Komatsu HM300-5 Articulated Dump Truck Shop Manual SEN06511-20 – PDF DOWNLOAD

Description

Komatsu HM300-5 Articulated Dump Truck Shop Manual SEN06511-20 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HM300-5 Articulated Dump Truck Shop Manual SEN06511-20 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.

TABLE OF CONTENTS:

Komatsu HM300-5 Articulated Dump Truck Shop Manual SEN06511-20 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
SAFETY NOTICE FOR OPERATION 34
PRECAUTIONS TO PREVENT FIRE 42
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 45
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 46
PRECAUTIONS FOR DEF 47
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 47
PRECAUTIONS FOR ADDING 47
PRECAUTIONS FOR STORING 47
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 47
THE OTHER PRECAUTIONS 47
STORE AdBlue/DEF 48
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 52
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 59
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 61
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 62
PRACTICAL USE OF KOMTRAX 63
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 66
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 68
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 76
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 78
HOW TO READ ELECTRICAL WIRE CODE 79
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 83
STANDARD TIGHTENING TORQUE TABLE 86
CONVERSION TABLE 93
01 SPECIFICATIONS 99
CONTENTS 100
ABBREVIATION LIST 101
SPECIFICATIONS 107
SPECIFICATION DRAWING 107
SPECIFICATION DRAWING: HM300-5 107
SPECIFICATIONS 109
SPECIFICATIONS: HM300-5 109
WEIGHT TABLE 115
WEIGHT TABLE: HM300-5 115
TABLE OF FUEL, COOLANT, AND LUBRICANTS 117
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 124
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR SYSTEM 130
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 136
COMPONENT PARTS OF UREA SCR SYSTEM 150
AdBlue/DEF MIXING TUBE 150
SCR ASSEMBLY 150
AdBlue/DEF TANK 153
AdBlue/DEF PUMP 155
AdBlue/DEF INJECTOR 156
AdBlue/DEF HOSE 157
AdBlue/DEF TANK HEATING VALVE 158
BOOT-UP SYSTEM 159
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 159
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 161
SYSTEM OPERATING LAMP SYSTEM 163
SYSTEM DIAGRAM OF OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 163
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 163
SYSTEM DIAGRAM OF OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
BATTERY DISCONNECT SWITCH 166
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 166
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 166
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 167
ENGINE SYSTEM 168
LAYOUT DRAWING OF ENGINE SYSTEM 168
FUNCTION OF ENGINE SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM 171
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 171
COMPONENT PARTS OF ENGINE SYSTEM 173
OUTPUT SHAFT 173
VGT 174
EGR SYSTEM 178
EGR VALVE 180
EGR COOLER 182
KCCV SYSTEM 183
KCCV VENTILATOR 185
KDPF 187
COOLING SYSTEM 191
LAYOUT DRAWING OF COOLING SYSTEM 191
SPECIFICATIONS OF COOLING SYSTEM 192
RADIATOR FAN CONTROL SYSTEM 194
RADIATOR FAN CONTROL SYSTEM DIAGRAM 194
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 194
AFTERCOOLER FAN CONTROL SYSTEM 196
AFTERCOOLER FAN CONTROL SYSTEM DIAGRAM 196
FUNCTION OF AFTERCOOLER FAN CONTROL SYSTEM 196
COMPONENT PARTS OF COOLING SYSTEM 198
RADIATOR FAN PUMP 198
RADIATOR FAN MOTOR 206
AFTERCOOLER FAN MOTOR 211
HYDRAULIC OIL COOLER BYPASS VALVE 222
CONTROL SYSTEM 223
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 223
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 225
RETARDER AND HOIST CONTROL SYSTEM 227
SYSTEM DIAGRAM OF RETARDER AND HOIST CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 227
SYSTEM DIAGRAM OF RETARDER AND HOIST CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 228
MACHINE MONITOR SYSTEM 229
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 229
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 230
FUNCTION OF MACHINE MONITOR SYSTEM 231
REARVIEW MONITOR SYSTEM 232
REARVIEW MONITOR SYSTEM DIAGRAM 232
FUNCTION OF REARVIEW MONITOR SYSTEM 232
KOMTRAX SYSTEM 233
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 233
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 233
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 234
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 234
COMPONENT PARTS OF CONTROL SYSTEM 235
MACHINE MONITOR 235
SWITCH PANEL 257
REARVIEW MONITOR 258
REARVIEW CAMERA 260
KOMTRAX TERMINAL 261
GATEWAY FUNCTION CONTROLLER 263
COMMUNICATION TERMINAL 266
TRANSMISSION CONTROLLER 268
RETARDER AND HOIST CONTROLLER 272
MONITOR CONTROLLER 277
ENGINE CONTROLLER 282
ACCELERATOR PEDAL 289
SHIFT LEVER 290
RETARDER CONTROL LEVER 291
HYDRAULIC SYSTEM 292
LAYOUT DRAWING OF HYDRAULIC SYSTEM 292
COMPONENT PARTS OF HYDRAULIC SYSTEM 294
HYDRAULIC TANK 294
STEERING AND HOIST PUMP 295
LS VALVE 303
PC VALVE 304
POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP 308
HOIST VALVE 310
POWER TRAIN SYSTEM 317
LAYOUT DRAWING OF POWER TRAIN SYSTEM 317
TRANSMISSION CONTROL SYSTEM 320
SYSTEM DIAGRAM OF TRANSMISSION CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 320
SYSTEM DIAGRAM OF TRANSMISSION CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 321
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 322
GEAR SHIFT CONTROL SYSTEM 326
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 326
SHIFT HOLD SYSTEM 329
FUNCTION OF SHIFT HOLD SYSTEM 329
DIRECTION CONTROL SYSTEM 330
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 330
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 330
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 331
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 331
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 331
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 332
COMPONENT PARTS OF POWER TRAIN SYSTEM 334
DRIVE SHAFT 334
TORQUE CONVERTER AND PTO 336
LOCKUP CLUTCH ECMV 341
TRANSMISSION 344
TRANSMISSION CONTROL VALVE 366
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 368
DIFFERENTIAL LOCK CLUTCH ECMV 373
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 376
AXLE 380
DIFFERENTIAL 383
FINAL DRIVE 387
WORK EQUIPMENT SYSTEM 391
WORK EQUIPMENT CONTROL 391
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 391
FUNCTION OF WORK EQUIPMENT CONTROL 392
HOIST CONTROL 393
HOIST CONTROL SYSTEM DIAGRAM 393
FUNCTION OF HOIST CONTROL 393
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 395
HOIST AND RADIATOR FAN DIRECTION SELECTOR SOLENOID VALVE 395
DUMP LEVER 397
DUMP EPC VALVE 402
STEERING SYSTEM 404
LAYOUT DRAWING OF STEERING SYSTEM 404
FUNCTION OF STEERING SYSTEM 405
STEERING COLUMN 406
STRUCTURE OF STEERING COLUMN 406
COMPONENT PARTS OF STEERING SYSTEM 407
FLOW AMPLIFIER VALVE 407
STEERING VALVE 411
STEERING PUMP SELECTOR SOLENOID VALVE 416
SECONDARY STEERING PUMP 417
SECONDARY STEERING MOTOR 418
BRAKE SYSTEM 419
LAYOUT DRAWING OF BRAKE SYSTEM 419
RETARDER CONTROL 420
RETARDER CONTROL SYSTEM DIAGRAM 420
FUNCTION OF RETARDER CONTROL 421
PARKING BRAKE INTERLOCK FUNCTION 423
FUNCTION OF PARKING BRAKE INTERLOCK FUNCTION 423
OPERATION OF PARKING BRAKE INTERLOCK FUNCTION 423
ARAC SYSTEM 424
ARAC SYSTEM DIAGRAM 424
FUNCTION OF ARAC SYSTEM 424
COMPONENT PARTS OF BRAKE SYSTEM 425
BRAKE CHARGE PUMP 425
PARKING BRAKE SOLENOID VALVE AND ACCUMULATOR CHARGE VALVE 426
PARKING BRAKE SOLENOID VALVE 427
ACCUMULATOR CHARGE VALVE 427
BRAKE CIRCUIT ACCUMULATOR 432
SHUT OFF SOLENOID VALVE 434
BRAKE VALVE 435
PROPORTIONAL PRESSURE REDUCING VALVE 438
SLACK ADJUSTER 439
BRAKE 442
BRAKE COOLING OIL CONTROL VALVE 445
FRONT BRAKE COOLING RELIEF VALVE 447
BRAKE SYSTEM TANK 448
PARKING BRAKE 449
SPRING CYLINDER 450
PARKING BRAKE CALIPER 452
UNDERCARRIAGE AND FRAME 454
FRONT SUSPENSION 454
STRUCTURE OF FRONT SUSPENSION 454
