Komatsu HM400-5 Articulated Dump Truck Shop Manual SEN06519-19 – PDF DOWNLOAD

Description

Komatsu HM400-5 Articulated Dump Truck Shop Manual SEN06519-19 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu HM400-5 Articulated Dump Truck Shop Manual SEN06519-19 – 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 HM400-5 Articulated Dump Truck Shop Manual SEN06519-19 – 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: HM400-5 107
SPECIFICATIONS 109
SPECIFICATIONS: HM400-5 109
WEIGHT TABLE 115
WEIGHT TABLE: HM400-5 115
TABLE OF QUANTITY OF OIL AND COOLANT TO BE ADDED (NORTH AMERICA SPECIFICATION) 117
TABLE OF QUANTITY OF FUEL, COOLANT AND LUBRICANTS (AUSTRALIA SPECIFICATION) 119
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 126
UREA SCR SYSTEM 132
LAYOUT DRAWING OF UREA SCR SYSTEM 132
UREA SCR SYSTEM DIAGRAM 134
FUNCTION OF UREA SCR SYSTEM 135
FUNCTION OF AdBlue/DEF SYSTEM 135
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 151
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 160
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 162
SYSTEM OPERATING LAMP SYSTEM 164
SYSTEM DIAGRAM OF OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 164
SYSTEM DIAGRAM OF OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 165
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 165
BATTERY DISCONNECT SWITCH 167
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 167
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 167
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 168
ENGINE SYSTEM 169
LAYOUT DRAWING OF ENGINE SYSTEM 169
FUNCTION OF ENGINE SYSTEM 171
AUTOMATIC IDLE STOP SYSTEM 172
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 172
COMPONENT PARTS OF ENGINE SYSTEM 174
OUTPUT SHAFT 174
VGT 175
EGR SYSTEM 179
EGR VALVE 182
EGR COOLER 184
KCCV SYSTEM 185
KCCV VENTILATOR 187
KDPF 189
COOLING SYSTEM 193
LAYOUT DRAWING OF COOLING SYSTEM 193
SPECIFICATIONS OF COOLING SYSTEM 194
RADIATOR FAN CONTROL SYSTEM 195
RADIATOR FAN CONTROL SYSTEM DIAGRAM 195
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 195
AFTERCOOLER FAN CONTROL SYSTEM 197
AFTERCOOLER FAN CONTROL SYSTEM DIAGRAM 197
FUNCTION OF AFTERCOOLER FAN CONTROL SYSTEM 197
COMPONENT PARTS OF COOLING SYSTEM 199
RADIATOR FAN PUMP 199
RADIATOR FAN MOTOR 206
AFTERCOOLER FAN MOTOR 211
CENTER BRAKE COOLING REMOTE MOTOR 222
CENTER BRAKE COOLING REMOTE PUMP 225
HYDRAULIC OIL COOLER BYPASS VALVE 226
CONTROL SYSTEM 227
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 227
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 228
RETARDER AND HOIST CONTROL SYSTEM 229
SYSTEM DIAGRAM OF RETARDER AND HOIST CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 229
SYSTEM DIAGRAM OF RETARDER AND HOIST CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 230
MACHINE MONITOR SYSTEM 231
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 231
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 232
FUNCTION OF MACHINE MONITOR SYSTEM 233
REARVIEW MONITOR SYSTEM 234
REARVIEW MONITOR SYSTEM DIAGRAM 234
FUNCTION OF REARVIEW MONITOR SYSTEM 234
KOMTRAX SYSTEM 235
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 235
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 235
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 236
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 236
PAYLOAD METER SYSTEM 237
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 237
PAYLOAD METER SYSTEM DIAGRAM 238
FUNCTION OF PAYLOAD METER SYSTEM 238
MACHINE WEIGHT MEASURING METHOD IN PAYLOAD METER SYSTEM 238
MACHINE WEIGHT CALIBRATION METHOD IN PAYLOAD METER SYSTEM 240
COMPONENT PARTS OF CONTROL SYSTEM 241
MACHINE MONITOR 241
SWITCH PANEL 263
REARVIEW MONITOR 264
REARVIEW CAMERA 266
KOMTRAX TERMINAL 267
GATEWAY FUNCTION CONTROLLER 269
COMMUNICATION TERMINAL 272
TRANSMISSION CONTROLLER 274
RETARDER AND HOIST CONTROLLER 281
MONITOR CONTROLLER 286
ENGINE CONTROLLER 291
PAYLOAD METER CONTROLLER 298
ACCELERATOR PEDAL 307
SHIFT LEVER 308
RETARDER CONTROL LEVER 309
HYDRAULIC SYSTEM 310
LAYOUT DRAWING OF HYDRAULIC SYSTEM 310
COMPONENT PARTS OF HYDRAULIC SYSTEM 311
HYDRAULIC TANK 311
STEERING AND HOIST PUMP 312
LS VALVE 319
PC VALVE 320
POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP, AFTERCOOLER FAN PUMP, AND CENTER BRAKE COOLING REMOTE MOTOR DRIVE PUMP 324
HOIST VALVE 326
POWER TRAIN SYSTEM 331
LAYOUT DRAWING OF POWER TRAIN SYSTEM 331
TRANSMISSION CONTROL SYSTEM 333
SYSTEM DIAGRAM OF TRANSMISSION CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 333
SYSTEM DIAGRAM OF TRANSMISSION CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 334
SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 335
GEAR SHIFT CONTROL SYSTEM 339
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 339
SHIFT HOLD SYSTEM 342
FUNCTION OF SHIFT HOLD SYSTEM 342
DIRECTION CONTROL SYSTEM 343
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 343
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 343
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 344
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 344
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 344
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 345
COMPONENT PARTS OF POWER TRAIN SYSTEM 347
DRIVE SHAFT 347
TORQUE CONVERTER AND PTO 349
LOCKUP CLUTCH ECMV 353
TRANSMISSION 356
TRANSMISSION CONTROL VALVE 377
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 379
DIFFERENTIAL LOCK CLUTCH ECMV 384
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 387
AXLE 391
DIFFERENTIAL 394
FINAL DRIVE 398
WORK EQUIPMENT SYSTEM 402
WORK EQUIPMENT CONTROL 402
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 402
FUNCTION OF WORK EQUIPMENT CONTROL 402
HOIST CONTROL 403
HOIST CONTROL SYSTEM DIAGRAM 403
FUNCTION OF HOIST CONTROL 403
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 405
DUMP LEVER 405
DUMP EPC VALVE 410
STEERING SYSTEM 412
LAYOUT DRAWING OF STEERING SYSTEM 412
FUNCTION OF STEERING SYSTEM 413
STEERING COLUMN 414
STRUCTURE OF STEERING COLUMN 414
COMPONENT PARTS OF STEERING SYSTEM 415
FLOW AMPLIFIER VALVE 415
STEERING VALVE 419
STEERING PUMP SELECTOR SOLENOID VALVE 424
SECONDARY STEERING PUMP 425
SECONDARY STEERING MOTOR 426
BRAKE SYSTEM 427
LAYOUT DRAWING OF BRAKE SYSTEM 427
RETARDER CONTROL 429
RETARDER CONTROL SYSTEM DIAGRAM 429
FUNCTION OF RETARDER CONTROL 430
PARKING BRAKE INTERLOCK FUNCTION 432
FUNCTION OF PARKING BRAKE INTERLOCK FUNCTION 432
OPERATION OF PARKING BRAKE INTERLOCK FUNCTION 432
ARAC SYSTEM 433
ARAC SYSTEM DIAGRAM 433
FUNCTION OF ARAC SYSTEM 433
COMPONENT PARTS OF BRAKE SYSTEM 434
BRAKE CHARGE PUMP 434
PARKING BRAKE SOLENOID VALVE AND ACCUMULATOR CHARGE VALVE 435
PARKING BRAKE SOLENOID VALVE 436
ACCUMULATOR CHARGE VALVE 436
BRAKE CIRCUIT ACCUMULATOR 441
SHUT OFF SOLENOID VALVE 443
BRAKE VALVE 444
PROPORTIONAL PRESSURE REDUCING VALVE 447
SLACK ADJUSTER 448
BRAKE 451
FRONT BRAKE COOLING RELIEF VALVE 454
CENTER BRAKE COOLING RELIEF VALVE 454
BRAKE SYSTEM TANK 455
PARKING BRAKE 456
SPRING CYLINDER 457
PARKING BRAKE CALIPER 459
UNDERCARRIAGE AND FRAME 461
FRONT SUSPENSION 461
STRUCTURE OF FRONT SUSPENSION 461
FUNCTION OF FRONT SUSPENSION 461
CENTER AND REAR SUSPENSIONS 463
STRUCTURE OF CENTER AND REAR SUSPENSIONS 463
FUNCTION OF CENTER SUSPENSION 463
FUNCTION OF REAR SUSPENSION 464
SUSPENSION CYLINDER 465
STRUCTURE OF SUSPENSION CYLINDER 465
FUNCTION OF SUSPENSION CYLINDER 466
OPERATION OF SUSPENSION CYLINDER 467
OSCILLATION HITCH 468
STRUCTURE OF OSCILLATION HITCH 468
FUNCTION OF OSCILLATION HITCH 469
WORK EQUIPMENT 470
STRUCTURE OF WORK EQUIPMENT 470
FUNCTION OF WORK EQUIPMENT 471
CAB AND ITS ATTACHMENTS 472
ROPS CAB 472
STRUCTURE OF ROPS CAB 472
FUNCTION OF ROPS CAB 473
CAB TILT 474
STRUCTURE OF CAB TILT 474
20 STANDARD VALUE TABLE 475
CONTENTS 476
ABBREVIATION LIST 477
STANDARD VALUE TABLE FOR ENGINE 483
STANDARD VALUE TABLE FOR ENGINE: HM400-5 483
STANDARD VALUE TABLE FOR MACHINE 487
STANDARD VALUE TABLE FOR MACHINE: HM400-5 487
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 501
STANDARD VALUE TABLE FOR ELECTRICAL 502
