Komatsu DUMP TRUCK HD1500-8 Shop Manual SEN06630-25 – PDF

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Komatsu DUMP TRUCK HD1500-8 Shop Manual SEN06630-25 – PDF DOWNLOAD

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Komatsu DUMP TRUCK HD1500-8 Shop Manual SEN06630-25 – PDF DOWNLOAD

Language : English
Pages :3002
Downloadable : Yes
File Type : PDF

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Komatsu DUMP TRUCK HD1500-8 Shop Manual SEN06630-25 – PDF DOWNLOAD

SERIAL NUMBERS 81001 and up

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD1500-8 Shop Manual SEN06630-25 – PDF DOWNLOAD

SERIAL NUMBERS 81001 and up

Cover 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATIONS 24
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS 40
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS 41
GENERAL CHARACTER AND PRECAUTIONS FOR USAGE 42
PRECAUTIONS WHEN YOU ADD DEF 42
PRECAUTIONS WHEN YOU STORE DEF 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 55
PRACTICAL USE OF KOMTRAX 56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 75
STANDARD TIGHTENING TORQUE TABLE 77
CONVERSION TABLE 84
01 SPECIFICATIONS 89
CONTENTS 90
ABBREVIATIONS 91
SPECIFICATIONS 96
SPECIFICATION DRAWING 96
SPECIFICATION DRAWING: HD1500-8 96
SPECIFICATION DRAWING: HD1500-8 (EU SPECIFICATIONS) 98
SPECIFICATIONS 100
SPECIFICATIONS: HD1500-8 100
SPECIFICATIONS: HD1500-8 (EU SPECIFICATIONS) 106
WEIGHT TABLE 112
WEIGHT TABLE: HD1500-8 112
FUEL, COOLANT, AND LUBRICATING OIL 114
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 114
10 STRUCTURE AND FUNCTION 117
CONTENTS 118
ABBREVIATIONS 123
BOOT-UP SYSTEM 128
LAYOUT DRAWING OF BOOT-UP SYSTEM 128
SYSTEM OPERATING LAMP SYSTEM 131
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 131
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 131
BATTERY DISCONNECT SWITCH 132
FUNCTION OF BATTERY DISCONNECT SWITCH 132
FUNCTION OF BATTERY DISCONNECT SWITCH (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 133
STARTING MOTOR DISCONNECT SWITCH 134
FUNCTION OF STARTING MOTOR DISCONNECT SWITCH 134
OPERATION OF STARTING MOTOR DISCONNECT SWITCH 134
ENGINE SHUTDOWN SECONDARY SWITCH 135
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 135
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 135
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 136
EXTERNAL POWER SUPPLY ENGINE PREHEATER 137
LAYOUT DRAWING OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 137
FUNCTION OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 138
ENGINE SYSTEM 140
LAYOUT DRAWING OF ENGINE SYSTEM 140
ENGINE CONTROL SYSTEM 142
ENGINE CONTROL SYSTEM DIAGRAM 142
COMPONENT PARTS OF ENGINE SYSTEM 146
OUTPUT SHAFT 146
COOLING SYSTEM 147
LAYOUT DRAWING OF COOLING SYSTEM 147
SPECIFICATIONS OF COOLING SYSTEM 148
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 149
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 149
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 149
COMPONENT PARTS OF COOLING SYSTEM 150
DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 150
REAR BRAKE COOLING REMOTE TRIPLEX PUMP 160
FRONT BRAKE COOLING REMOTE PUMP 161
FRONT BRAKE COOLING REMOTE MOTOR 162
REAR BRAKE COOLING REMOTE MOTOR 170
FAN CLUTCH 176
HYDRAULIC OIL COOLER BYPASS VALVE 177
CONTROL SYSTEM 178
LAYOUT DRAWING OF CONTROL SYSTEM 178
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 181
RETARDER AND HOIST CONTROL SYSTEM 183
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 183
MACHINE MONITOR SYSTEM 185
MACHINE MONITOR SYSTEM DIAGRAM 185
FUNCTION OF MACHINE MONITOR SYSTEM 186
REARVIEW MONITOR SYSTEM 187
REARVIEW MONITOR SYSTEM DIAGRAM 187
FUNCTION OF REARVIEW MONITOR SYSTEM 187
KOMTRAX Plus SYSTEM 188
KOMTRAX Plus SYSTEM DIAGRAM 188
SYSTEM DIAGRAM OF KOMTRAX Plus SYSTEM (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 190
FUNCTION OF KOMTRAX Plus SYSTEM 192
PAYLOAD METER SYSTEM 195
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 195
PAYLOAD METER SYSTEM DIAGRAM 196
FUNCTION OF PAYLOAD METER SYSTEM 196
