB3255] 1640
FAILURE CODE [CB3256] 1642
FAILURE CODE [CB3311] 1644
FAILURE CODE [CB3312] 1646
FAILURE CODE [CB3313] 1648
FAILURE CODE [CB3314] 1649
FAILURE CODE [CB3315] 1650
FAILURE CODE [CB3316] 1653
FAILURE CODE [CB3317] 1654
FAILURE CODE [CB3318] 1655
FAILURE CODE [CB3319] 1658
FAILURE CODE [CB3321] 1659
FAILURE CODE [CB3322] 1660
FAILURE CODE [CB4151] 1663
FAILURE CODE [CB4158] 1666
FAILURE CODE [CB4161] 1667
FAILURE CODE [CB4162] 1669
FAILURE CODE [CB4163] 1671
FAILURE CODE [CB4259] 1673
FAILURE CODE [CB4952] 1675
FAILURE CODE [CB5383] 1678
FAILURE CODE [D150KB] 1679
FAILURE CODE [D150KZ] 1681
FAILURE CODE [D164KY] 1683
FAILURE CODE [D19HKZ] 1684
FAILURE CODE [D19JKZ] 1686
FAILURE CODE [D19QKZ] 1688
FAILURE CODE [D1EHKA] 1690
FAILURE CODE [D1EHKB] 1692
FAILURE CODE [D1EHKY] 1694
FAILURE CODE [D1EMKA] 1695
FAILURE CODE [D1EMKB] 1696
FAILURE CODE [D1EMKY] 1697
FAILURE CODE [D1FBKB] 1698
FAILURE CODE [D5ZHL6] 1700
FAILURE CODE [D5ZKKZ] 1702
FAILURE CODE [D862KA] 1704
FAILURE CODE [DAF0KT] 1705
FAILURE CODE [DAF0MB] 1706
FAILURE CODE [DAF0MC] 1707
FAILURE CODE [DAF3KK] 1708
FAILURE CODE [DAF8KB] 1710
FAILURE CODE [DAFDKB] 1712
FAILURE CODE [DAFGMC] 1714
FAILURE CODE [DAFLKA] 1715
FAILURE CODE [DAFLKB] 1718
FAILURE CODE [DAFQKR] 1721
FAILURE CODE [DAQ0KK] 1722
FAILURE CODE [DAQ0KT] 1725
FAILURE CODE [DAQ0MC] 1726
FAILURE CODE [DAQ1KA] 1727
FAILURE CODE [DAQ2KK] 1730
FAILURE CODE [DAQ9KQ] 1733
FAILURE CODE [DAQLKA] 1734
FAILURE CODE [DAQLKB] 1737
FAILURE CODE [DAQQKR] 1740
FAILURE CODE [DAQRKR] 1741
FAILURE CODE [DAQRMA] 1742
FAILURE CODE [DAQV00] 1743
FAILURE CODE [DAQW00] 1744
FAILURE CODE [DAZ9KQ] 1745
FAILURE CODE [DAZQKR] 1746
FAILURE CODE [DB10KT] 1748
FAILURE CODE [DB10MC] 1749
FAILURE CODE [DB11KA] 1750
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch) 1753
FAILURE CODE [DB12KK] 1756
FAILURE CODE [DB13KK] 1759
FAILURE CODE [DB19KQ] 1762
FAILURE CODE [DB1LKA] 1763
FAILURE CODE [DB1LKB] 1766
FAILURE CODE [DB1QKR] 1769
FAILURE CODE [DB1QMA] 1770
FAILURE CODE [DB1RKR] 1771
FAILURE CODE [DB2QKR] 1772
FAILURE CODE [DB2QKR] 1779
FAILURE CODE [DB2RKR] 1787
FAILURE CODE [DB2RKR] 1794
FAILURE CODE [DBC0KT] 1802
FAILURE CODE [DBC0MC] 1803
FAILURE CODE [DBC1KA] 1804
FAILURE CODE [DBC2KK] 1807
FAILURE CODE [DBC3KK] 1809
FAILURE CODE [DBC9KQ] 1812
FAILURE CODE [DBCLKA] 1813
FAILURE CODE [DBCLKB] 1815
FAILURE CODE [DBCQKR] 1817
FAILURE CODE [DBCQMA] 1818
FAILURE CODE [DBCRKR] 1819
FAILURE CODE [DBV0MC] 1820
FAILURE CODE [DBV1KK] 1821
FAILURE CODE [DBV6KB] 1823
FAILURE CODE [DBV7KB] 1825
FAILURE CODE [DBVLKA] 1826
FAILURE CODE [DBVLKB] 1829
FAILURE CODE [DBVQKR] 1832
FAILURE CODE [DBVRKR] 1833
FAILURE CODE [DBVVKR] 1834
FAILURE CODE [DBVWKR] 1835
FAILURE CODE [DDAAL6] 1836
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch) 1838
FAILURE CODE [DDACL4] 1841
FAILURE CODE [DDADKA] 1843
FAILURE CODE [DDADKY] 1845
FAILURE CODE [DDD7KX] 1847
FAILURE CODE [DDP6L4] 1849
FAILURE CODE [DDTHKA] 1851
FAILURE CODE [DDTJKA] 1853
FAILURE CODE [DDTKKA] 1855
FAILURE CODE [DDTLKA] 1857
FAILURE CODE [DDTMKA] 1859
FAILURE CODE [DDTNKA] 1861
FAILURE CODE [DDTPKA] 1863
FAILURE CODE [DF10KA] 1865
FAILURE CODE [DF10KB] 1869
FAILURE CODE [DGE5KX] 1874
FAILURE CODE [DGF1KX] 1876
FAILURE CODE [DGR2KB] 1878
FAILURE CODE [DGR6KB] 1880
FAILURE CODE [DGR6L8] 1881
FAILURE CODE [DGT1KX] 1883
FAILURE CODE [DGT4KA] 1885
FAILURE CODE [DGT4KB] 1887
FAILURE CODE [DGT4KY] 1889
FAILURE CODE [DHA4KA] 1891
FAILURE CODE [DHAAMA] 1893
FAILURE CODE [DHABMA] 1894
FAILURE CODE [DHACMA] 1895
FAILURE CODE [DHADMA] 1896
FAILURE CODE [DHP4KY] 1897
FAILURE CODE [DHP4KZ] 1899
FAILURE CODE [DHP5KY] 1901
FAILURE CODE [DHP5KZ] 1903
FAILURE CODE [DHP6KA] 1905
FAILURE CODE [DHP6KX] 1907
FAILURE CODE [DHP6KY] 1909
FAILURE CODE [DHP6KZ] 1911
FAILURE CODE [DHP7KA] 1913
FAILURE CODE [DHP7KX] 1915
FAILURE CODE [DHP7KY] 1917
FAILURE CODE [DHP7KZ] 1919
FAILURE CODE [DHQ2KX] 1921
FAILURE CODE [DHQ4KX] 1923
FAILURE CODE [DHT5KX] 1925
FAILURE CODE [DHT5L6] 1927
FAILURE CODE [DHT8KX] 1929
FAILURE CODE [DHT8ZG] 1931
FAILURE CODE [DHU2KX] 1933
FAILURE CODE [DHU3KX] 1935
FAILURE CODE [DHU6KX] 1937
FAILURE CODE [DHU7KX] 1939
FAILURE CODE [DHU8KX] 1941
FAILURE CODE [DHU9KX] 1943
FAILURE CODE [DHUCKX] 1945
FAILURE CODE [DHUDKX] 1948
FAILURE CODE [DHUHKX] 1950
FAILURE CODE [DHULKX] 1952
FAILURE CODE [DHUMKX] 1955
FAILURE CODE [DHUPKX] 1958
FAILURE CODE [DHUTKX] 1960