FUNCTION OF FRONT SUSPENSION 455
CENTER AND REAR SUSPENSIONS 456
STRUCTURE OF CENTER AND REAR SUSPENSIONS 456
FUNCTION OF CENTER SUSPENSION 457
FUNCTION OF REAR SUSPENSION 458
SUSPENSION CYLINDER 459
STRUCTURE OF SUSPENSION CYLINDER 459
FUNCTION OF SUSPENSION CYLINDER 460
OPERATION OF SUSPENSION CYLINDER 461
OSCILLATION HITCH 462
STRUCTURE OF OSCILLATION HITCH 462
FUNCTION OF OSCILLATION HITCH 463
WORK EQUIPMENT 464
STRUCTURE OF WORK EQUIPMENT 464
FUNCTION OF WORK EQUIPMENT 465
CAB AND ITS ATTACHMENTS 466
ROPS CAB 466
STRUCTURE OF ROPS CAB 466
FUNCTION OF ROPS CAB 467
CAB TILT 468
STRUCTURE OF CAB TILT 468
20 STANDARD VALUE TABLE 469
CONTENTS 470
ABBREVIATION LIST 471
STANDARD VALUE TABLE FOR ENGINE 477
STANDARD VALUE TABLE FOR ENGINE: HM300-5 477
STANDARD VALUE TABLE FOR MACHINE 481
STANDARD VALUE TABLE FOR MACHINE: HM300-5 481
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 495
STANDARD VALUE TABLE FOR ELECTRICAL 496
STANDARD VALUE TABLE FOR ELECTRICITY 496
30 TESTING AND ADJUSTING 511
CONTENTS 512
ABBREVIATION LIST 515
RELATED INFORMATION ON TESTING AND ADJUSTING 521
TOOLS FOR TESTING AND ADJUSTING 521
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 529
ENGINE AND COOLING SYSTEM 530
TEST ENGINE SPEED 530
METHOD FOR TESTING ENGINE SPEED 530
TEST BOOST PRESSURE 533
METHOD FOR TESTING BOOST PRESSURE 533
TEST EXHAUST GAS TEMPERATURE 535
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 535
TEST EXHAUST GAS COLOR 538
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 538
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 539
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 541
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 541
TEST AND ADJUST VALVE CLEARANCE 544
METHOD FOR TESTING VALVE CLEARANCE 544
METHOD FOR ADJUSTING VALVE CLEARANCE 545
TEST COMPRESSION PRESSURE 547
METHOD FOR TESTING COMPRESSION PRESSURE 547
TEST BLOWBY PRESSURE 550
METHOD FOR TESTING BLOWBY PRESSURE 550
TEST ENGINE OIL PRESSURE 553
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 553
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 553
TEST EGR VALVE AND VGT OIL PRESSURE 555
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 555
TEST FUEL PRESSURE 557
METHOD FOR TESTING FUEL PRESSURE 557
TEST FUEL RETURN RATE AND LEAKAGE 559
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 560
BLEED AIR FROM FUEL SYSTEM 565
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 565
TEST FUEL CIRCUIT FOR LEAKAGE 567
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 567
HANDLE CYLINDER CUT-OUT MODE OPERATION 569
HANDLE NO-INJECTION CRANKING OPERATION 570
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 571
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 571
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 571
CLEAN FUEL DOSER 572
METHOD FOR CLEANING FUEL DOSER 572
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 575
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 575
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 582
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 582
TEST SCR RELATED FUNCTIONS 583
TEST AdBlue/DEF PUMP RAISED PRESSURE 587
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 590
TEST AdBlue/DEF LINE HEATER RELAY 1 595
TEST AdBlue/DEF LINE HEATER RELAY 2 599
TEST AdBlue/DEF PUMP HEATER RELAY 603
TEST AdBlue/DEF TANK HEATER VALVE 607
TEST DENITRATION EFFICIENCY OF SCR 611
CLEAN AdBlue/DEF TANK 615
METHOD FOR CLEANING AdBlue/DEF TANK 615
CLEAN AdBlue/DEF PUMP 620
CLEAN AdBlue/DEF PUMP 620
TEST TORQUE CONVERTER STALL SPEED 627
METHOD FOR TESTING TORQUE CONVERTER STALL SPEED 627
TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED 632
METHOD FOR TESTING RADIATOR FAN AND AFTERCOOLER FAN SPEED 632
POWER TRAIN 634
TEST POWER TRAIN OIL PRESSURE 634
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 637
ADJUST TRANSMISSION SPEED SENSOR 652
METHOD FOR ADJUSTING TRANSMISSION SPEED SENSOR 652
ADJUST TRANSMISSION CONTROLLER 655
METHOD FOR ADJUSTING TRANSMISSION CONTROLLER 655
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM 656
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN ENGINE CONTROL SYSTEM 656
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN TRANSMISSION CONTROL SYSTEM 657
MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS) 663
METHOD FOR MOVING MACHINE WITH SECONDARY KTCS OPERATION CONNECTOR 665
STEERING SYSTEM 666
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 666
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 666
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 667
BLEED AIR FROM STEERING CYLINDER CIRCUIT 668
BLEED AIR FROM STEERING CYLINDER CIRCUIT 668
BRAKE SYSTEM 670
TEST AND ADJUST BRAKE OIL PRESSURE 670
METHOD FOR TESTING BRAKE OIL PRESSURE 670
METHOD FOR ADJUSTING BRAKE OIL PRESSURE 674
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE GAS 675
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE 675
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 679
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 684
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 684
BLEED AIR FROM BRAKE CIRCUIT 685
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 685
TEST BRAKE PERFORMANCE 687
METHOD FOR TESTING BRAKE PERFORMANCE 687
TEST WEAR OF WHEEL BRAKE DISC 691
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 691
RELEASE PARKING BRAKE MANUALLY 693
METHOD FOR RELEASING PARKING BRAKE MANUALLY 693
TEST AND ADJUST WEAR OF PARKING BRAKE PAD 694
METHOD FOR TESTING WEAR OF PARKING BRAKE PAD 694
METHOD FOR ADJUSTING CLEARANCE OF PARKING BRAKE PAD 695
HYDRAULIC SYSTEM 697
TEST AND ADJUST SUSPENSION CYLINDER 697
METHOD FOR TESTING SUSPENSION CYLINDER 698
METHOD FOR ADJUSTING SUSPENSION CYLINDER 698
TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE 703
METHOD FOR TESTING DUMP CIRCUIT OIL PRESSURE 703
METHOD FOR ADJUSTING DUMP CIRCUIT OIL PRESSURE 704
WORK EQUIPMENT 706
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 706
METHOD FOR TESTING BODY POSITIONER SENSOR 706
METHOD FOR ADJUSTING DUMP BODY POSITIONER SENSOR 706
TEST AND ADJUST DUMP BODY MOUNT 708
METHOD FOR TESTING DUMP BODY MOUNT 708
METHOD FOR ADJUSTING DUMP BODY MOUNT 709
CAB AND ITS ATTACHMENTS 710
CAB TILT UP 710
METHOD FOR TILTING UP CAB 711
ADJUST STEERING WHEEL TILT LOCK LEVER 717
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 717
ADJUST RATTLING OPERATOR’S SEAT 719
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 719
ELECTRICAL SYSTEM 720
SET AND ADJUST EACH EQUIPMENT 720
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 722
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 723
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 726
METHOD FOR SETTING CHARACTERISTIC VALUE OF ARAC (Automatic Retarder Accelerator Control) 731
METHOD FOR PERFORMING SYSTEM CHECK OF KTCS (Komatsu Traction Control System) 734
SET AND OPERATE MACHINE MONITOR 736
OPERATOR MODE 740
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 740
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 740
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 741
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 742
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 742
SERVICE MODE 746
METHOD FOR OPERATING SERVICE MODE 746
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 749
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 757
ABNORMALITY RECORD MENU 774
METHOD FOR CONFIRMING MAINTENANCE RECORD 779
METHOD FOR OPERATING MAINTENANCE MODE SETTING 781
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 785
DEFAULT MENU 787
DIAGNOSTIC TESTS MENU 802
ADJUSTMENT MENU 814
METHOD FOR PERFORMING NO-INJECTION CRANKING 820
PAYLOAD METER SETTING 822
KOMTRAX SETTINGS MENU 845
METHOD FOR DISPLAYING SERVICE MESSAGE 849
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 851
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 855
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 857