STANDARD VALUE TABLE FOR ELECTRICITY 502
30 TESTING AND ADJUSTING 519
CONTENTS 520
ABBREVIATION LIST 523
RELATED INFORMATION ON TESTING AND ADJUSTING 529
TOOLS FOR TESTING AND ADJUSTING 529
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 537
ENGINE AND COOLING SYSTEM 539
TEST ENGINE SPEED 539
METHOD FOR TESTING ENGINE SPEED 539
TEST BOOST PRESSURE 542
METHOD FOR TESTING BOOST PRESSURE 542
TEST EXHAUST GAS TEMPERATURE 544
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 544
TEST EXHAUST GAS COLOR 547
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 547
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 548
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 550
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 550
TEST AND ADJUST VALVE CLEARANCE 553
METHOD FOR TESTING VALVE CLEARANCE 553
METHOD FOR ADJUSTING VALVE CLEARANCE 554
TEST COMPRESSION PRESSURE 555
METHOD FOR TESTING COMPRESSION PRESSURE 555
TEST BLOWBY PRESSURE 558
METHOD FOR TESTING BLOWBY PRESSURE 558
TEST ENGINE OIL PRESSURE 560
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 560
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 560
TEST EGR VALVE AND VGT OIL PRESSURE 562
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 562
TEST FUEL PRESSURE 564
METHOD FOR TESTING FUEL PRESSURE 564
TEST FUEL RETURN RATE AND LEAKAGE 566
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 567
BLEED AIR FROM FUEL SYSTEM 572
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 572
TEST FUEL CIRCUIT FOR LEAKAGE 574
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 574
HANDLE CYLINDER CUT-OUT MODE OPERATION 576
HANDLE NO-INJECTION CRANKING OPERATION 577
CLEAN FUEL DOSER 578
METHOD FOR CLEANING FUEL DOSER 578
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 581
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 581
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 588
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 588
TEST SCR RELATED FUNCTIONS 589
TEST AdBlue/DEF PUMP RAISED PRESSURE 593
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 596
TEST AdBlue/DEF LINE HEATER RELAY 1 601
TEST AdBlue/DEF LINE HEATER RELAY 2 605
TEST AdBlue/DEF PUMP HEATER RELAY 609
TEST AdBlue/DEF TANK HEATER VALVE 613
TEST DENITRATION EFFICIENCY OF SCR 617
CLEAN AdBlue/DEF TANK 621
METHOD FOR CLEANING AdBlue/DEF TANK 621
CLEAN AdBlue/DEF PUMP 626
CLEAN AdBlue/DEF PUMP 626
TEST TORQUE CONVERTER STALL SPEED 633
METHOD FOR TESTING TORQUE CONVERTER STALL SPEED 633
TEST RADIATOR FAN AND AFTERCOOLER FAN SPEED 638
METHOD FOR TESTING RADIATOR FAN AND AFTERCOOLER FAN SPEED 638
POWER TRAIN 640
TEST POWER TRAIN OIL PRESSURE 640
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 643
ADJUST TRANSMISSION SPEED SENSOR 658
METHOD FOR ADJUSTING TRANSMISSION SPEED SENSOR 659
ADJUST TRANSMISSION CONTROLLER 661
METHOD FOR ADJUSTING TRANSMISSION CONTROLLER 661
MOVE MACHINE WHICH HAS A TROUBLE IN ELECTRICAL SYSTEM 662
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN ENGINE CONTROL SYSTEM 662
METHOD FOR MOVING MACHINE WHICH HAS A TROUBLE IN TRANSMISSION CONTROL SYSTEM 663
MOVE MACHINE WHICH HAS A TROUBLE IN TRACTION CONTROL SYSTEM (KTCS) 669
METHOD FOR MOVING MACHINE WITH SECONDARY KTCS OPERATION CONNECTOR 671
STEERING SYSTEM 672
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 672
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 672
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 673
BLEED AIR FROM STEERING CYLINDER CIRCUIT 674
BLEED AIR FROM STEERING CYLINDER CIRCUIT 674
BRAKE SYSTEM 676
TEST AND ADJUST BRAKE OIL PRESSURE 676
METHOD FOR TESTING BRAKE OIL PRESSURE 676
METHOD FOR ADJUSTING BRAKE OIL PRESSURE 680
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE GAS 682
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE 682
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 686
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 691
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 691
BLEED AIR FROM BRAKE CIRCUIT 692
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 692
TEST BRAKE PERFORMANCE 694
METHOD FOR TESTING BRAKE PERFORMANCE 694
TEST WEAR OF WHEEL BRAKE DISC 698
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 698
RELEASE PARKING BRAKE MANUALLY 700
METHOD FOR RELEASING PARKING BRAKE MANUALLY 700
TEST AND ADJUST WEAR OF PARKING BRAKE PAD 701
METHOD FOR TESTING WEAR OF PARKING BRAKE PAD 701
METHOD FOR ADJUSTING CLEARANCE OF PARKING BRAKE PAD 702
HYDRAULIC SYSTEM 704
TEST AND ADJUST SUSPENSION CYLINDER 704
METHOD FOR TESTING SUSPENSION CYLINDER 705
METHOD FOR ADJUSTING SUSPENSION CYLINDER 705
TEST AND ADJUST DUMP CIRCUIT OIL PRESSURE 709
METHOD FOR TESTING DUMP CIRCUIT OIL PRESSURE 709
METHOD FOR ADJUSTING DUMP CIRCUIT OIL PRESSURE 710
WORK EQUIPMENT 712
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 712
METHOD FOR TESTING BODY POSITIONER SENSOR 712
METHOD FOR ADJUSTING DUMP BODY POSITIONER SENSOR 712
TEST AND ADJUST DUMP BODY MOUNT 715
METHOD FOR TESTING DUMP BODY MOUNT 715
METHOD FOR ADJUSTING DUMP BODY MOUNT 716
CAB AND ITS ATTACHMENTS 717
CAB TILT UP 717
METHOD FOR TILTING UP CAB 718
ADJUST STEERING WHEEL TILT LOCK LEVER 724
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 724
ADJUST RATTLING OPERATOR’S SEAT 726
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 726
ELECTRICAL SYSTEM 727
SET AND ADJUST EACH EQUIPMENT 727
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 729
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 730
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 733
METHOD FOR SETTING CHARACTERISTIC VALUE OF ARAC (Automatic Retarder Accelerator Control) 738
METHOD FOR PERFORMING SYSTEM CHECK OF KTCS (Komatsu Traction Control System) 741
SET AND OPERATE OF MACHINE MONITOR 743
OPERATOR MODE 747
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 747
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 747
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 748
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 749
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 749
SERVICE MODE 753
METHOD FOR OPERATING SERVICE MODE 753
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 756
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 764
ABNORMALITY RECORD MENU 781
METHOD FOR CONFIRMING MAINTENANCE RECORD 786
METHOD FOR OPERATING MAINTENANCE MODE SETTING 788
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 792
DEFAULT MENU 794
DIAGNOSTIC TESTS MENU 809
ADJUSTMENT MENU 821
METHOD FOR PERFORMING NO-INJECTION CRANKING 827
PAYLOAD METER SETTING 829
KOMTRAX SETTINGS MENU 852
METHOD FOR DISPLAYING SERVICE MESSAGE 856
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 858
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 862
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 864
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 869
ADJUST OPTICAL AXIS OF HEAD LAMP 871
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 871
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 875
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 876
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 877
TEST DIODES 878
METHOD FOR TESTING DIODE USING DIGITAL TESTER 878
METHOD FOR TESTING DIODE USING ANALOG TESTER 878
Pm CLINIC 879
Pm CLINIC SERVICE 879
Pm CLINIC CHECK SHEET 882
40 TROUBLESHOOTING 891
CONTENTS 892
ABBREVIATION LIST 905
RELATED INFORMATION ON TROUBLESHOOTING 911
GENERAL TROUBLESHOOTING POINTS 911
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 912
SEQUENCE OF EVENTS IN TROUBLESHOOTING 927
CHECKS BEFORE TROUBLESHOOTING 929
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 931
WALK-AROUND CHECK 931
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 933
CHECK FUEL LEVEL AND TYPE 933
CHECK IMPURE INGREDIENT IN FUEL 933
CHECK AdBule/DEF LEVEL AND TYPE 934
CHECK FUEL PREFILTER 934
CHECK MAIN FILTER 936
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 937
CHECK COOLANT LEVEL (RESERVOIR TANK) 938
CHECK CLOGGING OF AIR CLEANER 939
OUTER ELEMENT – CLEAN 940
REPLACE ELEMENT 942