FAILURE CODE [DHY9KX] 1962
FAILURE CODE [DJF1KA] 1964
FAILURE CODE [DK30KX] 1966
FAILURE CODE [DK51L5] 1968
FAILURE CODE [DK52KX] 1971
FAILURE CODE [DK53L8] 1973
FAILURE CODE [DK54KX] 1975
FAILURE CODE [DK60KX] 1977
FAILURE CODE [DKD0L6] 1979
FAILURE CODE [DKH0KX] 1981
FAILURE CODE [DKH1KX] 1983
FAILURE CODE [DLF1KA] 1985
FAILURE CODE [DLF1LC] 1986
FAILURE CODE [DLF2KA] 1988
FAILURE CODE [DLF2LC] 1990
FAILURE CODE [DLF6KA] 1992
FAILURE CODE [DLF6L3] 1993
FAILURE CODE [DLF7KA] 1995
FAILURE CODE [DLF7L3] 1996
FAILURE CODE [DLF8KA] 1998
FAILURE CODE [DLF8L3] 1999
FAILURE CODE [DLF8LC] 2000
FAILURE CODE [DLF8MA] 2002
FAILURE CODE [DLF9KA] 2003
FAILURE CODE [DLF9L3] 2004
FAILURE CODE [DLF9LC] 2005
FAILURE CODE [DLF9MA] 2007
FAILURE CODE [DLM3KA] 2008
FAILURE CODE [DLM3LC] 2009
FAILURE CODE [DLM3MB] 2011
FAILURE CODE [DLT3KA] 2012
FAILURE CODE [DLT3LC] 2013
FAILURE CODE [DPQ1KR] 2015
FAILURE CODE [DPQ2KR] 2018
FAILURE CODE [DPQ3KR] 2021
FAILURE CODE [DSJ0KR] 2025
FAILURE CODE [DV00KB] 2026
FAILURE CODE [DW2AKA] 2028
FAILURE CODE [DW2AKB] 2029
FAILURE CODE [DW2AKY] 2031
FAILURE CODE [DW2AL1] 2032
FAILURE CODE [DW2ALH] 2033
FAILURE CODE [DW2BKA] 2034
FAILURE CODE [DW2BKB] 2035
FAILURE CODE [DW2BKY] 2036
FAILURE CODE [DW2BL1] 2037
FAILURE CODE [DW2BLH] 2038
FAILURE CODE [DW35KZ] 2039
FAILURE CODE [DW36KZ] 2041
FAILURE CODE [DW4BK4] 2043
FAILURE CODE [DW4BMA] 2047
FAILURE CODE [DW72KZ] 2051
FAILURE CODE [DW73KA] 2053
FAILURE CODE [DW73KB] 2055
FAILURE CODE [DW73KY] 2057
FAILURE CODE [DW78KZ] 2058
FAILURE CODE [DW7BKB] 2060
FAILURE CODE [DW7BKY] 2062
FAILURE CODE [DW7BKZ] 2063
FAILURE CODE [DW7NKZ] 2065
FAILURE CODE [DWD6KA] 2067
FAILURE CODE [DWD6KB] 2069
FAILURE CODE [DWD6KY] 2071
FAILURE CODE [DWD6MA] 2072
FAILURE CODE [DWD7K4] 2074
FAILURE CODE [DWD7KA] 2075
FAILURE CODE [DWD7KB] 2077
FAILURE CODE [DWD7KY] 2079
FAILURE CODE [DWD7MA] 2080
FAILURE CODE [DWNDKZ] 2081
FAILURE CODE [DWNDMA] 2083
FAILURE CODE [DWNEKZ] 2085
FAILURE CODE [DWNEMA] 2087
FAILURE CODE [DWNMKZ] 2089
FAILURE CODE [DX11K4] 2091
FAILURE CODE [DX11KA] 2093
FAILURE CODE [DX11KB] 2095
FAILURE CODE [DX11KY] 2097
FAILURE CODE [DX11MA] 2098
FAILURE CODE [DX13KA] 2100
FAILURE CODE [DX13KB] 2102
FAILURE CODE [DX13KY] 2104
FAILURE CODE [DX16KA] 2105
FAILURE CODE [DX16KB] 2106
FAILURE CODE [DX16KY] 2108
FAILURE CODE [DX21KA] 2109
FAILURE CODE [DX21KB] 2110
FAILURE CODE [DX21KY] 2112
FAILURE CODE [DX21MA] 2113
FAILURE CODE [DX22KA] 2115
FAILURE CODE [DX22KB] 2116
FAILURE CODE [DX22KY] 2118
FAILURE CODE [DX22MA] 2119
FAILURE CODE [DX23KA] 2121
FAILURE CODE [DX23KB] 2122
FAILURE CODE [DX23KY] 2124
FAILURE CODE [DX23MA] 2125
FAILURE CODE [DX24KA] 2127
FAILURE CODE [DX24KB] 2128
FAILURE CODE [DX24KY] 2130
FAILURE CODE [DX24MA] 2131
FAILURE CODE [DX25MA] 2133
FAILURE CODE [DX26MA] 2134
FAILURE CODE [DX37K4] 2135
FAILURE CODE [DX37KA] 2137
FAILURE CODE [DX37KB] 2138
FAILURE CODE [DX37KY] 2140
FAILURE CODE [DX37MA] 2141
FAILURE CODE [DX38K4] 2143
FAILURE CODE [DX38KA] 2145
FAILURE CODE [DX38KB] 2146
FAILURE CODE [DX38KY] 2148
FAILURE CODE [DX38MA] 2149
FAILURE CODE [DXH1KA] 2151
FAILURE CODE [DXH1KB] 2153
FAILURE CODE [DXH1KY] 2155
FAILURE CODE [DXH2KA] 2156
FAILURE CODE [DXH2KB] 2158
FAILURE CODE [DXH2KY] 2160
FAILURE CODE [DXH3KA] 2163
FAILURE CODE [DXH3KB] 2165
FAILURE CODE [DXH3KY] 2167
FAILURE CODE [DXH4KA] 2170
FAILURE CODE [DXH4KB] 2172
FAILURE CODE [DXH4KY] 2174
FAILURE CODE [DXH5KA] 2177
FAILURE CODE [DXH5KB] 2179
FAILURE CODE [DXH5KY] 2181
FAILURE CODE [DXH6KA] 2184
FAILURE CODE [DXH6KB] 2186
FAILURE CODE [DXH6KY] 2188
FAILURE CODE [DXH7KA] 2191
FAILURE CODE [DXH7KB] 2193
FAILURE CODE [DXH7KY] 2195
FAILURE CODE [DXHHKA] 2197
FAILURE CODE [DXHHKB] 2199
FAILURE CODE [DXHHKY] 2201
FAILURE CODE [DY30MA] 2203
FAILURE CODE [DY30MC] 2205
FAILURE CODE [DY30ME] 2208
FAILURE CODE [F@BYNR] 2210
FAILURE CODE [F@BYNS] 2211
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2212
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2212
MANUAL PREHEATING SYSTEM DOES NOT WORK 2220
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2223
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2225
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2227
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch) 2230
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2233
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2235
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2237