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 862
ADJUST OPTICAL AXIS OF HEAD LAMP 864
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 864
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 868
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 869
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 870
TEST DIODES 871
METHOD FOR TESTING DIODE USING DIGITAL TESTER 871
METHOD FOR TESTING DIODE USING ANALOG TESTER 871
Pm CLINIC 872
Pm CLINIC SERVICE 872
Pm CLINIC CHECK SHEET 875
40 TROUBLESHOOTING 885
CONTENTS 886
ABBREVIATION LIST 899
RELATED INFORMATION ON TROUBLESHOOTING 905
GENERAL TROUBLESHOOTING POINTS 905
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 906
SEQUENCE OF EVENTS IN TROUBLESHOOTING 921
CHECKS BEFORE TROUBLESHOOTING 923
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 925
WALK-AROUND CHECK 925
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 927
CHECK FUEL LEVEL AND TYPE 927
CHECK IMPURE INGREDIENT IN FUEL 927
CHECK AdBule/DEF LEVEL AND TYPE 928
CHECK FUEL PREFILTER 928
CHECK MAIN FILTER 930
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 931
CHECK COOLANT LEVEL (RESERVOIR TANK) 932
CHECK CLOGGING OF AIR CLEANER 933
OUTER ELEMENT – CLEAN 934
REPLACE ELEMENT 936
CHECK HYDRAULIC OIL LEVEL 938
CHECK HYDRAULIC OIL STRAINER 938
CHECK HYDRAULIC FILTER 939
CHECK OIL LEVEL IN TRANSMISSION CASE 939
CHECK OIL LEVEL IN DIFFERENTIAL CASE 940
CHECK OIL LEVEL IN FINAL DRIVE CASE 941
BLEED AIR FROM FUEL SYSTEM 941
BLEED AIR FROM HYDRAULIC SYSTEM 941
METHOD FOR CHECKING ELECTRIC EQUIPMENTMETHOD 941
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 951
PROCEDURE FOR TESTING AND TROUBLESHOOTING 960
SYMPTOM AND TROUBLESHOOTING NUMBERS 962
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 965
CONNECTOR LIST AND LAYOUT 967
CONNECTOR CONTACT IDENTIFICATION 993
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1033
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) 1039
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1043
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1047
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1051
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1053
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1059
FAILURE CODE TABLE 1061
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1087
FAILURE CODE [1500L0] 1087
FAILURE CODE [15B0NX] 1088
FAILURE CODE [15F0KM] 1090
FAILURE CODE [15F0MB] 1091
FAILURE CODE [15F7KM] 1092
FAILURE CODE [15G0MW] 1093
FAILURE CODE [15G7KM] 1096
FAILURE CODE [15H0MW] 1097
FAILURE CODE [15J0MW] 1100
FAILURE CODE [15K0MW] 1103
FAILURE CODE [15L0MW] 1106
FAILURE CODE [15M0MW] 1109
FAILURE CODE [15SBL1] 1112
FAILURE CODE [15SBMA] 1115
FAILURE CODE [15SCL1] 1116
FAILURE CODE [15SCMA] 1120
FAILURE CODE [15SDL1] 1121
FAILURE CODE [15SDMA] 1124
FAILURE CODE [15SEL1] 1125
FAILURE CODE [15SEMA] 1128
FAILURE CODE [15SFL1] 1129
FAILURE CODE [15SFMA] 1132
FAILURE CODE [15SGL1] 1133
FAILURE CODE [15SGMA] 1136
FAILURE CODE [15SJMA] 1137
FAILURE CODE [15SKMA] 1139
FAILURE CODE [2F00KM] 1141
FAILURE CODE [2G42ZG] 1143
FAILURE CODE [2G43ZG] 1144
FAILURE CODE [879AKA] 1145
FAILURE CODE [879AKB] 1146
FAILURE CODE [879BKA] 1147
FAILURE CODE [879BKB] 1149
FAILURE CODE [879CKA] 1151
FAILURE CODE [879CKB] 1152
FAILURE CODE [879EMC] 1153
FAILURE CODE [879FMC] 1154
FAILURE CODE [879GKX] 1155
FAILURE CODE [989D00] 1157
FAILURE CODE [989L00] 1158
FAILURE CODE [989M00] 1159
FAILURE CODE [989N00] 1160
FAILURE CODE [A1U0N3] 1161
FAILURE CODE [A1U0N4] 1163
FAILURE CODE [AA10NX] 1165
FAILURE CODE [AB00KE] 1167
FAILURE CODE [AB00KY] 1169
FAILURE CODE [AQ10N3] 1171
FAILURE CODE [AS00N3] 1173
FAILURE CODE [AS00R2] 1175
FAILURE CODE [AS00R3] 1176
FAILURE CODE [AS00R4] 1177
FAILURE CODE [AS00R5] 1178
FAILURE CODE [AS00R6] 1179
FAILURE CODE [AS00ZK] 1180
FAILURE CODE [AS10KM] 1181
FAILURE CODE [AS10NR] 1182
FAILURE CODE [AS10NT] 1183
FAILURE CODE [B@BAZG] 1184
FAILURE CODE [B@BAZK] 1185
FAILURE CODE [B@BCNS] 1186
FAILURE CODE [B@BCQA] 1187
FAILURE CODE [B@BCZK] 1189
FAILURE CODE [B@C6NS] 1191
FAILURE CODE [B@C8NS] 1192
FAILURE CODE [B@CENS] 1193
FAILURE CODE [B@JANS] 1194
FAILURE CODE [CA115] 1195
FAILURE CODE [CA122] 1196
FAILURE CODE [CA123] 1198
FAILURE CODE [CA131] 1200
FAILURE CODE [CA132] 1202
FAILURE CODE [CA135] 1205
FAILURE CODE [CA141] 1207
FAILURE CODE [CA144] 1209
FAILURE CODE [CA145] 1211
FAILURE CODE [CA153] 1213
FAILURE CODE [CA154] 1216
FAILURE CODE [CA187] 1219
FAILURE CODE [CA221] 1221
FAILURE CODE [CA222] 1223
FAILURE CODE [CA227] 1225
FAILURE CODE [CA234] 1226
FAILURE CODE [CA238] 1227
FAILURE CODE [CA239] 1229
FAILURE CODE [CA249] 1231
FAILURE CODE [CA256] 1233
FAILURE CODE [CA271] 1235
FAILURE CODE [CA272] 1237
FAILURE CODE [CA273] 1238
FAILURE CODE [CA274] 1240
FAILURE CODE [CA322] 1241
FAILURE CODE [CA323] 1243
FAILURE CODE [CA324] 1245
FAILURE CODE [CA325] 1247
FAILURE CODE [CA331] 1249
FAILURE CODE [CA332] 1251
FAILURE CODE [CA343] 1253
FAILURE CODE [CA351] 1254
FAILURE CODE [CA352] 1255
FAILURE CODE [CA356] 1258
FAILURE CODE [CA357] 1260
FAILURE CODE [CA386] 1262
FAILURE CODE [CA431] 1263
FAILURE CODE [CA432] 1266
FAILURE CODE [CA441] 1270
FAILURE CODE [CA442] 1273
FAILURE CODE [CA449] 1274
FAILURE CODE [CA451] 1275
FAILURE CODE [CA452] 1277
FAILURE CODE [CA515] 1279
FAILURE CODE [CA516] 1281
FAILURE CODE [CA553] 1283
FAILURE CODE [CA555] 1284
FAILURE CODE [CA556] 1285
FAILURE CODE [CA559] 1286
FAILURE CODE [CA595] 1291
FAILURE CODE [CA687] 1292
FAILURE CODE [CA689] 1294
FAILURE CODE [CA691] 1296
FAILURE CODE [CA692] 1298
FAILURE CODE [CA697] 1300
FAILURE CODE [CA698] 1301
FAILURE CODE [CA731] 1302
FAILURE CODE [CA778] 1303
FAILURE CODE [CA1117] 1306
FAILURE CODE [CA1664] 1307
FAILURE CODE [CA1669] 1310
FAILURE CODE [CA1673] 1311
FAILURE CODE [CA1677] 1312
FAILURE CODE [CA1678] 1313
FAILURE CODE [CA1682] 1314
FAILURE CODE [CA1683] 1318
FAILURE CODE [CA1684] 1320
FAILURE CODE [CA1686] 1322
FAILURE CODE [CA1691] 1323
FAILURE CODE [CA1694] 1326
FAILURE CODE [CA1695] 1328
FAILURE CODE [CA1696] 1329
FAILURE CODE [CA1712] 1331
FAILURE CODE [CA1713] 1334
FAILURE CODE [CA1714] 1337
FAILURE CODE [CA1715] 1338
FAILURE CODE [CA1776] 1339
FAILURE CODE [CA1777] 1342
FAILURE CODE [CA1843] 1345
FAILURE CODE [CA1844] 1347
FAILURE CODE [CA1879] 1350
FAILURE CODE [CA1881] 1353
FAILURE CODE [CA1883] 1355
FAILURE CODE [CA1885] 1359
FAILURE CODE [CA1887] 1361
FAILURE CODE [CA1921] 1363
FAILURE CODE [CA1922] 1366
FAILURE CODE [CA1923] 1371
FAILURE CODE [CA1924] 1373
FAILURE CODE [CA1925] 1376
FAILURE CODE [CA1927] 1379
FAILURE CODE [CA1928] 1381
FAILURE CODE [CA1942] 1383
FAILURE CODE [CA1963] 1384
FAILURE CODE [CA1977] 1388
FAILURE CODE [CA1993] 1391
FAILURE CODE [CA2185] 1394
FAILURE CODE [CA2186] 1396
FAILURE CODE [CA2249] 1398
FAILURE CODE [CA2265] 1399
FAILURE CODE [CA2266] 1401
FAILURE CODE [CA2271] 1404
FAILURE CODE [CA2272] 1406
FAILURE CODE [CA2349] 1409
FAILURE CODE [CA2353] 1411
FAILURE CODE [CA2357] 1413
FAILURE CODE [CA2381] 1414
FAILURE CODE [CA2382] 1416
FAILURE CODE [CA2383] 1418
FAILURE CODE [CA2386] 1420
FAILURE CODE [CA2387] 1422
TROUBLESHOOTING FLOWCHART 1426
FAILURE CODE [CA2555] 1427
FAILURE CODE [CA2556] 1429
FAILURE CODE [CA2637] 1431
FAILURE CODE [CA2639] 1433
FAILURE CODE [CA2732] 1436
FAILURE CODE [CA2733] 1438
FAILURE CODE [CA2741] 1440
FAILURE CODE [CA2765] 1441
FAILURE CODE [CA2771] 1442
FAILURE CODE [CA2777] 1448
FAILURE CODE [CA2878] 1451
FAILURE CODE [CA2881] 1454
FAILURE CODE [CA2976] 1457
FAILURE CODE [CA3133] 1459
FAILURE CODE [CA3134] 1461
FAILURE CODE [CA3135] 1463
FAILURE CODE [CA3142] 1467
FAILURE CODE [CA3143] 1468
FAILURE CODE [CA3144] 1469
FAILURE CODE [CA3146] 1472
FAILURE CODE [CA3147] 1473
FAILURE CODE [CA3148] 1474
FAILURE CODE [CA3151] 1476
FAILURE CODE [CA3165] 1482
FAILURE CODE [CA3167] 1484
FAILURE CODE [CA3229] 1487
FAILURE CODE [CA3231] 1489
FAILURE CODE [CA3232] 1491
FAILURE CODE [CA3235] 1495