CHECK HYDRAULIC OIL LEVEL 944
CHECK HYDRAULIC OIL STRAINER 944
CHECK HYDRAULIC FILTER 945
CHECK OIL LEVEL IN TRANSMISSION CASE 946
CHECK OIL LEVEL IN DIFFERENTIAL CASE 946
CHECK OIL LEVEL IN FINAL DRIVE CASE 947
BLEED AIR FROM FUEL SYSTEM 947
BLEED AIR FROM HYDRAULIC SYSTEM 947
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 947
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 956
PROCEDURE FOR TESTING AND TROUBLESHOOTING 965
SYMPTOM AND TROUBLESHOOTING NUMBERS 967
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 970
CONNECTORS LIST AND LAYOUT 972
CONNECTOR CONTACT IDENTIFICATION 999
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1039
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) 1045
FUSE LOCATION TABLE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1049
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1053
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1057
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1059
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1065
FAILURE CODES TABLE 1067
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1093
FAILURE CODE [1500L0] 1093
FAILURE CODE [15B0NX] 1094
FAILURE CODE [15F0KM] 1096
FAILURE CODE [15F0MB] 1097
FAILURE CODE [15F7KM] 1098
FAILURE CODE [15G0MW] 1099
FAILURE CODE [15G7KM] 1102
FAILURE CODE [15H0MW] 1103
FAILURE CODE [15J0MW] 1106
FAILURE CODE [15K0MW] 1109
FAILURE CODE [15L0MW] 1112
FAILURE CODE [15M0MW] 1115
FAILURE CODE [15SBL1] 1118
FAILURE CODE [15SBMA] 1121
FAILURE CODE [15SCL1] (APPLICABLE MACHINE: 10001 TO 10171) 1122
FAILURE CODE [15SCL1] (APPLICABLE MACHINE: 10172 AND UP) 1126
FAILURE CODE [15SCMA] 1130
FAILURE CODE [15SDL1] (APPLICABLE MACHINE: 10001 TO 10171) 1131
FAILURE CODE [15SDL1] (APPLICABLE MACHINE: 10172 AND UP) 1134
FAILURE CODE [15SDMA] 1137
FAILURE CODE [15SEL1] (APPLICABLE MACHINE: 10001 TO 10171) 1138
FAILURE CODE [15SEL1] (APPLICABLE MACHINE: 10172 AND UP) 1141
FAILURE CODE [15SEMA] 1144
FAILURE CODE [15SFL1] (APPLICABLE MACHINE: 10001 TO 10171) 1145
FAILURE CODE [15SFL1] (APPLICABLE MACHINE: 10172 AND UP) 1148
FAILURE CODE [15SFMA] 1151
FAILURE CODE [15SGL1] 1152
FAILURE CODE [15SGMA] 1155
FAILURE CODE [15SJMA] 1156
FAILURE CODE [15SKMA] 1158
FAILURE CODE [2F00KM] 1160
FAILURE CODE [2G42ZG] 1162
FAILURE CODE [2G43ZG] 1163
FAILURE CODE [879AKA] 1164
FAILURE CODE [879AKB] 1165
FAILURE CODE [879BKA] 1166
FAILURE CODE [879BKB] 1168
FAILURE CODE [879CKA] 1170
FAILURE CODE [879CKB] 1171
FAILURE CODE [879EMC] 1172
FAILURE CODE [879FMC] 1173
FAILURE CODE [879GKX] 1174
FAILURE CODE [989D00] 1176
FAILURE CODE [989L00] 1177
FAILURE CODE [989M00] 1178
FAILURE CODE [989N00] 1179
FAILURE CODE [A1U0N3] 1180
FAILURE CODE [A1U0N4] 1182
FAILURE CODE [AA10NX] 1184
FAILURE CODE [AB00KE] 1186
FAILURE CODE [AB00KY] 1188
FAILURE CODE [AQ10N3] 1190
FAILURE CODE [AS00N3] 1192
FAILURE CODE [AS00R2] 1194
FAILURE CODE [AS00R3] 1195
FAILURE CODE [AS00R4] 1196
FAILURE CODE [AS00R5] 1197
FAILURE CODE [AS00R6] 1198
FAILURE CODE [AS00ZK] 1199
FAILURE CODE [AS10KM] 1200
FAILURE CODE [AS10NR] 1201
FAILURE CODE [AS10NT] 1202
FAILURE CODE [B@BAZG] 1203
FAILURE CODE [B@BAZK] 1204
FAILURE CODE [B@BCNS] 1205
FAILURE CODE [B@BCQA] 1206
FAILURE CODE [B@BCZK] 1208
FAILURE CODE [B@C6NS] 1210
FAILURE CODE [B@C8NS] 1211
FAILURE CODE [B@CENS] 1212
FAILURE CODE [B@JANS] 1213
FAILURE CODE [CA115] 1214
FAILURE CODE [CA122] 1215
FAILURE CODE [CA123] 1217
FAILURE CODE [CA131] 1219
FAILURE CODE [CA132] 1221
FAILURE CODE [CA135] 1224
FAILURE CODE [CA141] 1226
FAILURE CODE [CA144] 1228
FAILURE CODE [CA145] 1230
FAILURE CODE [CA153] 1232
FAILURE CODE [CA154] 1235
FAILURE CODE [CA187] 1238
FAILURE CODE [CA221] 1240
FAILURE CODE [CA222] 1242
FAILURE CODE [CA227] 1244
FAILURE CODE [CA234] 1245
FAILURE CODE [CA238] 1246
FAILURE CODE [CA239] 1248
FAILURE CODE [CA249] 1250
FAILURE CODE [CA256] 1252
FAILURE CODE [CA271] 1254
FAILURE CODE [CA272] 1256
FAILURE CODE [CA273] 1257
FAILURE CODE [CA274] 1259
FAILURE CODE [CA322] 1260
FAILURE CODE [CA323] 1262
FAILURE CODE [CA324] 1264
FAILURE CODE [CA325] 1266
FAILURE CODE [CA331] 1268
FAILURE CODE [CA332] 1270
FAILURE CODE [CA343] 1272
FAILURE CODE [CA351] 1273
FAILURE CODE [CA352] 1274
FAILURE CODE [CA356] 1277
FAILURE CODE [CA357] 1279
FAILURE CODE [CA386] 1281
FAILURE CODE [CA431] 1282
FAILURE CODE [CA432] 1285
FAILURE CODE [CA441] 1288
FAILURE CODE [CA442] 1291
FAILURE CODE [CA449] 1292
FAILURE CODE [CA451] 1293
FAILURE CODE [CA452] 1295
FAILURE CODE [CA515] 1297
FAILURE CODE [CA516] 1299
FAILURE CODE [CA553] 1301
FAILURE CODE [CA555] 1302
FAILURE CODE [CA556] 1303
FAILURE CODE [CA559] 1304
FAILURE CODE [CA595] 1309
FAILURE CODE [CA687] 1310
FAILURE CODE [CA689] 1312
FAILURE CODE [CA691] 1314
FAILURE CODE [CA692] 1316
FAILURE CODE [CA697] 1318
FAILURE CODE [CA698] 1319
FAILURE CODE [CA731] 1320
FAILURE CODE [CA778] 1321
FAILURE CODE [CA1117] 1324
FAILURE CODE [CA1664] 1325
FAILURE CODE [CA1669] 1328
FAILURE CODE [CA1673] 1329
FAILURE CODE [CA1677] 1330
FAILURE CODE [CA1678] 1331
FAILURE CODE [CA1682] 1332
FAILURE CODE [CA1683] 1336
FAILURE CODE [CA1684] 1338
FAILURE CODE [CA1686] 1340
FAILURE CODE [CA1691] 1341
FAILURE CODE [CA1694] 1344
FAILURE CODE [CA1695] 1346
FAILURE CODE [CA1696] 1347
FAILURE CODE [CA1712] 1349
FAILURE CODE [CA1713] 1352
FAILURE CODE [CA1714] 1355
FAILURE CODE [CA1715] 1356
FAILURE CODE [CA1776] 1357
FAILURE CODE [CA1777] 1360
FAILURE CODE [CA1843] 1363
FAILURE CODE [CA1844] 1365
FAILURE CODE [CA1879] 1368
FAILURE CODE [CA1881] 1371
FAILURE CODE [CA1883] 1373
FAILURE CODE [CA1885] 1377
FAILURE CODE [CA1887] 1379
FAILURE CODE [CA1921] 1381
FAILURE CODE [CA1922] 1384
FAILURE CODE [CA1923] 1389
FAILURE CODE [CA1924] 1391
FAILURE CODE [CA1925] 1393
FAILURE CODE [CA1927] 1395
FAILURE CODE [CA1928] 1397
FAILURE CODE [CA1942] 1399
FAILURE CODE [CA1963] 1400
FAILURE CODE [CA1977] 1404
FAILURE CODE [CA1993] 1407
FAILURE CODE [CA2185] 1410
FAILURE CODE [CA2186] 1412
FAILURE CODE [CA2249] 1414
FAILURE CODE [CA2265] 1415
FAILURE CODE [CA2266] 1417
FAILURE CODE [CA2271] 1420
FAILURE CODE [CA2272] 1422
FAILURE CODE [CA2349] 1425
FAILURE CODE [CA2353] 1427
FAILURE CODE [CA2357] 1429
FAILURE CODE [CA2381] 1430
FAILURE CODE [CA2382] 1432
FAILURE CODE [CA2383] 1434
FAILURE CODE [CA2386] 1436
FAILURE CODE [CA2387] 1438
TROUBLESHOOTING FLOWCHART 1442
FAILURE CODE [CA2555] 1443
FAILURE CODE [CA2556] 1445
FAILURE CODE [CA2637] 1447
FAILURE CODE [CA2639] 1449
FAILURE CODE [CA2732] 1452
FAILURE CODE [CA2733] 1454
FAILURE CODE [CA2741] 1456
FAILURE CODE [CA2765] 1457
FAILURE CODE [CA2771] 1458
FAILURE CODE [CA2777] 1464
FAILURE CODE [CA2878] 1467
FAILURE CODE [CA2881] 1470
FAILURE CODE [CA2976] 1473
FAILURE CODE [CA3133] 1475
FAILURE CODE [CA3134] 1477
FAILURE CODE [CA3135] 1479
FAILURE CODE [CA3142] 1483
FAILURE CODE [CA3143] 1484
FAILURE CODE [CA3144] 1485
FAILURE CODE [CA3146] 1488
FAILURE CODE [CA3147] 1489
FAILURE CODE [CA3148] 1490
FAILURE CODE [CA3151] 1492
FAILURE CODE [CA3165] 1498
FAILURE CODE [CA3167] 1500
FAILURE CODE [CA3229] 1503
FAILURE CODE [CA3231] 1505
FAILURE CODE [CA3232] 1507
FAILURE CODE [CA3235] 1511
FAILURE CODE [CA3239] 1513
FAILURE CODE [CA3241] 1516
FAILURE CODE [CA3242] 1519
FAILURE CODE [CA3251] 1522
FAILURE CODE [CA3253] 1524
FAILURE CODE [CA3254] 1528
FAILURE CODE [CA3255] 1531
FAILURE CODE [CA3256] 1535
FAILURE CODE [CA3311] 1537
FAILURE CODE [CA3312] 1539
FAILURE CODE [CA3313] 1542
FAILURE CODE [CA3314] 1543
FAILURE CODE [CA3315] 1544
FAILURE CODE [CA3316] 1547
FAILURE CODE [CA3317] 1548
FAILURE CODE [CA3318] 1549
FAILURE CODE [CA3319] 1552
FAILURE CODE [CA3321] 1553
FAILURE CODE [CA3322] 1555
FAILURE CODE [CA3419] 1558
FAILURE CODE [CA3421] 1560
FAILURE CODE [CA3497] 1562
FAILURE CODE [CA3498] 1563
FAILURE CODE [CA3543] 1564
FAILURE CODE [CA3545] 1571
FAILURE CODE [CA3547] 1573
FAILURE CODE [CA3558] 1574
FAILURE CODE [CA3559] 1576
FAILURE CODE [CA3562] 1578
FAILURE CODE [CA3563] 1580
FAILURE CODE [CA3567] 1583
FAILURE CODE [CA3568] 1586
FAILURE CODE [CA3571] 1592
FAILURE CODE [CA3572] 1594
FAILURE CODE [CA3574] 1596
FAILURE CODE [CA3575] 1599