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2239
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2242
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2246
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2248
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2250
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2252
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2254
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2255
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2259
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2263
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2267
REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2269
GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2272
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2274
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2276
MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2278
ALARM BUZZER DOES NOT SOUND 2279
ALARM BUZZER DOES NOT STOP SOUNDING 2281
AISS FUNCTION DOES NOT OPERATE PROPERLY 2283
HOIST LEVER DOES NOT OPERATE PROPERLY 2285
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2287
TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2292
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2296
SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2299
TAIL LAMP DOES NOT LIGHT UP 2302
(LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2305
(HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2307
NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2309
HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2311
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2313
DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 2315
CANNOT ACCESS TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL 2316
CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL BECAUSE THE LOG IN PASSWORD IS UNKNOWN 2323
KOMTRAX Plus CONTROLLER IS NOT DETECTED 2325
KOMTRAX Plus CONTROLLER DOES NOT BECOME ACTIVE 2327
COMMUNICATION BETWEEN MOBILE COMMUNICATION TERMINAL AND KOMTRAX Plus SERVER FAILS 2328
RESTRICTIONS ON RADIO RECEPTION 2330
DATA IS NOT SENT TO KOMTRAX Plus SERVER 2331
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2333
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2333
FAILURE MODE AND CAUSE TABLE 2334
MACHINE DOES NOT START 2344
MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2347
LOCKUP IS NOT RELEASED 2348
ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2349
GEAR IS NOT SHIFTED UP 2351
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2354
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2355
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2356
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2358
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2361
OIL PRESSURE OF TORQUE CONVERTER IS LOW 2362
STEERING WHEEL IS HEAVY TO OPERATE 2363
STEERING WHEEL CANNOT BE OPERATED 2364
STEERING WHEEL WAGGLES 2365
FRONT BRAKE DOES NOT WORK ENOUGH 2366
REAR BRAKE DOES NOT WORK ENOUGH 2367
DUMP BODY RISING SPEED IS LOW 2368
HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2370
DUMP BODY DOES NOT MOVE 2371
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2372
UNUSUAL NOISE IS HEARD FROM AROUND FAN 2373
TROUBLESHOOTING OF ENGINE (S-MODE) 2374
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2374
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2375
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2376
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING:ENGINE CRANKS BUT DOES NOT START) 2377
ENGINE STARTABILITY IS POOR 2378
ENGINE DOES NOT PICK UP SMOOTHLY 2380
ENGINE STOPS DURING OPERATION 2382
ENGINE RUNS ROUGH OR IS UNSTABLE 2384
ENGINE LACKS POWER 2385
KDPF GETS CLOGGED IN A SHORT TIME 2387
ENGINE OIL CONSUMPTION IS EXCESSIVE 2389
OIL BECOMES CONTAMINATED QUICKLY 2390
FUEL CONSUMPTION IS EXCESSIVE 2391
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2392
OIL PRESSURE DROPS 2393
FUEL MIXES INTO ENGINE OIL 2395
WATER MIXES INTO ENGINE OIL (MILKY) 2396
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2397
UNUSUAL NOISE IS HEARD 2398
VIBRATION IS EXCESSIVE 2399
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2400
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2401
ACTIVE REGENERATION TAKES TIME 2402
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2403
50 DISASSEMBLY AND ASSEMBLY 2405