FAILURE CODE [CA3239] 1497
FAILURE CODE [CA3241] 1500
FAILURE CODE [CA3242] 1503
FAILURE CODE [CA3251] 1506
FAILURE CODE [CA3253] 1508
FAILURE CODE [CA3254] 1512
FAILURE CODE [CA3255] 1515
FAILURE CODE [CA3256] 1519
FAILURE CODE [CA3311] 1521
FAILURE CODE [CA3312] 1523
FAILURE CODE [CA3313] 1526
FAILURE CODE [CA3314] 1527
FAILURE CODE [CA3315] 1528
FAILURE CODE [CA3316] 1531
FAILURE CODE [CA3317] 1532
FAILURE CODE [CA3318] 1533
FAILURE CODE [CA3319] 1536
FAILURE CODE [CA3321] 1537
FAILURE CODE [CA3322] 1539
FAILURE CODE [CA3419] 1542
FAILURE CODE [CA3421] 1544
FAILURE CODE [CA3497] 1546
FAILURE CODE [CA3498] 1547
FAILURE CODE [CA3543] 1548
FAILURE CODE [CA3545] 1555
FAILURE CODE [CA3547] 1557
FAILURE CODE [CA3558] 1558
FAILURE CODE [CA3559] 1560
FAILURE CODE [CA3562] 1562
FAILURE CODE [CA3563] 1564
FAILURE CODE [CA3567] 1567
FAILURE CODE [CA3568] 1570
FAILURE CODE [CA3571] 1576
FAILURE CODE [CA3572] 1578
FAILURE CODE [CA3574] 1580
FAILURE CODE [CA3575] 1583
FAILURE CODE [CA3577] 1585
FAILURE CODE [CA3578] 1587
FAILURE CODE [CA3582] 1589
FAILURE CODE [CA3583] 1596
FAILURE CODE [CA3596] 1598
FAILURE CODE [CA3649] 1603
FAILURE CODE [CA3681] 1605
FAILURE CODE [CA3682] 1610
FAILURE CODE [CA3713] 1616
FAILURE CODE [CA3717] 1619
FAILURE CODE [CA3718] 1620
FAILURE CODE [CA3725] 1621
FAILURE CODE [CA3748] 1624
FAILURE CODE [CA3751] 1627
FAILURE CODE [CA3755] 1629
FAILURE CODE [CA3866] 1631
FAILURE CODE [CA3867] 1635
FAILURE CODE [CA3868] 1638
FAILURE CODE [CA3899] 1642
FAILURE CODE [CA3911] 1644
FAILURE CODE [CA3912] 1648
FAILURE CODE [CA3932] 1650
FAILURE CODE [CA3933] 1652
FAILURE CODE [CA3934] 1654
FAILURE CODE [CA3935] 1657
FAILURE CODE [CA3936] 1659
FAILURE CODE [CA4151] 1661
FAILURE CODE [CA4152] 1665
FAILURE CODE [CA4155] 1669
FAILURE CODE [CA4156] 1672
FAILURE CODE [CA4157] 1675
FAILURE CODE [CA4158] 1677
FAILURE CODE [CA4159] 1678
FAILURE CODE [CA4161] 1679
FAILURE CODE [CA4162] 1682
FAILURE CODE [CA4163] 1685
FAILURE CODE [CA4164] 1687
FAILURE CODE [CA4165] 1689
FAILURE CODE [CA4166] 1691
FAILURE CODE [CA4168] 1693
FAILURE CODE [CA4169] 1696
FAILURE CODE [CA4171] 1701
FAILURE CODE [CA4249] 1705
FAILURE CODE [CA4251] 1709
FAILURE CODE [CA4259] 1713
FAILURE CODE [CA4261] 1716
FAILURE CODE [CA4277] 1718
FAILURE CODE [CA4281] 1722
FAILURE CODE [CA4459] 1725
FAILURE CODE [CA4461] 1728
FAILURE CODE [CA4658] 1731
FAILURE CODE [CA4731] 1735
FAILURE CODE [CA4732] 1736
FAILURE CODE [CA4739] 1737
FAILURE CODE [CA4768] 1738
FAILURE CODE [CA4769] 1740
FAILURE CODE [CA4842] 1743
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) 1747
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1749
FAILURE CODE [CA5115] 1751
FAILURE CODE [CA5179] 1754
FAILURE CODE [CA5181] 1756
FAILURE CODE [CA5383] 1758
FAILURE CODE [D150KB] 1760
FAILURE CODE [D150KZ] 1761
FAILURE CODE [D164KY] 1762
FAILURE CODE [D19HKZ] 1764
FAILURE CODE [D19JKZ] 1766
FAILURE CODE [D1EHKA] 1768
FAILURE CODE [D1EHKB] 1769
FAILURE CODE [D1EHKY] 1770
FAILURE CODE [D1EMKA] 1771
FAILURE CODE [D1EMKB] 1772
FAILURE CODE [D1EMKY] 1773
FAILURE CODE [D1FBKB] 1774
FAILURE CODE [D5ZHL6] 1776
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) 1778
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1779
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) 1780
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1781
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) 1782
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1784
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) 1786
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1788
FAILURE CODE [D8AQK4] (MACHINE WITH KOMTRAX TERMINAL) 1790
FAILURE CODE [D8AQK4] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1791
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) 1792
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1794
FAILURE CODE [D8G1KT] 1796
FAILURE CODE [D8G6KT] 1797
FAILURE CODE [DAF0KT] 1798
FAILURE CODE [DAF0MB] 1799
FAILURE CODE [DAF0MC] 1800
FAILURE CODE [DAF3KK] 1801
FAILURE CODE [DAF8KB] 1803
FAILURE CODE [DAFDKB] 1805
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) 1807
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1808
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) 1809
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1811
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) 1813
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1815
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) 1817
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1818
FAILURE CODE [DAQ0KK] 1819
FAILURE CODE [DAQ0KT] 1821
FAILURE CODE [DAQ0MC] 1822
FAILURE CODE [DAQ1KA] 1823
FAILURE CODE [DAQ2KK] 1826
FAILURE CODE [DAQ9KQ] 1828
FAILURE CODE [DAQLKA] (MACHINE WITH KOMTRAX TERMINAL) 1829
FAILURE CODE [DAQLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1831
FAILURE CODE [DAQLKB] (MACHINE WITH KOMTRAX TERMINAL) 1833
FAILURE CODE [DAQLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1835
FAILURE CODE [DAQQKR] 1837
FAILURE CODE [DAQRKR] 1838
FAILURE CODE [DAQRMA] 1839
FAILURE CODE [DAQV00] 1840
FAILURE CODE [DAQW00] 1841
FAILURE CODE [DAZ9KQ] 1842
FAILURE CODE [DAZQKR] 1843
FAILURE CODE [DB10KT] 1844
FAILURE CODE [DB10MC] 1845
FAILURE CODE [DB11KA] 1846
FAILURE CODE [DB11KA] (MACHINE WITH EMERGENCY ENGINE STOP SWITCH) 1848
FAILURE CODE [DB12KK] 1851
FAILURE CODE [DB13KK] 1853
FAILURE CODE [DB19KQ] 1855
FAILURE CODE [DB1LKA] (MACHINE WITH KOMTRAX TERMINAL) 1856
FAILURE CODE [DB1LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1858
FAILURE CODE [DB1LKB] (MACHINE WITH KOMTRAX TERMINAL) 1860
FAILURE CODE [DB1LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1862
FAILURE CODE [DB1QKR] 1864
FAILURE CODE [DB1QMA] 1865
FAILURE CODE [DB1RKR] 1866
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) 1867
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1873
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1879
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1885
FAILURE CODE [DB2RKR] 1891
FAILURE CODE [DBS6KP] 1897
FAILURE CODE [DBS6KP] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1900
FAILURE CODE [DBSQKQ] 1903
FAILURE CODE [DBSQKR] (MACHINE WITH KOMTRAX TERMINAL) 1904
FAILURE CODE [DBSQKR] (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1909
FAILURE CODE [DBSQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1914
FAILURE CODE [DBSQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1919
FAILURE CODE [DD1ML4] 1924
FAILURE CODE [DDAAL6] 1927
FAILURE CODE [DDAAL6] (MACHINE WITH EMERGENCY ENGINE STOP SWITCH) 1929
FAILURE CODE [DDTHKA] 1932
FAILURE CODE [DDTJKA] 1934
FAILURE CODE [DDTKKA] 1936
FAILURE CODE [DDTLKA] 1938
FAILURE CODE [DDTMKA] 1940
FAILURE CODE [DDTNKA] 1942
FAILURE CODE [DF10KA] 1944
FAILURE CODE [DF10KB] 1948
FAILURE CODE [DGF1KX] 1953
FAILURE CODE [DGR3KB] 1955
FAILURE CODE [DGR3L8] 1956
FAILURE CODE [DGR4KB] 1958
FAILURE CODE [DGR4L8] 1959
FAILURE CODE [DGR6KB] 1961
FAILURE CODE [DGR6L8] 1962
FAILURE CODE [DGT1KX] 1964
FAILURE CODE [DHAAMA] 1966
FAILURE CODE [DHACMA] 1968
FAILURE CODE [DHP4KY] 1970
FAILURE CODE [DHP4KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1972
FAILURE CODE [DHP4KZ] 1974
FAILURE CODE [DHP4KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1976
FAILURE CODE [DHP5KY] 1978
FAILURE CODE [DHP5KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1980
FAILURE CODE [DHP5KZ] 1982
FAILURE CODE [DHP5KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1984
FAILURE CODE [DHP6KY] 1986
FAILURE CODE [DHP6KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1988
FAILURE CODE [DHP6KZ] 1990
FAILURE CODE [DHP6KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1992
FAILURE CODE [DHP7KY] 1994
FAILURE CODE [DHP7KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1996
FAILURE CODE [DHP7KZ] 1998
FAILURE CODE [DHP7KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2000
FAILURE CODE [DHQ2KX] 2002
FAILURE CODE [DHT5KX] 2004