FAILURE CODE [CA3577] 1601
FAILURE CODE [CA3578] 1603
FAILURE CODE [CA3582] 1605
FAILURE CODE [CA3583] 1612
FAILURE CODE [CA3596] 1614
FAILURE CODE [CA3649] 1619
FAILURE CODE [CA3681] 1621
FAILURE CODE [CA3682] 1626
FAILURE CODE [CA3713] 1632
FAILURE CODE [CA3717] 1635
FAILURE CODE [CA3718] 1636
FAILURE CODE [CA3725] 1637
FAILURE CODE [CA3748] 1640
FAILURE CODE [CA3751] 1643
FAILURE CODE [CA3755] 1645
FAILURE CODE [CA3866] 1647
FAILURE CODE [CA3867] 1651
FAILURE CODE [CA3868] 1654
FAILURE CODE [CA3899] 1658
FAILURE CODE [CA3911] 1660
FAILURE CODE [CA3912] 1664
FAILURE CODE [CA3932] 1666
FAILURE CODE [CA3933] 1668
FAILURE CODE [CA3934] 1670
FAILURE CODE [CA3935] 1673
FAILURE CODE [CA3936] 1675
FAILURE CODE [CA4151] 1677
FAILURE CODE [CA4152] 1681
FAILURE CODE [CA4155] 1685
FAILURE CODE [CA4156] 1688
FAILURE CODE [CA4157] 1691
FAILURE CODE [CA4158] 1693
FAILURE CODE [CA4159] 1694
FAILURE CODE [CA4161] 1695
FAILURE CODE [CA4162] 1698
FAILURE CODE [CA4163] 1701
FAILURE CODE [CA4164] 1703
FAILURE CODE [CA4165] 1705
FAILURE CODE [CA4166] 1707
FAILURE CODE [CA4168] 1709
FAILURE CODE [CA4169] 1712
FAILURE CODE [CA4171] 1717
FAILURE CODE [CA4249] 1721
FAILURE CODE [CA4251] 1725
FAILURE CODE [CA4259] 1729
FAILURE CODE [CA4261] 1732
FAILURE CODE [CA4277] 1734
FAILURE CODE [CA4281] 1738
FAILURE CODE [CA4459] 1741
FAILURE CODE [CA4461] 1744
FAILURE CODE [CA4658] 1747
FAILURE CODE [CA4731] 1751
FAILURE CODE [CA4732] 1752
FAILURE CODE [CA4739] 1753
FAILURE CODE [CA4768] 1754
FAILURE CODE [CA4769] 1756
FAILURE CODE [CA4842] 1759
FAILURE CODE [CA4952] (MACHINE WITH KOMTRAX TERMINAL) 1763
FAILURE CODE [CA4952] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1765
FAILURE CODE [CA5115] 1767
FAILURE CODE [CA5179] 1770
FAILURE CODE [CA5181] 1772
FAILURE CODE [CA5383] 1774
FAILURE CODE [D150KB] 1776
FAILURE CODE [D150KZ] 1777
FAILURE CODE [D151KB] 1778
FAILURE CODE [D151KZ] 1779
FAILURE CODE [D164KY] 1780
FAILURE CODE [D19HKZ] 1782
FAILURE CODE [D19JKZ] 1784
FAILURE CODE [D1EHKA] 1786
FAILURE CODE [D1EHKB] 1787
FAILURE CODE [D1EHKY] 1788
FAILURE CODE [D1EMKA] 1789
FAILURE CODE [D1EMKB] 1790
FAILURE CODE [D1EMKY] 1791
FAILURE CODE [D1FBKB] 1792
FAILURE CODE [D5ZHL6] 1794
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) 1796
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1797
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) 1798
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1799
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) 1800
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1802
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) 1804
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1806
FAILURE CODE [D8AQK4] (MACHINE WITH KOMTRAX TERMINAL) 1808
FAILURE CODE [D8AQK4] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1809
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) 1810
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1812
FAILURE CODE [D8G1KT] 1814
FAILURE CODE [D8G6KT] 1815
FAILURE CODE [DAF0KT] 1816
FAILURE CODE [DAF0MB] 1817
FAILURE CODE [DAF0MC] 1818
FAILURE CODE [DAF3KK] 1819
FAILURE CODE [DAF8KB] 1821
FAILURE CODE [DAFDKB] 1823
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) 1825
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1826
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) 1827
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1829
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) 1831
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1833
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) 1835
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1836
FAILURE CODE [DAQ0KK] 1837
FAILURE CODE [DAQ0KT] 1839
FAILURE CODE [DAQ0MC] 1840
FAILURE CODE [DAQ1KA] 1841
FAILURE CODE [DAQ2KK] 1844
FAILURE CODE [DAQ9KQ] 1846
FAILURE CODE [DAQLKA] (MACHINE WITH KOMTRAX TERMINAL) 1847
FAILURE CODE [DAQLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1849
FAILURE CODE [DAQLKB] (MACHINE WITH KOMTRAX TERMINAL) 1851
FAILURE CODE [DAQLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1853
FAILURE CODE [DAQQKR] 1855
FAILURE CODE [DAQRKR] 1856
FAILURE CODE [DAQRMA] 1857
FAILURE CODE [DAQV00] 1858
FAILURE CODE [DAQW00] 1859
FAILURE CODE [DAZ9KQ] 1860
FAILURE CODE [DAZQKR] 1861
FAILURE CODE [DB10KT] 1862
FAILURE CODE [DB10MC] 1863
FAILURE CODE [DB11KA] 1864
FAILURE CODE [DB11KA] (MACHINE WITH EMERGENCY ENGINE STOP SWITCH) 1866
FAILURE CODE [DB12KK] 1869
FAILURE CODE [DB13KK] 1871
FAILURE CODE [DB19KQ] 1873
FAILURE CODE [DB1LKA] (MACHINE WITH KOMTRAX TERMINAL) 1874
FAILURE CODE [DB1LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1876
FAILURE CODE [DB1LKB] (MACHINE WITH KOMTRAX TERMINAL) 1878
FAILURE CODE [DB1LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1880
FAILURE CODE [DB1QKR] 1882
FAILURE CODE [DB1QMA] 1883
FAILURE CODE [DB1RKR] 1884
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) 1885
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1891
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1897
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1903
FAILURE CODE [DB2RKR] 1909
FAILURE CODE [DBS6KP] 1915
FAILURE CODE [DBS6KP] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1918
FAILURE CODE [DBSQKQ] 1921
FAILURE CODE [DBSQKR] (MACHINE WITH KOMTRAX TERMINAL) 1922
FAILURE CODE [DBSQKR] (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1927
FAILURE CODE [DBSQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1932
FAILURE CODE [DBSQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 1937
FAILURE CODE [DD1ML4] 1942
FAILURE CODE [DDAAL6] 1945
FAILURE CODE [DDAAL6] (MACHINE WITH EMERGENCY ENGINE STOP SWITCH) 1947
FAILURE CODE [DDTHKA] (SERIAL NUMBER: 10001 – 10171) 1950
FAILURE CODE [DDTHKA] (SERIAL NUMBER: 10172 AND UP) 1952
FAILURE CODE [DDTJKA] (SERIAL NUMBER: 10001 – 10171) 1954
FAILURE CODE [DDTJKA] (SERIAL NUMBER: 10172 AND UP) 1956
FAILURE CODE [DDTKKA] (SERIAL NUMBER: 10001 – 10171) 1958
FAILURE CODE [DDTKKA] (SERIAL NUMBER: 10172 AND UP) 1960
FAILURE CODE [DDTLKA] (SERIAL NUMBER: 10001 – 10171) 1962
FAILURE CODE [DDTLKA] (SERIAL NUMBER: 10172 AND UP) 1964
FAILURE CODE [DDTMKA] 1966
FAILURE CODE [DDTNKA] 1968
FAILURE CODE [DF10KA] 1970
FAILURE CODE [DF10KB] 1974
FAILURE CODE [DGF1KX] 1979
FAILURE CODE [DGR3KB] 1981
FAILURE CODE [DGR3L8] 1982
FAILURE CODE [DGR4KB] 1984
FAILURE CODE [DGR4L8] 1985
FAILURE CODE [DGR6KB] 1987
FAILURE CODE [DGR6L8] 1988
FAILURE CODE [DGR7KX] 1990
FAILURE CODE [DGT1KX] 1992
FAILURE CODE [DHAAMA] 1994
FAILURE CODE [DHACMA] 1996
FAILURE CODE [DHP4KY] 1998
FAILURE CODE [DHP4KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2000
FAILURE CODE [DHP4KZ] 2002
FAILURE CODE [DHP4KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2004
FAILURE CODE [DHP5KY] 2006
FAILURE CODE [DHP5KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2008
FAILURE CODE [DHP5KZ] 2010
FAILURE CODE [DHP5KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2012
FAILURE CODE [DHP6KY] 2014
FAILURE CODE [DHP6KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2016
FAILURE CODE [DHP6KZ] 2018
FAILURE CODE [DHP6KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2020
FAILURE CODE [DHP7KY] 2022
FAILURE CODE [DHP7KY] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2024
FAILURE CODE [DHP7KZ] 2026
FAILURE CODE [DHP7KZ] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2028
FAILURE CODE [DHQ2KX] 2030
FAILURE CODE [DHT5KX] 2032
FAILURE CODE [DHT5L6] 2034
FAILURE CODE [DHT8KX] 2036
FAILURE CODE [DHT8ZG] 2038
FAILURE CODE [DHU2KX] 2040
FAILURE CODE [DHU3KX] 2042
FAILURE CODE [DHUAKX] 2044
FAILURE CODE [DHUBKX] 2046
FAILURE CODE [DHUCKX] 2048
FAILURE CODE [DHUDKX] 2050
FAILURE CODE [DHUEKX] 2052
FAILURE CODE [DHUQKX] 2054
FAILURE CODE [DHURKX] 2056
FAILURE CODE [DJF1KA] 2058
FAILURE CODE [DK30KX] 2060
FAILURE CODE [DK51L5] 2062
FAILURE CODE [DK52KX] 2065
FAILURE CODE [DK53L8] 2067
FAILURE CODE [DK54KX] 2069
FAILURE CODE [DK60KX] 2071
FAILURE CODE [DKH0KX] 2073
FAILURE CODE [DKH1KX] 2075
FAILURE CODE [DKH1KX] (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) 2077