CONTENTS 2406
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2410
HOW TO READ THIS MANUAL 2410
COATING MATERIALS LIST 2412
SPECIAL TOOLS LIST 2416
SKETCHES OF SPECIAL TOOLS 2424
ENGINE AND COOLING SYSTEM 2427
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2427
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY 2428
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY 2439
REMOVE AND INSTALL INJECTOR ASSEMBLY 2455
PROCEDURE TO REMOVE INJECTOR ASSEMBLY 2457
PROCEDURE TO INSTALL INJECTOR ASSEMBLY 2478
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2508
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY 2509
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY 2510
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2513
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY 2515
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY 2560
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2622
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY 2623
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY 2625
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2628
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY 2629
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY 2638
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2648
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY 2648
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY 2649
REMOVE AND INSTALL ALTERNATOR BELT 2651
PROCEDURE TO REMOVE ALTERNATOR BELT 2651
PROCEDURE TO INSTALL ALTERNATOR BELT 2652
REMOVE AND INSTALL COOLER ASSEMBLY 2654
PROCEDURE TO REMOVE COOLER ASSEMBLY 2655
PROCEDURE TO INSTALL COOLER ASSEMBLY 2670
REMOVE AND INSTALL RADIATOR 2684
PROCEDURE TO REMOVE RADIATOR 2685
PROCEDURE TO INSTALL RADIATOR 2691
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2698
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2699
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2701
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2704
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY 2705
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY 2711
REMOVE AND INSTALL ENGINE ASSEMBLY 2718
PROCEDURE TO REMOVE ENGINE ASSEMBLY 2720
PROCEDURE TO INSTALL ENGINE ASSEMBLY 2733
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2746
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL 2746
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL 2748
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2750
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL 2750
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL 2751
REMOVE AND INSTALL DAMPER ASSEMBLY 2756
PROCEDURE TO REMOVE DAMPER ASSEMBLY 2756
PROCEDURE TO INSTALL DAMPER ASSEMBLY 2760
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 2765
PROCEDURE TO DISASSEMBLE DAMPER ASSEMBLY 2766
PROCEDURE TO ASSEMBLE DAMPER ASSEMBLY 2767
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET) 2770
PROCEDURE TO REMOVE KDPF ASSEMBLY 2771
PROCEDURE TO INSTALL KDPF ASSEMBLY 2775
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET) 2781
PROCEDURE TO REMOVE KDPF ASSEMBLY 2782
PROCEDURE TO INSTALL KDPF ASSEMBLY 2788
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2796
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY 2797
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY 2802
REMOVE AND INSTALL KCCV ASSEMBLY 2809
PROCEDURE TO REMOVE KCCV ASSEMBLY 2810
PROCEDURE TO INSTALL KCCV ASSEMBLY 2812
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2815
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY 2815
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY 2816
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2818
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2818
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2819
POWER TRAIN 2821
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2821
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2822
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2827
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2832
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2833
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2841
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY 2859
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY 2860
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY 2866
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 2877