FAILURE CODE [DHT5L6] 2006
FAILURE CODE [DHT8KX] 2008
FAILURE CODE [DHT8ZG] 2010
FAILURE CODE [DHU2KX] 2012
FAILURE CODE [DHU3KX] 2014
FAILURE CODE [DHUAKX] 2016
FAILURE CODE [DHUBKX] 2018
FAILURE CODE [DHUCKX] 2020
FAILURE CODE [DHUDKX] 2022
FAILURE CODE [DHUQKX] 2024
FAILURE CODE [DHURKX] 2026
FAILURE CODE [DJF1KA] 2028
FAILURE CODE [DK30KX] 2030
FAILURE CODE [DK51L5] 2032
FAILURE CODE [DK52KX] 2035
FAILURE CODE [DK53L8] 2037
FAILURE CODE [DK54KX] 2039
FAILURE CODE [DK60KX] 2041
FAILURE CODE [DKH0KX] 2043
FAILURE CODE [DKH1KX] 2045
FAILURE CODE [DKH1KX] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2047
FAILURE CODE [DLF1KA] 2049
FAILURE CODE [DLF1LC] 2051
FAILURE CODE [DLF2KA] 2053
FAILURE CODE [DLF2LC] 2055
FAILURE CODE [DLF400] 2057
FAILURE CODE [DLF4KA] 2058
FAILURE CODE [DLF4LC] 2060
FAILURE CODE [DLF6LC] 2062
FAILURE CODE [DLF7LC] 2064
FAILURE CODE [DLFDLC] 2066
FAILURE CODE [DLFELC] 2068
FAILURE CODE [DLFFLC] 2070
FAILURE CODE [DLFGLC] 2071
FAILURE CODE [DLM3KA] 2072
FAILURE CODE [DLM3LC] 2074
FAILURE CODE [DLM3MB] 2076
FAILURE CODE [DLM4KA] 2077
FAILURE CODE [DLM4LC] 2079
FAILURE CODE [DLM4MB] 2081
FAILURE CODE [DLT3KA] 2083
FAILURE CODE [DLT3LC] 2085
FAILURE CODE [DPQ1KR] 2087
FAILURE CODE [DPQ2KR] 2090
FAILURE CODE [DPQ3KR] 2093
FAILURE CODE [DSJ0KR] 2097
FAILURE CODE [DV00KB] 2098
FAILURE CODE [DW2BKA] 2100
FAILURE CODE [DW2BKB] 2101
FAILURE CODE [DW2BKY] 2102
FAILURE CODE [DW2BL1] 2103
FAILURE CODE [DW2BLH] 2105
FAILURE CODE [DW4BK4] 2106
FAILURE CODE [DW4BMA] 2109
FAILURE CODE [DW72KZ] 2112
FAILURE CODE [DW73KA] 2114
FAILURE CODE [DW73KB] 2116
FAILURE CODE [DW73KY] 2118
FAILURE CODE [DW78KZ] 2120
FAILURE CODE [DW7BKB] 2122
FAILURE CODE [DW7BKY] 2124
FAILURE CODE [DW7BKZ] 2125
FAILURE CODE [DW7LKB] 2127
FAILURE CODE [DW7LKY] 2128
FAILURE CODE [DW7LKZ] 2129
FAILURE CODE [DW7MKB] 2130
FAILURE CODE [DW7MKY] 2132
FAILURE CODE [DW7MKZ] 2133
FAILURE CODE [DW7NKZ] 2135
FAILURE CODE [DWNJKZ] 2137
FAILURE CODE [DWNKKZ] 2139
FAILURE CODE [DX13KA] 2141
FAILURE CODE [DX13KB] 2143
FAILURE CODE [DX13KY] 2145
FAILURE CODE [DX16KA] 2147
FAILURE CODE [DX16KB] 2148
FAILURE CODE [DX16KY] 2150
FAILURE CODE [DX29KA] 2151
FAILURE CODE [DX29KB] 2153
FAILURE CODE [DX29KY] 2155
FAILURE CODE [DX30K4] 2156
FAILURE CODE [DX30KA] 2158
FAILURE CODE [DX30KB] 2160
FAILURE CODE [DX30KY] 2162
FAILURE CODE [DX30MA] 2164
FAILURE CODE [DX31K4] 2166
FAILURE CODE [DX31KA] 2168
FAILURE CODE [DX31KB] 2170
FAILURE CODE [DX31KY] 2172
FAILURE CODE [DX31MA] 2174
FAILURE CODE [DX32K4] 2176
FAILURE CODE [DX32KA] 2178
FAILURE CODE [DX32KB] 2180
FAILURE CODE [DX32KY] 2182
FAILURE CODE [DX32MA] 2184
FAILURE CODE [DX33K4] 2186
FAILURE CODE [DX33KA] 2188
FAILURE CODE [DX33KB] 2190
FAILURE CODE [DX33KY] 2192
FAILURE CODE [DX33MA] 2194
FAILURE CODE [DXH0KA] 2196
FAILURE CODE [DXH0KB] 2198
FAILURE CODE [DXH0KY] 2200
FAILURE CODE [DXH1KA] 2202
FAILURE CODE [DXH1KB] 2204
FAILURE CODE [DXH1KY] 2206
FAILURE CODE [DXH2KA] 2208
FAILURE CODE [DXH2KB] 2211
FAILURE CODE [DXH2KY] 2214
FAILURE CODE [DXH3KA] 2217
FAILURE CODE [DXH3KB] 2220
FAILURE CODE [DXH3KY] 2223
FAILURE CODE [DXH4KA] 2226
FAILURE CODE [DXH4KB] 2228
FAILURE CODE [DXH4KY] 2230
FAILURE CODE [DXH5KA] 2233
FAILURE CODE [DXH5KB] 2235
FAILURE CODE [DXH5KY] 2237
FAILURE CODE [DXH6KA] 2240
FAILURE CODE [DXH6KB] 2242
FAILURE CODE [DXH6KY] 2244
FAILURE CODE [DXH7KA] 2247
FAILURE CODE [DXH7KB] 2249
FAILURE CODE [DXH7KY] 2251
FAILURE CODE [DY30MA] 2254
FAILURE CODE [DY30MC] 2256
FAILURE CODE [DY30ME] 2259
FAILURE CODE [F313KA] 2261
FAILURE CODE [F313KB] 2263
FAILURE CODE [F318KB] 2264
FAILURE CODE [F318KY] 2266
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2267
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2267
MANUAL PREHEATING SYSTEM DOES NOT WORK 2273
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2276
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2278
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2280
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (FOR MACHINES EQUIPPED WITH EMERGENCY ENGINE STOP SWITCH) 2283
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2286
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OUT OR FLICKERS) 2289
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2292
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2295
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2298
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2302
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2304
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2307
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2310
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2313
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2314
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2317
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2320
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2324
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2327
REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2329
GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2332
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2334
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2336
MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2337
ALARM BUZZER DOES NOT SOUND 2338
ALARM BUZZER DOES NOT STOP SOUNDING 2339
ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY 2341
AISS FUNCTION DOES NOT OPERATE PROPERLY 2343
HOIST LEVER DOES NOT OPERATE PROPERLY 2345
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2347
TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2350
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2354
SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2356
TAIL LAMP DOES NOT LIGHT UP 2358
(LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2360
(HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2362
EITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2364
HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2366
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY (MACHINE WITH KOMTRAX TERMINAL) 2368
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2370
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2372
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2372
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2373
FAILURE MODE AND CAUSE TABLE 2375
MACHINE DOES NOT START 2385
MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2388
LOCKUP IS NOT RELEASED 2389
ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2390
GEAR IS NOT SHIFTED UP 2392
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2395
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2396
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2397
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2399
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2402
OIL PRESSURE OF TORQUE CONVERTER IS LOW 2404
STEERING WHEEL IS HEAVY TO OPERATE 2406
STEERING WHEEL CANNOT BE OPERATED 2407
STEERING WHEEL WAGGLES 2408
FRONT BRAKE DOES NOT WORK ENOUGH 2409
CENTER BRAKE DOES NOT WORK ENOUGH 2410
DUMP BODY RISING SPEED IS LOW 2411
HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2413
DUMP BODY DOES NOT MOVE 2414
RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2416
AFTERCOOLER FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2417
UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN 2418
UNUSUAL NOISE IS HEARD FROM AROUND AFTERCOOLER FAN 2419
TROUBLESHOOTING OF ENGINE (S-MODE) 2420
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2420
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2421
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2422
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2423
ENGINE STARTABILITY IS POOR 2424
ENGINE DOES NOT PICK UP SMOOTHLY 2426
ENGINE STOPS DURING OPERATION 2428
ENGINE RUNS ROUGH OR IS UNSTABLE 2430
ENGINE LACKS POWER 2431
KDPF GETS CLOGGED IN A SHORT TIME 2433
ENGINE OIL CONSUMPTION IS EXCESSIVE 2435