FAILURE CODE [DLF1KA] 2079
FAILURE CODE [DLF1LC] 2081
FAILURE CODE [DLF2KA] 2083
FAILURE CODE [DLF2LC] 2085
FAILURE CODE [DLF400] 2087
FAILURE CODE [DLF4KA] 2088
FAILURE CODE [DLF4LC] 2090
FAILURE CODE [DLF6LC] 2092
FAILURE CODE [DLF7LC] 2094
FAILURE CODE [DLFDLC] 2096
FAILURE CODE [DLFELC] 2098
FAILURE CODE [DLFFLC] 2100
FAILURE CODE [DLFGLC] 2101
FAILURE CODE [DLM3KA] 2102
FAILURE CODE [DLM3LC] 2104
FAILURE CODE [DLM3MB] 2106
FAILURE CODE [DLM4KA] 2107
FAILURE CODE [DLM4LC] 2109
FAILURE CODE [DLM4MB] 2111
FAILURE CODE [DLT3KA] 2113
FAILURE CODE [DLT3LC] 2115
FAILURE CODE [DPQ1KR] 2117
FAILURE CODE [DPQ2KR] 2120
FAILURE CODE [DPQ3KR] 2123
FAILURE CODE [DSJ0KR] 2127
FAILURE CODE [DV00KB] 2128
FAILURE CODE [DW2BKA] 2130
FAILURE CODE [DW2BKB] 2131
FAILURE CODE [DW2BKY] 2132
FAILURE CODE [DW2BL1] 2133
FAILURE CODE [DW2BLH] 2135
FAILURE CODE [DW4BK4] 2136
FAILURE CODE [DW4BMA] 2139
FAILURE CODE [DW72KZ] 2142
FAILURE CODE [DW73KA] 2144
FAILURE CODE [DW73KB] 2146
FAILURE CODE [DW73KY] 2148
FAILURE CODE [DW7BKB] 2150
FAILURE CODE [DW7BKY] 2152
FAILURE CODE [DW7BKZ] 2153
FAILURE CODE [DW7LKB] 2155
FAILURE CODE [DW7LKY] 2156
FAILURE CODE [DW7LKZ] 2157
FAILURE CODE [DW7NKZ] 2158
FAILURE CODE [DWNJKZ] 2160
FAILURE CODE [DWNKKZ] 2162
FAILURE CODE [DX13KA] 2164
FAILURE CODE [DX13KB] 2166
FAILURE CODE [DX13KY] 2168
FAILURE CODE [DX16KA] 2170
FAILURE CODE [DX16KB] 2171
FAILURE CODE [DX16KY] 2173
FAILURE CODE [DX29KA] 2174
FAILURE CODE [DX29KB] 2176
FAILURE CODE [DX29KY] 2178
FAILURE CODE [DX30K4] 2179
FAILURE CODE [DX30KA] 2181
FAILURE CODE [DX30KB] 2183
FAILURE CODE [DX30KY] 2185
FAILURE CODE [DX30MA] 2187
FAILURE CODE [DX31K4] 2189
FAILURE CODE [DX31KA] 2191
FAILURE CODE [DX31KB] 2193
FAILURE CODE [DX31KY] 2195
FAILURE CODE [DX31MA] 2197
FAILURE CODE [DX32K4] 2199
FAILURE CODE [DX32KA] 2201
FAILURE CODE [DX32KB] 2203
FAILURE CODE [DX32KY] 2205
FAILURE CODE [DX32MA] 2207
FAILURE CODE [DX33K4] 2209
FAILURE CODE [DX33KA] 2211
FAILURE CODE [DX33KB] 2213
FAILURE CODE [DX33KY] 2215
FAILURE CODE [DX33MA] 2217
FAILURE CODE [DX34KA] 2219
FAILURE CODE [DX34KB] 2220
FAILURE CODE [DX34KY] 2222
FAILURE CODE [DXH0KA] 2223
FAILURE CODE [DXH0KB] 2225
FAILURE CODE [DXH0KY] 2227
FAILURE CODE [DXH1KA] 2229
FAILURE CODE [DXH1KB] 2231
FAILURE CODE [DXH1KY] 2233
FAILURE CODE [DXH2KA] 2235
FAILURE CODE [DXH2KB] 2238
FAILURE CODE [DXH2KY] 2241
FAILURE CODE [DXH3KA] 2244
FAILURE CODE [DXH3KB] 2247
FAILURE CODE [DXH3KY] 2250
FAILURE CODE [DXH4KA] 2253
FAILURE CODE [DXH4KB] 2255
FAILURE CODE [DXH4KY] 2257
FAILURE CODE [DXH5KA] 2260
FAILURE CODE [DXH5KB] 2262
FAILURE CODE [DXH5KY] 2264
FAILURE CODE [DXH6KA] 2267
FAILURE CODE [DXH6KB] 2269
FAILURE CODE [DXH6KY] 2271
FAILURE CODE [DXH7KA] 2274
FAILURE CODE [DXH7KB] 2276
FAILURE CODE [DXH7KY] 2278
FAILURE CODE [DY30MA] 2281
FAILURE CODE [DY30MC] 2284
FAILURE CODE [DY30ME] 2287
FAILURE CODE [DY32MC] 2289
FAILURE CODE [F313KA] 2292
FAILURE CODE [F313KB] 2294
FAILURE CODE [F318KB] 2295
FAILURE CODE [F318KY] 2297
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2298
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2298
MANUAL PREHEATING SYSTEM DOES NOT WORK 2304
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2307
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2309
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2311
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (FOR MACHINES EQUIPPED WITH EMERGENCY ENGINE STOP SWITCH) 2314
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2317
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2320
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2323
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2326
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2329
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2333
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2335
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2338
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2341
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2344
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2345
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2348
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2351
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2355
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2358
REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED 2360
GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET 2363
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2365
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2367
MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 2368
ALARM BUZZER DOES NOT SOUND 2369
ALARM BUZZER DOES NOT STOP SOUNDING 2370
ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY 2372
AISS FUNCTION DOES NOT OPERATE PROPERLY 2374
HOIST LEVER DOES NOT OPERATE PROPERLY 2376
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY 2378
TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 2381
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2385
SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 2387
TAIL LAMP DOES NOT LIGHT UP 2389
(LOW BEAM) HEAD LAMP DOES NOT LIGHT UP 2391
(HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP 2393
NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP 2395
HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 2397
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY (MACHINE WITH KOMTRAX TERMINAL) 2399
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2401
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2403
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2403
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2404
FAILURE MODE AND CAUSE TABLE 2406
MACHINE DOES NOT START 2416
MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 2419
LOCKUP IS NOT RELEASED 2420
ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 2421
GEAR IS NOT SHIFTED UP 2423
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS 2426
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE 2428
MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED 2429
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2431
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2434
OIL PRESSURE OF TORQUE CONVERTER IS LOW 2436
STEERING WHEEL IS HEAVY TO OPERATE 2438
STEERING WHEEL CANNOT BE OPERATED 2439
STEERING WHEEL WAGGLES 2440
FRONT BRAKE DOES NOT WORK ENOUGH 2441
CENTER BRAKE DOES NOT WORK ENOUGH 2442
DUMP BODY RISING SPEED IS LOW 2443
HYDRAULIC DRIFT OF DUMP BODY IS LARGE 2445
DUMP BODY DOES NOT MOVE 2446
RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2448
AFTERCOOLER FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 2449
UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN 2450
UNUSUAL NOISE IS HEARD FROM AROUND AFTERCOOLER FAN 2451
TROUBLESHOOTING OF ENGINE (S-MODE) 2452
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2452
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2453
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2454
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2455
ENGINE STARTABILITY IS POOR 2456
ENGINE DOES NOT PICK UP SMOOTHLY 2458
ENGINE STOPS DURING OPERATION 2460
ENGINE RUNS ROUGH OR IS UNSTABLE 2462
ENGINE LACKS POWER 2463
KDPF GETS CLOGGED IN A SHORT TIME 2465
ENGINE OIL CONSUMPTION IS EXCESSIVE 2467
OIL BECOMES CONTAMINATED QUICKLY 2468
FUEL CONSUMPTION IS EXCESSIVE 2469
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2470
OIL PRESSURE DROPS 2471
FUEL MIXES INTO ENGINE OIL 2473
WATER MIXES INTO ENGINE OIL (MILKY) 2474
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2475
UNUSUAL NOISE IS HEARD 2476
VIBRATION IS EXCESSIVE 2477
AIR CANNOT BE BLED FROM FUEL CIRCUIT 2478
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2479
ACTIVE REGENERATION TAKES TIME 2481
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2483
AdBlue/DEF CONSUMPTION IS EXCESSIVE 2484
THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2486
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2487
50 DISASSEMBLY AND ASSEMBLY 2489
CONTENTS 2490
ABBREVIATION LIST 2495