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY 2879
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY 2898
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY 2926
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY 2927
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY 2930
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 2933
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY 2934
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY 2940
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD 2950
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD 2950
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD 2951
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY 2952
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY 2952
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY 2953
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2954
DISASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2954
ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY 2954
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2957
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY 2958
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 2961
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2965
PROCEDURE TO REMOVE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2965
PROCEDURE TO INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2968
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2972
PROCEDURE TO DISASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2973
PROCEDURE TO ASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY 2978
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 2986
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY 2986
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY 2988
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 2990
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2990
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY 2990
STEERING SYSTEM 2991
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 2991
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY 2992
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY 2993
UNDERCARRIAGE AND FRAME 2996
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 2996
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY 2996
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY 2997
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 2999
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY 2999
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY 3001
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 3003
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY 3003
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 3004
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFERRING) 3007
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 3007
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY 3009
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 3013
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY 3013
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 3014
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFERRING) 3015
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 3016
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY 3017
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY 3021
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY 3021
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY 3023
HYDRAULIC SYSTEM 3027
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 3027
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY 3028
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY 3030
WORK EQUIPMENT 3036
REMOVE AND INSTALL DUMP BODY ASSEMBLY 3036
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY 3036
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY 3037
CAB RELATED PARTS 3040
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 3040
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY 3041
PROCEDURE TO INSTALL AIR CONDITIONER ASSEMBLY 3048
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3056
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY 3056
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY 3058
REMOVE AND INSTALL SEATBELT 3061
PROCEDURE TO REMOVE SEAT BELT 3061
PROCEDURE TO INSTALL SEAT BELT 3062
ELECTRICAL SYSTEM 3064