OIL BECOMES CONTAMINATED QUICKLY 2436
FUEL CONSUMPTION IS EXCESSIVE 2437
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2438
OIL PRESSURE DROPS 2439
FUEL MIXES INTO ENGINE OIL 2441
WATER MIXES INTO ENGINE OIL (MILKY) 2442
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2443
UNUSUAL NOISE IS HEARD 2444
VIBRATION IS EXCESSIVE 2445
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2446
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2447
ACTIVE REGENERATION TAKES TIME 2449
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2451
AdBlue/DEF CONSUMPTION IS EXCESSIVE 2452
THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2454
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2455
50 DISASSEMBLY AND ASSEMBLY 2457
CONTENTS 2458
ABBREVIATION LIST 2463
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2469
HOW TO READ THIS MANUAL 2469
COATING MATERIALS LIST 2471
SPECIAL TOOLS LIST 2475
SKETCHES OF SPECIAL TOOLS 2494
ENGINE AND COOLING SYSTEM 2512
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2512
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2513
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2518
REMOVE AND INSTALL INJECTOR ASSEMBLY 2524
METHOD FOR REMOVING INJECTOR ASSEMBLY 2525
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2535
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2549
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2549
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2550
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2552
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2553
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2564
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2579
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2579
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2580
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2582
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2582
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2586
REMOVE AND INSTALL STARTER ASSEMBLY 2590
METHOD FOR REMOVING STARTER ASSEMBLY 2590
METHOD FOR INSTALLING STARTER ASSEMBLY 2592
REMOVE AND INSTALL ALTERNATOR BELT 2594
METHOD FOR REMOVING ALTERNATOR BELT 2594
METHOD FOR INSTALLING ALTERNATOR BELT 2596
REMOVE AND INSTALL RADIATOR ASSEMBLY 2598
METHOD FOR REMOVING RADIATOR ASSEMBLY 2598
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2600
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2604
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2604
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2607
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2612
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2613
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2616
REMOVE AND INSTALL AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2620
METHOD FOR REMOVING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2620
METHOD FOR INSTALLING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2621
REMOVE AND INSTALL ENGINE ASSEMBLY 2625
METHOD FOR REMOVING ENGINE ASSEMBLY 2627
METHOD FOR INSTALLING ENGINE ASSEMBLY 2632
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2639
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2639
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2643
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2649
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2649
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2651
REMOVE AND INSTALL OUTPUT SHAFT 2657
METHOD FOR REMOVING OUTPUT SHAFT 2658
METHOD FOR INSTALLING OUTPUT SHAFT 2660
DISASSEMBLE AND ASSEMBLE OUTPUT SHAFT 2665
METHOD FOR DISASSEMBLING OUTPUT SHAFT 2665
METHOD FOR ASSEMBLING OUTPUT SHAFT 2667
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2670
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2670
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2675
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2678
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2678
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2683
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2687
REMOVE AdBlue/DEF TANK SENSOR 2687
INSTALL AdBlue/DEF TANK SENSOR 2688
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2690
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2690
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2690
REMOVE AND INSTALL KDPF ASSEMBLY 2691
METHOD FOR REMOVING KDPF ASSEMBLY 2692
METHOD FOR INSTALLING KDPF ASSEMBLY 2695
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2699
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2699
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2703
REMOVE AND INSTALL SCR ASSEMBLY 2708
METHOD FOR REMOVING SCR ASSEMBLY 2708
METHOD FOR INSTALLING SCR ASSEMBLY 2712
REMOVE AND INSTALL KCCV ASSEMBLY 2717
METHOD FOR REMOVING KCCV ASSEMBLY 2717
METHOD FOR INSTALLING KCCV ASSEMBLY 2718
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2719
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2719
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2725
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2732
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2732
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2735
REMOVE AND INSTALL AdBlue/DEF PUMP 2738
METHOD FOR REMOVING AdBlue/DEF PUMP 2738
METHOD FOR INSTALLING AdBlue/DEF PUMP 2742
REMOVE AND INSTALL AdBlue/DEF HOSE 2746
METHOD FOR REMOVING AdBlue/DEF HOSE 2746
METHOD FOR INSTALLING AdBlue/DEF HOSE 2750
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2754
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2754
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2757
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2760
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2760
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2762
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2764
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2764
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2765
POWER TRAIN 2766
REMOVE AND INSTALL TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2766
METHOD FOR REMOVING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2767
METHOD FOR INSTALLING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2779
DISCONNECT AND CONNECT TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2793
METHOD FOR DISCONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2793
METHOD FOR CONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2794
DISASSEMBLE AND ASSEMBLE FRONT DIFFERENTIAL ASSEMBLY 2796
METHOD FOR DISASSEMBLING FRONT DIFFERENTIAL ASSEMBLY 2796
METHOD FOR ASSEMBLING FRONT DIFFERENTIAL ASSEMBLY 2801
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2812
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2813
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2817
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2822
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2823
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2848
REMOVE AND INSTALL CENTER DIFFERENTIAL ASSEMBLY 2875
METHOD FOR REMOVING CENTER DIFFERENTIAL ASSEMBLY 2875
METHOD FOR INSTALLING CENTER DIFFERENTIAL ASSEMBLY 2878
DISASSEMBLE AND ASSEMBLE CENTER DIFFERENTIAL ASSEMBLY 2882
METHOD FOR DISASSEMBLING CENTER DIFFERENTIAL ASSEMBLY 2883
METHOD FOR ASSEMBLING CENTER DIFFERENTIAL ASSEMBLY 2888
REMOVE AND INSTALL REAR DIFFERENTIAL ASSEMBLY 2899
METHOD FOR REMOVING REAR DIFFERENTIAL ASSEMBLY 2899
METHOD FOR INSTALLING REAR DIFFERENTIAL ASSEMBLY 2901
DISASSEMBLE AND ASSEMBLE REAR DIFFERENTIAL ASSEMBLY 2903
METHOD FOR DISASSEMBLING REAR DIFFERENTIAL ASSEMBLY 2903
METHOD FOR ASSEMBLING REAR DIFFERENTIAL ASSEMBLY 2907
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2916
METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2916
METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2921
DISASSEMBLE AND ASSEMBLE FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2926