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2501
HOW TO READ THIS MANUAL 2501
COATING MATERIALS LIST 2503
SPECIAL TOOLS LIST 2507
SKETCHES OF SPECIAL TOOLS 2525
ENGINE AND COOLING SYSTEM 2544
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2544
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2544
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2545
REMOVE AND INSTALL INJECTOR ASSEMBLY 2549
METHOD FOR REMOVING INJECTOR ASSEMBLY 2549
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2562
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2580
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2580
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2581
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2584
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2585
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2599
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2623
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2623
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2625
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2627
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2627
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2631
REMOVE AND INSTALL STARTER ASSEMBLY 2635
METHOD FOR REMOVING STARTER ASSEMBLY 2635
METHOD FOR INSTALLING STARTER ASSEMBLY 2636
REMOVE AND INSTALL ALTERNATOR BELT 2639
METHOD FOR REMOVING ALTERNATOR BELT 2639
METHOD FOR INSTALLING ALTERNATOR BELT 2640
REMOVE AND INSTALL RADIATOR ASSEMBLY 2642
METHOD FOR REMOVING RADIATOR ASSEMBLY 2642
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2647
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2654
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2654
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2660
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2667
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2667
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2669
REMOVE AND INSTALL AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2673
METHOD FOR REMOVING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2673
METHOD FOR INSTALLING AFTERCOOLER FAN AND FAN MOTOR ASSEMBLY 2674
REMOVE AND INSTALL ENGINE ASSEMBLY 2677
METHOD FOR REMOVING ENGINE ASSEMBLY 2678
METHOD FOR INSTALLING ENGINE ASSEMBLY 2686
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2696
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2696
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2697
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2700
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2700
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2701
REMOVE AND INSTALL OUTPUT SHAFT 2708
METHOD FOR REMOVING OUTPUT SHAFT 2709
METHOD FOR INSTALLING OUTPUT SHAFT 2712
DISASSEMBLE AND ASSEMBLE OUTPUT SHAFT 2716
METHOD FOR DISASSEMBLING OUTPUT SHAFT 2716
METHOD FOR ASSEMBLING OUTPUT SHAFT 2717
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2719
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2719
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2724
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2728
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2728
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2733
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2738
REMOVE AdBlue/DEF TANK SENSOR 2738
INSTALL AdBlue/DEF TANK SENSOR 2739
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2741
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2741
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2741
REMOVE AND INSTALL KDPF ASSEMBLY 2742
METHOD FOR REMOVING KDPF ASSEMBLY 2743
METHOD FOR INSTALLING KDPF ASSEMBLY 2746
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2750
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2750
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2754
REMOVE AND INSTALL SCR ASSEMBLY 2759
METHOD FOR REMOVING SCR ASSEMBLY 2759
METHOD FOR INSTALLING SCR ASSEMBLY 2763
REMOVE AND INSTALL KCCV ASSEMBLY 2768
METHOD FOR REMOVING KCCV ASSEMBLY 2768
METHOD FOR INSTALLING KCCV ASSEMBLY 2770
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2773
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2773
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2780
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2788
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2788
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2791
REMOVE AND INSTALL AdBlue/DEF PUMP 2794
METHOD FOR REMOVING AdBlue/DEF PUMP 2794
METHOD FOR INSTALLING AdBlue/DEF PUMP 2798
REMOVE AND INSTALL AdBlue/DEF HOSE 2802
METHOD FOR REMOVING AdBlue/DEF HOSE 2802
METHOD FOR INSTALLING AdBlue/DEF HOSE 2806
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2811
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2811
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2814
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2817
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2818
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2819
POWER TRAIN 2822
REMOVE AND INSTALL TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2822
METHOD FOR REMOVING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2822
METHOD FOR INSTALLING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2835
DISCONNECT AND CONNECT TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2849
METHOD FOR DISCONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2849
METHOD FOR CONNECTING TRANSMISSION AND FRONT DIFFERENTIAL ASSEMBLY 2850
DISASSEMBLE AND ASSEMBLE FRONT DIFFERENTIAL ASSEMBLY 2853
METHOD FOR DISASSEMBLING FRONT DIFFERENTIAL ASSEMBLY 2854
METHOD FOR ASSEMBLING FRONT DIFFERENTIAL ASSEMBLY 2861
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 2873
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 2874
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2878
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 2884
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 2885
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 2915
REMOVE AND INSTALL CENTER DIFFERENTIAL ASSEMBLY 2950
METHOD FOR REMOVING CENTER DIFFERENTIAL ASSEMBLY 2950
METHOD FOR INSTALLING CENTER DIFFERENTIAL ASSEMBLY 2953
DISASSEMBLE AND ASSEMBLE CENTER DIFFERENTIAL ASSEMBLY 2957
METHOD FOR DISASSEMBLING CENTER DIFFERENTIAL ASSEMBLY 2958
METHOD FOR ASSEMBLING CENTER DIFFERENTIAL ASSEMBLY 2965
REMOVE AND INSTALL REAR DIFFERENTIAL ASSEMBLY 2978
METHOD FOR REMOVING REAR DIFFERENTIAL ASSEMBLY 2978
METHOD FOR INSTALLING REAR DIFFERENTIAL ASSEMBLY 2980
DISASSEMBLE AND ASSEMBLE REAR DIFFERENTIAL ASSEMBLY 2982
METHOD FOR DISASSEMBLING REAR DIFFERENTIAL ASSEMBLY 2983
METHOD FOR ASSEMBLING REAR DIFFERENTIAL ASSEMBLY 2987
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2996
METHOD FOR REMOVING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2996
METHOD FOR INSTALLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2997
DISASSEMBLE AND ASSEMBLE FRONT FINAL DRIVE AND BRAKE ASSEMBLY 2999
METHOD FOR DISASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 3000
METHOD FOR ASSEMBLING FRONT FINAL DRIVE AND BRAKE ASSEMBLY 3008
REMOVE AND INSTALL CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3019
METHOD FOR REMOVING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3019
METHOD FOR INSTALLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3021
DISASSEMBLE AND ASSEMBLE CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3023
METHOD FOR DISASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3023
METHOD FOR ASSEMBLING CENTER FINAL DRIVE AND BRAKE ASSEMBLY 3030
REMOVE AND INSTALL REAR FINAL DRIVE ASSEMBLY 3039
METHOD FOR REMOVING REAR FINAL DRIVE ASSEMBLY 3039
METHOD FOR INSTALLING REAR FINAL DRIVE ASSEMBLY 3040
DISASSEMBLE AND ASSEMBLE REAR FINAL DRIVE ASSEMBLY 3042
METHOD FOR DISASSEMBLING REAR FINAL DRIVE ASSEMBLY 3042
METHOD FOR ASSEMBLING REAR FINAL DRIVE ASSEMBLY 3045
REMOVE AND INSTALL CENTER AXLE ASSEMBLY 3050
METHOD FOR REMOVING CENTER AXLE ASSEMBLY 3050
METHOD FOR INSTALLING CENTER AXLE ASSEMBLY 3053