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3064
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY 3064
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY 3066
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3069
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY 3069
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3070
REMOVE AND INSTALL ABS CONTROLLER ASSEMBLY 3072
PROCEDURE TO REMOVE ABS CONTROLLER ASSEMBLY 3072
PROCEDURE TO INSTALL ABS CONTROLLER ASSEMBLY 3073
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3074
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY 3074
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3075
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3076
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY 3077
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY 3079
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3082
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY 3082
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY 3083
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3084
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR 3084
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3085
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3087
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR 3087
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR 3088
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 3090
PROCEDURE TO REMOVE KOMTRAX PLUS CONTROLLER ASSEMBLY 3090
PROCEDURE TO INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 3091
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL 3093
REMOVE MOBILE COMMUNICATION TERMINAL 3093
INSTALL MOBILE COMMUNICATION TERMINAL 3094
REMOVE AND INSTALL DC-DC CONVERTER 3096
REMOVE DC-DC CONVERTER 3096
INSTALL DC-DC CONVERTER 3097
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3098
REMOVE MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3098
INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS 3103
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY 3109
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY 3109
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY 3111
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 3112
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY 3112
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY 3113
60 MAINTENANCE STANDARD 3117
CONTENTS 3118
ENGINE AND COOLING SYSTEM 3119
MAINTENANCE STANDARD FOR ENGINE MOUNT 3119
MAINTENANCE STANDARD FOR OUTPUT SHAFT 3120
MAINTENANCE STANDARD FOR COOLING FAN PUMP 3122
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP 3124
MAINTENANCE STANDARD FOR COOLING FAN MOTOR 3125
POWER TRAIN 3127
MAINTENANCE STANDARD FOR DRIVE SHAFT 3127
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT 3128
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO 3129
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE 3133
MAINTENANCE STANDARD FOR TRANSMISSION 3135
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE 3141
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV 3142
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV 3143
MAINTENANCE STANDARD FOR FRONT AXLE 3144
MAINTENANCE STANDARD FOR REAR AXLE 3145
MAINTENANCE STANDARD FOR DIFFERENTIAL 3146
MAINTENANCE STANDARD FOR FINAL DRIVE 3147
STEERING SYSTEM 3148
MAINTENANCE STANDARD FOR STEERING COLUMN 3148
MAINTENANCE STANDARD FOR STEERING LINKAGE 3149
MAINTENANCE STANDARD FOR DEMAND VALVE 3152
MAINTENANCE STANDARD FOR STEERING CYLINDER 3155
BRAKE SYSTEM 3156
MAINTENANCE STANDARD FOR SLACK ADJUSTER 3156
MAINTENANCE STANDARD FOR FRONT BRAKE 3157
MAINTENANCE STANDARD FOR REAR BRAKE 3158
UNDERCARRIAGE AND FRAME 3160
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER 3160
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER 3163
HYDRAULIC SYSTEM 3165
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP 3165
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP 3166
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP 3168
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP 3169
MAINTENANCE STANDARD FOR HOIST VALVE 3171
WORK EQUIPMENT 3173
MAINTENANCE STANDARD FOR HOIST CYLINDER 3173
CAB RELATED PARTS 3174
MAINTENANCE STANDARD FOR CAB MOUNT 3174
80 OTHERS 3175
CONTENTS 3176
AIR CONDITIONER SYSTEM 3178
PRECAUTIONS FOR REFRIGERANT 3178
AIR CONDITIONER COMPONENT 3179
SPECIFICATIONS OF AIR CONDITIONER 3181