METHOD FOR DISASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2927
METHOD FOR ASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2933
REMOVE AND INSTALL CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2942
METHOD FOR REMOVING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2942
METHOD FOR INSTALLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2944
DISASSEMBLE AND ASSEMBLE CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2946
METHOD FOR DISASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2947
METHOD FOR ASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 2950
DISASSEMBLE AND ASSEMBLE REAR FINAL DRIVE ASSEMBLY 2957
METHOD FOR DISASSEMBLING REAR FINAL DRIVE ASSEMBLY 2957
METHOD FOR ASSEMBLING REAR FINAL DRIVE ASSEMBLY 2961
REMOVE AND INSTALL CENTER AXLE ASSEMBLY 2966
METHOD FOR REMOVING CENTER AXLE ASSEMBLY 2966
METHOD FOR INSTALLING CENTER AXLE ASSEMBLY 2969
REMOVE AND INSTALL REAR AXLE ASSEMBLY 2972
METHOD FOR REMOVING REAR AXLE ASSEMBLY 2972
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 2974
STEERING SYSTEM 2977
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY 2977
METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY 2978
METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY 2981
UNDERCARRIAGE AND FRAME 2986
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 2986
METHOD FOR REMOVING FRONT SUSPENSION CYLINDER ASSEMBLY 2987
METHOD FOR INSTALLING FRONT SUSPENSION CYLINDER ASSEMBLY 2990
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 2995
METHOD FOR REMOVING REAR SUSPENSION CYLINDER ASSEMBLY 2995
METHOD FOR INSTALLING REAR SUSPENSION CYLINDER ASSEMBLY 2996
DISASSEMBLE AND ASSEMBLE SUSPENSION CYLINDER ASSEMBLY 2998
METHOD FOR DISASSEMBLING SUSPENSION CYLINDER ASSEMBLY 2998
METHOD FOR ASSEMBLING SUSPENSION CYLINDER ASSEMBLY 2998
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 3000
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 3000
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 3002
REMOVE AND INSTALL HITCH FRAME ASSEMBLY 3004
METHOD FOR REMOVING HITCH FRAME ASSEMBLY 3005
METHOD FOR INSTALLING HITCH FRAME ASSEMBLY 3014
DISASSEMBLE AND ASSEMBLE HITCH FRAME ASSEMBLY 3025
METHOD FOR DISASSEMBLING HITCH FRAME ASSEMBLY 3025
METHOD FOR ASSEMBLING HITCH FRAME ASSEMBLY 3027
HYDRAULIC SYSTEM 3032
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3032
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3032
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3037
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 3041
METHOD FOR REMOVING FLOW AMPLIFIER VALVE ASSEMBLY 3041
METHOD FOR INSTALLING FLOW AMPLIFIER VALVE ASSEMBLY 3043
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 3046
METHOD FOR REMOVING HOIST VALVE ASSEMBLY 3046
METHOD FOR INSTALLING HOIST VALVE ASSEMBLY 3049
DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY 3051
METHOD FOR DISASSEMBLING HOIST CYLINDER ASSEMBLY 3051
METHOD FOR ASSEMBLING HOIST CYLINDER ASSEMBLY 3054
WORK EQUIPMENT 3060
REMOVE AND INSTALL DUMP BODY ASSEMBLY 3060
METHOD FOR REMOVING DUMP BODY ASSEMBLY 3060
METHOD FOR INSTALLING DUMP BODY ASSEMBLY 3062
CAB AND ITS ATTACHMENTS 3064
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3064
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 3065
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 3067
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 3071
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 3072
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 3072
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3077
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3078
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3084
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY GRAMMER) 3091
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3091
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3092
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY SEARS) 3094
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3094
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3096
REMOVE AND INSTALL SEAT BELT 3099
METHOD FOR REMOVING SEAT BELT 3099
METHOD FOR INSTALLING SEAT BELT 3100
ELECTRICAL SYSTEM 3101
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3101
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3101
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3103
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3106
METHOD FOR REMOVING RETARDER AND HOIST CONTROLLER ASSEMBLY 3106
METHOD FOR INSTALLING RETARDER AND HOIST CONTROLLER ASSEMBLY 3107
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3108
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3108
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3109
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3110
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3110
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3112
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3115
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3115
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3117
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3119
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3119
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3121
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3123
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3123
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3124
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3125
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3125
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3127
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3131
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 3131
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 3138
REMOVE AND INSTALL COMMUNICATION TERMINAL 3144
METHOD FOR REMOVING COMMUNICATION TERMINAL 3144
METHOD FOR INSTALLING COMMUNICATION TERMINAL 3150
60 MAINTENANCE STANDARD 3157
CONTENTS 3158
ABBREVIATION LIST 3160
ENGINE AND COOLING SYSTEM 3166
MAINTENANCE STANDARD OF ENGINE MOUNT 3166
MAINTENANCE STANDARD OF OUTPUT SHAFT 3167
MAINTENANCE STANDARD OF RADIATOR FAN PUMP 3168
MAINTENANCE STANDARD OF SERVO VALVE OF RADIATOR FAN PUMP 3169
MAINTENANCE STANDARD OF RADIATOR FAN MOTOR 3170
MAINTENANCE STANDARD OF AFTERCOOLER FAN MOTOR 3172
POWER TRAIN 3175
MAINTENANCE STANDARD OF DRIVE SHAFT 3175
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 3176
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3177
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3180
MAINTENANCE STANDARD OF TRANSMISSION 3181
MAINTENANCE STANDARD OF FL, R CLUTCH 3185
MAINTENANCE STANDARD OF FH, 1ST CLUTCH 3186
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH 3187
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH 3189
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3191
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3192
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH ECMV 3193
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 3194
MAINTENANCE STANDARD OF FRONT AXLE 3196
MAINTENANCE STANDARD OF CENTER AXLE 3197
MAINTENANCE STANDARD OF REAR AXLE 3198
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL 3199
MAINTENANCE STANDARD OF CENTER DIFFERENTIAL 3200
MAINTENANCE STANDARD OF REAR DIFFERENTIAL 3201
MAINTENANCE STANDARD OF FRONT FINAL DRIVE 3202
MAINTENANCE STANDARD OF CENTER FINAL DRIVE 3204
MAINTENANCE STANDARD OF REAR FINAL DRIVE 3205
STEERING SYSTEM 3206
MAINTENANCE STANDARD OF STEERING COLUMN 3206
MAINTENANCE STANDARD OF STEERING CYLINDER 3207
BRAKE SYSTEM 3208
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER 3208
MAINTENANCE STANDARD OF CENTER SLACK ADJUSTER 3209
MAINTENANCE STANDARD OF FRONT BRAKE 3210
MAINTENANCE STANDARD OF CENTER BRAKE 3212
MAINTENANCE STANDARD OF PARKING BRAKE 3214
UNDERCARRIAGE AND FRAME 3216
MAINTENANCE STANDARD OF FRONT SUSPENSION 3216