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3057
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3057
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3060
STEERING SYSTEM 3063
DISASSEMBLE AND ASSEMBLE STEERING VALVE 3063
METHOD FOR DISASSEMBLING STEERING VALVE 3063
METHOD FOR ASSEMBLING STEERING VALVE 3066
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY 3073
METHOD FOR DISASSEMBLING STEERING CYLINDER ASSEMBLY 3073
METHOD FOR ASSEMBLING STEERING CYLINDER ASSEMBLY 3077
UNDERCARRIAGE AND FRAME 3082
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 3082
METHOD FOR REMOVING FRONT SUSPENSION CYLINDER ASSEMBLY 3082
METHOD FOR INSTALLING FRONT SUSPENSION CYLINDER ASSEMBLY 3083
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 3085
METHOD FOR REMOVING REAR SUSPENSION CYLINDER ASSEMBLY 3085
METHOD FOR INSTALLING REAR SUSPENSION CYLINDER ASSEMBLY 3086
DISASSEMBLE AND ASSEMBLE SUSPENSION CYLINDER ASSEMBLY 3088
METHOD FOR DISASSEMBLING SUSPENSION CYLINDER ASSEMBLY 3088
METHOD FOR ASSEMBLING SUSPENSION CYLINDER ASSEMBLY 3089
REMOVE AND INSTALL EQUALIZER BAR ASSEMBLY 3091
METHOD FOR REMOVING EQUALIZER BAR ASSEMBLY 3091
METHOD FOR INSTALLING EQUALIZER BAR ASSEMBLY 3093
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 3096
METHOD FOR REMOVING FRONT WHEEL ASSEMBLY 3097
METHOD FOR INSTALLING FRONT WHEEL ASSEMBLY 3102
REMOVE AND INSTALL REAR(FRONT SIDE) WHEEL ASSEMBLY 3107
METHOD FOR REMOVING REAR(FRONT SIDE) WHEEL ASSEMBLY 3107
METHOD FOR INSTALLING REAR(FRONT SIDE) WHEEL ASSEMBLY 3107
REMOVE AND INSTALL REAR(BACK SIDE) WHEEL ASSEMBLY 3108
METHOD FOR REMOVING REAR(BACK SIDE) WHEEL ASSEMBLY 3108
METHOD FOR INSTALLING REAR(BACK SIDE) WHEEL ASSEMBLY 3108
REMOVE AND INSTALL HITCH FRAME ASSEMBLY 3109
METHOD FOR REMOVING HITCH FRAME ASSEMBLY 3110
METHOD FOR INSTALLING HITCH FRAME ASSEMBLY 3118
DISASSEMBLE AND ASSEMBLE HITCH FRAME ASSEMBLY 3127
METHOD FOR DISASSEMBLING HITCH FRAME ASSEMBLY 3127
METHOD FOR ASSEMBLING HITCH FRAME ASSEMBLY 3129
HYDRAULIC SYSTEM 3134
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3134
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3134
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3139
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 3143
METHOD FOR REMOVING FLOW AMPLIFIER VALVE ASSEMBLY 3143
METHOD FOR INSTALLING FLOW AMPLIFIER VALVE ASSEMBLY 3146
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 3149
METHOD FOR REMOVING HOIST VALVE ASSEMBLY 3149
METHOD FOR INSTALLING HOIST VALVE ASSEMBLY 3154
DISASSEMBLE AND ASSEMBLE HOIST VALVE ASSEMBLY 3158
METHOD FOR DISASSEMBLING HOIST VALVE ASSEMBLY 3158
METHOD FOR ASSEMBLING HOIST VALVE ASSEMBLY 3159
DISASSEMBLE AND ASSEMBLE HOIST CYLINDER ASSEMBLY 3162
METHOD FOR DISASSEMBLING HOIST CYLINDER ASSEMBLY 3162
METHOD FOR ASSEMBLING HOIST CYLINDER ASSEMBLY 3165
WORK EQUIPMENT 3171
REMOVE AND INSTALL DUMP BODY ASSEMBLY 3171
METHOD FOR REMOVING DUMP BODY ASSEMBLY 3171
METHOD FOR INSTALLING DUMP BODY ASSEMBLY 3173
CAB AND ITS ATTACHMENTS 3176
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3176
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 3177
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 3180
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 3184
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 3185
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 3185
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3190
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3191
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3197
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY GRAMMER) 3203
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3203
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3204
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY (MANUFACTURED BY SEARS) 3206
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3206
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3208
REMOVE AND INSTALL SEAT BELT 3211
METHOD FOR REMOVING SEAT BELT 3211
METHOD FOR INSTALLING SEAT BELT 3212
ELECTRICAL SYSTEM 3213
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3213
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3213
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3216
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 3219
METHOD FOR REMOVING RETARDER AND HOIST CONTROLLER ASSEMBLY 3219
METHOD FOR INSTALLING RETARDER AND HOIST CONTROLLER ASSEMBLY 3220
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3221
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3221
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3222
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3223
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3223
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3225
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3228
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3228
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3230
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3232
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3232
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3234
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3236
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3236
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3237
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3238
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3238
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3240
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 3244
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 3244
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 3251
REMOVE AND INSTALL COMMUNICATION TERMINAL 3257
METHOD FOR REMOVING COMMUNICATION TERMINAL 3257
METHOD FOR INSTALLING COMMUNICATION TERMINAL 3263
60 MAINTENANCE STANDARD 3269
CONTENTS 3270
ABBREVIATION LIST 3272
ENGINE AND COOLING SYSTEM 3278
MAINTENANCE STANDARD OF ENGINE MOUNT 3278
MAINTENANCE STANDARD OF OUTPUT SHAFT 3279
MAINTENANCE STANDARD OF RADIATOR FAN PUMP 3280
MAINTENANCE STANDARD OF SERVO VALVE OF RADIATOR FAN PUMP 3281
MAINTENANCE STANDARD OF RADIATOR FAN MOTOR 3282
MAINTENANCE STANDARD OF AFTERCOOLER FAN MOTOR 3283
POWER TRAIN 3286
MAINTENANCE STANDARD OF DRIVE SHAFT 3286
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 3288
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 3289
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3292
MAINTENANCE STANDARD OF TRANSMISSION 3293
MAINTENANCE STANDARD OF FL, R CLUTCH 3298
MAINTENANCE STANDARD OF FH, 1ST CLUTCH 3299
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH 3300
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH 3301
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3303
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3304
MAINTENANCE STANDARD OF DIFFERENTIAL LOCK CLUTCH ECMV 3305
MAINTENANCE STANDARD OF MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 3306
MAINTENANCE STANDARD OF FRONT AXLE 3308
MAINTENANCE STANDARD OF CENTER AXLE 3309
MAINTENANCE STANDARD OF REAR AXLE 3310
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL 3311
MAINTENANCE STANDARD OF CENTER DIFFERENTIAL 3312
MAINTENANCE STANDARD OF REAR DIFFERENTIAL 3313
MAINTENANCE STANDARD OF FRONT FINAL DRIVE 3314
MAINTENANCE STANDARD OF CENTER FINAL DRIVE 3316
MAINTENANCE STANDARD OF REAR FINAL DRIVE 3317
STEERING SYSTEM 3319
MAINTENANCE STANDARD OF STEERING COLUMN 3319
MAINTENANCE STANDARD OF STEERING CYLINDER 3320
BRAKE SYSTEM 3321
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER 3321
MAINTENANCE STANDARD OF CENTER SLACK ADJUSTER 3322
MAINTENANCE STANDARD OF FRONT BRAKE 3323
MAINTENANCE STANDARD OF CENTER BRAKE 3325
MAINTENANCE STANDARD OF PARKING BRAKE 3326
UNDERCARRIAGE AND FRAME 3328
MAINTENANCE STANDARD OF FRONT SUSPENSION 3328
MAINTENANCE STANDARD OF CENTER AND REAR SUSPENSIONS 3330
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 3333
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 3334
MAINTENANCE STANDARD OF OSCILLATION HITCH 3335
HYDRAULIC SYSTEM 3337
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP 3337