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3182
OUTLINE OF REFRIGERATION CYCLE 3183
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3185
AIR CONDITIONER UNIT 3185
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3185
FUNCTION OF AIR CONDITIONER UNIT 3186
COMPONENT PARTS OF AIR CONDITIONER UNIT 3189
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3190
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3190
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3190
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3190
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3191
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3191
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3191
FUNCTION OF DUAL PRESSURE SWITCH 3192
AIR CONDITIONER CONTROLLER 3193
STRUCTURE OF AIR CONDITIONER CONTROLLER 3193
COMPRESSOR 3194
STRUCTURE OF COMPRESSOR 3194
SPECIFICATIONS OF COMPRESSOR 3194
FUNCTION OF COMPRESSOR 3194
CONDENSER 3195
STRUCTURE OF CONDENSER 3195
SPECIFICATIONS OF CONDENSER 3195
FUNCTION OF CONDENSER 3195
AIR CONDITIONER RELATED SENSORS 3197
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3197
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3197
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3198
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3201
AIR CONDITIONER SYSTEM DIAGRAM 3203
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3204
FUNCTION OF AIR CONDITIONER CONTROLLER 3205
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3206
TESTING AIR LEAKAGE (DUCT) 3209
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3209
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3212
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3213
TEST VENT (MODE) CHANGEOVER 3215
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3215
TESTING FRESH/RECIRC AIR CHANGEOVER 3216
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3216
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3217
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3217
TEST RELAYS 3218
METHOD FOR TESTING RELAYS 3218
AIR CONDITIONER TROUBLESHOOTING CHART 1 3220
AIR CONDITIONER TROUBLESHOOTING CHART 2 3221
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3224
FAILURE CODE [879AKA] 3226
FAILURE CODE [879AKB] 3227
FAILURE CODE [879BKA] 3228
FAILURE CODE [879BKB] 3229
FAILURE CODE [879CKA] 3231
FAILURE CODE [879CKB] 3232
FAILURE CODE [879EMC] 3233
FAILURE CODE [879FMC] 3234
FAILURE CODE [879GKX] 3235
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3236
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3238
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3241
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3243
TROUBLESHOOTING USING GAUGE PRESSURE 3245
CONNECTION OF SERVICE TOOL 3247
METHOD FOR CONNECTING SERVICE TOOL 3247
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3249
HANDLE COMPRESSOR OIL 3251
METHOD FOR REPLACING DESICCANT 3253
90 CIRCUIT DIAGRAMS 3255
CONTENTS 3256
HYDRAULIC CIRCUIT DIAGRAM 3257
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3257
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3261
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3263
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3265
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3267
ELECTRICAL CIRCUIT DIAGRAM 3269
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM 3269
INTERNAL CAB ELECTRICAL DIAGRAM (1/11) 3273
INTERNAL CAB ELECTRICAL DIAGRAM (2/11) 3275
INTERNAL CAB ELECTRICAL DIAGRAM (3/11) 3277
INTERNAL CAB ELECTRICAL DIAGRAM (4/11) 3279
INTERNAL CAB ELECTRICAL DIAGRAM (5/11) 3281
INTERNAL CAB ELECTRICAL DIAGRAM (6/11) 3283
INTERNAL CAB ELECTRICAL DIAGRAM (7/11) 3285
INTERNAL CAB ELECTRICAL DIAGRAM (8/11) 3287
INTERNAL CAB ELECTRICAL DIAGRAM (9/11) 3289
INTERNAL CAB ELECTRICAL DIAGRAM (10/11) 3291
INTERNAL CAB ELECTRICAL DIAGRAM (11/11) 3293
EXTERNAL CAB ELECTRICAL DIAGRAM (1/8) 3295
EXTERNAL CAB ELECTRICAL DIAGRAM (2/8) 3297
EXTERNAL CAB ELECTRICAL DIAGRAM (3/8) 3299
EXTERNAL CAB ELECTRICAL DIAGRAM (4/8) 3301
EXTERNAL CAB ELECTRICAL DIAGRAM (5/8) 3303
EXTERNAL CAB ELECTRICAL DIAGRAM (6/8) 3305
EXTERNAL CAB ELECTRICAL DIAGRAM (7/8) 3307
EXTERNAL CAB ELECTRICAL DIAGRAM (8/8) 3309
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2) 3311
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2) 3313
INDEX 3315

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