MAINTENANCE STANDARD OF CENTER AND REAR SUSPENSIONS 3218
MAINTENANCE STANDARD OF SUSPENSION CYLINDER 3221
MAINTENANCE STANDARD OF OSCILLATION HITCH 3223
HYDRAULIC SYSTEM 3225
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP 3225
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP 3226
MAINTENANCE STANDARD OF POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP AND AFTERCOOLER FAN PUMP 3228
MAINTENANCE STANDARD OF CENTER BRAKE COOLING PUMP 3230
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP 3231
MAINTENANCE STANDARD OF HOIST VALVE 3232
WORK EQUIPMENT 3234
MAINTENANCE STANDARD OF HOIST CYLINDER 3234
80 APPENDIX 3235
CONTENTS 3236
ABBREVIATION LIST 3238
AIR CONDITIONER SYSTEM 3244
PRECAUTIONS FOR REFRIGERANT 3244
AIR CONDITIONER COMPONENT 3245
SPECIFICATIONS OF AIR CONDITIONER 3247
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3248
OUTLINE OF REFRIGERATION CYCLE 3249
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3251
AIR CONDITIONER UNIT 3251
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3251
FUNCTION OF AIR CONDITIONER UNIT 3253
COMPONENT PARTS OF AIR CONDITIONER UNIT 3255
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3256
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3256
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3256
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3256
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3257
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3257
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3257
FUNCTION OF DUAL PRESSURE SWITCH 3258
AIR CONDITIONER CONTROLLER 3259
STRUCTURE OF AIR CONDITIONER CONTROLLER 3259
COMPRESSOR 3260
STRUCTURE OF COMPRESSOR 3260
SPECIFICATIONS OF COMPRESSOR 3260
FUNCTION OF COMPRESSOR 3260
CONDENSER 3261
STRUCTURE OF CONDENSER 3261
SPECIFICATIONS OF CONDENSER 3261
FUNCTION OF CONDENSER 3261
RECEIVER DRIER 3262
STRUCTURE OF RECEIVER DRIER 3262
SPECIFICATIONS OF RECEIVER DRIER 3262
FUNCTION OF RECEIVER DRIER 3262
SENSORS FOR AIR CONDITIONER SYSTEM 3263
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3263
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3263
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3264
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3266
AIR CONDITIONER SYSTEM DIAGRAM 3268
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3269
FUNCTION OF AIR CONDITIONER CONTROLLER 3270
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3271
TESTING AIR LEAKAGE (DUCT) 3274
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3274
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3278
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3279
TEST VENT (MODE) CHANGEOVER 3281
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3281
TESTING FRESH/RECIRC AIR CHANGEOVER 3282
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3282
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3283
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3283
TEST RELAYS 3284
METHOD FOR TESTING RELAYS 3284
AIR CONDITIONER TROUBLESHOOTING CHART 1 3286
AIR CONDITIONER TROUBLESHOOTING CHART 2 3287
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3290
FAILURE CODE [879AKA] 3292
FAILURE CODE [879AKB] 3293
FAILURE CODE [879BKA] 3294
FAILURE CODE [879BKB] 3296
FAILURE CODE [879CKA] 3298
FAILURE CODE [879CKB] 3299
FAILURE CODE [879EMC] 3300
FAILURE CODE [879FMC] 3301
FAILURE CODE [879GKX] 3302
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3304
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3306
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3309
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3311
TROUBLESHOOTING USING GAUGE PRESSURE 3313
CONNECTION OF SERVICE TOOL 3316
METHOD FOR CONNECTING SERVICE TOOL 3316
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3318
HANDLE COMPRESSOR OIL 3320
90 CIRCUIT DIAGRAMS 3323
CONTENTS 3324
ABBREVIATION LIST 3327
HYDRAULIC CIRCUIT DIAGRAM 3333
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3333
HYDRAULIC CIRCUIT DIAGRAM 3337
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3339
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (AT REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3341
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE (AT REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3342
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT REVERSE 1ST + RIGHT TURN + BRAKE OPERATION) 3343
HYDRAULIC CIRCUIT DIAGRAM OF STEERING, HOIST (AT DUMP BODY RAISE, FORWARD 2ND OPERATION) 3345
HYDRAULIC CIRCUIT DIAGRAM OF POWER TRAIN (AT DUMP BODY RAISE, FORWARD 2ND OPERATION) 3347
ELECTRICAL CIRCUIT DIAGRAM 3349
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3349
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (1/8) 3353
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (2/8) 3355
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (3/8) 3357
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (4/8) 3359
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (5/8) 3361
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (6/8) 3363
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (7/8) 3365
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (8/8) 3367
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (1/8) 3369
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (2/8) 3371
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (3/8) 3373
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (4/8) 3375
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (5/8) 3377
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (6/8) 3379
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (7/8) 3381
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (8/8) 3383
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/9) 3385
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/9) 3387
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/9) 3389
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/9) 3391
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/9) 3393
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/9) 3395
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/9) 3397
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/9) 3399
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/9) 3401
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (1/9) 3403
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (2/9) 3405
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (3/9) 3407
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (4/9) 3409
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (5/9) 3411
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (6/9) 3413
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (7/9) 3415
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (8/9) 3417
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (9/9) 3419
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (1/8) 3421
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (2/8) 3423
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (3/8) 3425
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (4/8) 3427
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (5/8) 3429
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (6/8) 3431
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (7/8) 3433
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (8/8) 3435
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/8) 3437
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/8) 3439
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/8) 3441
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/8) 3443
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/8) 3445
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/8) 3447
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/8) 3449
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/8) 3451
INDEX 3453

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