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP 3338
MAINTENANCE STANDARD OF POWER TRAIN AND FRONT BRAKE COOLING DUPLEX PUMP, AFTERCOOLER FAN PUMP, AND CENTER BRAKE COOLING REMOTE MOTOR DRIVE PUMP 3340
MAINTENANCE STANDARD OF CENTER BRAKE COOLING PUMP 3342
MAINTENANCE STANDARD OF CENTER BRAKE COOLING REMOTE PUMP 3343
MAINTENANCE STANDARD OF CENTER BRAKE COOLING REMOTE MOTOR 3344
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP 3347
MAINTENANCE STANDARD OF HOIST VALVE 3348
WORK EQUIPMENT 3350
MAINTENANCE STANDARD OF HOIST CYLINDER 3350
80 APPENDIX 3353
CONTENTS 3354
ABBREVIATION LIST 3356
AIR CONDITIONER SYSTEM 3362
PRECAUTIONS FOR REFRIGERANT 3362
AIR CONDITIONER COMPONENT 3363
SPECIFICATIONS OF AIR CONDITIONER 3365
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3366
OUTLINE OF REFRIGERATION CYCLE 3367
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3369
AIR CONDITIONER UNIT 3369
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3369
FUNCTION OF AIR CONDITIONER UNIT 3371
COMPONENT PARTS OF AIR CONDITIONER UNIT 3373
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3374
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3374
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3374
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3374
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3375
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3375
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3375
FUNCTION OF DUAL PRESSURE SWITCH 3376
AIR CONDITIONER CONTROLLER 3377
STRUCTURE OF AIR CONDITIONER CONTROLLER 3377
COMPRESSOR 3378
STRUCTURE OF COMPRESSOR 3378
SPECIFICATIONS OF COMPRESSOR 3378
FUNCTION OF COMPRESSOR 3378
CONDENSER 3379
STRUCTURE OF CONDENSER 3379
SPECIFICATIONS OF CONDENSER 3379
FUNCTION OF CONDENSER 3379
RECEIVER DRIER 3380
STRUCTURE OF RECEIVER DRIER 3380
SPECIFICATIONS OF RECEIVER DRIER 3380
FUNCTION OF RECEIVER DRIER 3380
SENSORS FOR AIR CONDITIONER SYSTEM 3381
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3381
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3381
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3382
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3384
AIR CONDITIONER SYSTEM DIAGRAM 3386
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3387
FUNCTION OF AIR CONDITIONER CONTROLLER 3388
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3389
TESTING AIR LEAKAGE (DUCT) 3392
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3392
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3396
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3397
TEST VENT (MODE) CHANGEOVER 3399
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3399
TESTING FRESH/RECIRC AIR CHANGEOVER 3400
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3400
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3401
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3401
TEST RELAYS 3402
METHOD FOR TESTING RELAYS 3402
AIR CONDITIONER TROUBLESHOOTING CHART 1 3404
AIR CONDITIONER TROUBLESHOOTING CHART 2 3405
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3408
FAILURE CODE [879AKA] 3410
FAILURE CODE [879AKB] 3411
FAILURE CODE [879BKA] 3412
FAILURE CODE [879BKB] 3414
FAILURE CODE [879CKA] 3416
FAILURE CODE [879CKB] 3417
FAILURE CODE [879EMC] 3418
FAILURE CODE [879FMC] 3419
FAILURE CODE [879GKX] 3420
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3422
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3424
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3427
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3429
TROUBLESHOOTING USING GAUGE PRESSURE 3431
CONNECTION OF SERVICE TOOL 3434
METHOD FOR CONNECTING SERVICE TOOL 3434
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3436
HANDLE COMPRESSOR OIL 3438
90 CIRCUIT DIAGRAMS 3441
CONTENTS 3442
ABBREVIATION LIST 3445
HYDRAULIC CIRCUIT DIAGRAM 3451
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3451
HYDRAULIC CIRCUIT DIAGRAM 3455
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3457
ELECTRICAL CIRCUIT DIAGRAM 3459
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3459
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (1/8) 3463
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (2/8) 3465
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (3/8) 3467
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (4/8) 3469
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (5/8) 3471
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (6/8) 3473
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (7/8) 3475
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10001 to 10171) (8/8) 3477
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (1/8) 3479
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (2/8) 3481
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (3/8) 3483
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (4/8) 3485
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (5/8) 3487
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (6/8) 3489
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (7/8) 3491
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (APPLICABLE MACHINE: 10172 AND UP) (8/8) 3493
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (1/8) 3495
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (2/8) 3497
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (3/8) 3499
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (4/8) 3501
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (5/8) 3503
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (6/8) 3505
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (7/8) 3507
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (8/8) 3509
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/9) 3511
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/9) 3513
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/9) 3515
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/9) 3517
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/9) 3519
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/9) 3521
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/9) 3523
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/9) 3525
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/9) 3527
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (1/9) 3529
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (2/9) 3531
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (3/9) 3533
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (4/9) 3535
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (5/9) 3537
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (6/9) 3539
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (7/9) 3541
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (8/9) 3543
ELECTRICAL CIRCUIT DIAGRAM OF INSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (MACHINE WITH PAYLOAD METER CONTROLLER: CR720) (9/9) 3545
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (1/8) 3547
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (2/8) 3549
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (3/8) 3551
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (4/8) 3553
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (5/8) 3555
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (6/8) 3557
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (7/8) 3559
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH KOMTRAX TERMINAL) (8/8) 3561
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/8) 3563
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/8) 3565
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/8) 3567
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/8) 3569
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/8) 3571
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/8) 3573
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/8) 3575
ELECTRICAL CIRCUIT DIAGRAM OF OUTSIDE OF CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/8) 3577
INDEX 3579

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