MEASUREMENT PRINCIPLE OF LOADING MASS 197
DATA DOWNLOAD FUNCTION 198
FUNCTIONS OF COMMUNICATING WITH EXTERNAL DEVICES FOR PURPOSES OTHER THAN DOWNLOADING 198
COMPONENT PARTS OF CONTROL SYSTEM 206
MACHINE MONITOR 206
SWITCH PANEL 220
REARVIEW MONITOR 221
REARVIEW CAMERA 222
KOMTRAX TERMINAL 223
KOMTRAX Plus CONTROLLER 225
COMMUNICATION TERMINAL 231
WIRELESS LAN UNIT 232
TRANSMISSION CONTROLLER 233
RETARDER AND HOIST CONTROLLER 237
OPTION CONTROLLER 241
MONITOR CONTROLLER 245
ACCELERATOR PEDAL 250
GEAR SHIFT LEVER 251
RETARDER CONTROL LEVER 252
HYDRAULIC SYSTEM 253
LAYOUT DRAWING OF HYDRAULIC SYSTEM 253
COMPONENT PARTS OF HYDRAULIC SYSTEM 254
HYDRAULIC TANK 254
STEERING AND HOIST PUMP 256
LS VALVE 262
CO VALVE 267
DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR 270
FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP 283
HOIST VALVE 284
POWER TRAIN SYSTEM 289
LAYOUT DRAWING OF POWER TRAIN SYSTEM 289
TRANSMISSION CONTROL SYSTEM 292
TRANSMISSION CONTROL SYSTEM DIAGRAM 292
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 294
GEAR SHIFT CONTROL SYSTEM 300
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 300
DIRECTION CONTROL SYSTEM 303
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM WHEN TCS IS ACTUATED 303
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 303
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 304
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 304
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 304
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 305
TRAVEL SPEED LIMITATION SYSTEM 306
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 306
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 307
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 308
REAR AXLE OIL FILTRATION SYSTEM 310
LAYOUT DRAWING OF REAR AXLE OIL FILTRATION SYSTEM 310
SYSTEM DIAGRAM OF REAR AXLE OIL FILTRATION SYSTEM 311
FUNCTION OF REAR AXLE OIL FILTRATION SYSTEM 311
OPERATION OF REAR AXLE OIL FILTRATION SYSTEM 311
COMPONENT PARTS OF POWER TRAIN SYSTEM 312
DRIVE SHAFT 312
TORQUE CONVERTER AND PTO 313
LOCKUP CLUTCH ECMV 318
TRANSMISSION 321
TRANSMISSION CONTROL VALVE 342
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 344
TORQUE CONVERTER REGULATOR VALVE 350
MAIN RELIEF VALVE, TORQUE CONVERTER RELIEF VALVE, AND MAIN FLOW SELECTOR VALVE 352
TRANSMISSION LUBRICATION OIL FLOW SELECTOR VALVE 361
AXLE 363
DIFFERENTIAL 365
FINAL DRIVE 367
WORK EQUIPMENT SYSTEM 368
WORK EQUIPMENT CONTROL 368
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 368
FUNCTION OF WORK EQUIPMENT CONTROL 368
HOIST CONTROL 369
HOIST CONTROL SYSTEM DIAGRAM 369
FUNCTION OF HOIST CONTROL 369
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 371
DUMP LEVER 371
HOIST EPC VALVE 376
HOIST AND FRONT BRAKE COOLING REMOTE SELECTOR VALVE 377
STEERING SYSTEM 378
LAYOUT DRAWING OF STEERING SYSTEM 378
FUNCTION OF STEERING SYSTEM 379
STEERING COLUMN 380
STRUCTURE OF STEERING COLUMN 380
STEERING CONTROL LINKAGE 381
STRUCTURE OF STEERING CONTROL LINKAGE 381
COMPONENT PARTS OF STEERING SYSTEM 382
FLOW AMPLIFIER VALVE 382
STEERING UNIT 386
STEERING PUMP SELECTOR SOLENOID VALVE 391
SECONDARY STEERING PUMP 392
SECONDARY STEERING MOTOR 393
BRAKE SYSTEM 394
LAYOUT DRAWING OF BRAKE SYSTEM 394
RETARDER CONTROL 397
RETARDER CONTROL SYSTEM DIAGRAM 397
FUNCTION OF RETARDER CONTROL 398
ARSC SYSTEM 399
ARSC SYSTEM DIAGRAM 399
FUNCTION OF ARSC SYSTEM 399
COMPONENT PARTS OF BRAKE SYSTEM 400
BRAKE CHARGE PUMP 400
PARKING BRAKE SOLENOID VALVE 401
ACCUMULATOR CHARGE VALVE 402
BRAKE CIRCUIT ACCUMULATOR 406
SHUT OFF SOLENOID VALVE 407
BRAKE VALVE 409
SECONDARY BRAKE VALVE 412
PROPORTIONAL PRESSURE REDUCING VALVE 413
SLACK ADJUSTER 415
FRONT BRAKE COOLING RELIEF VALVE 419
REAR BRAKE COOLING RELIEF VALVE 420
BRAKE 421
PARKING BRAKE 425
BRAKE TANK 428
AUTO-GREASING SYSTEM 429
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 429
AUTO-GREASING SYSTEM DIAGRAM 432
FUNCTION OF AUTO-GREASING SYSTEM 433
GREASE REFILL AUTOMATIC STOP SYSTEM 434
GREASE REFILL AUTOMATIC STOP SYSTEM DIAGRAM 434
FUNCTION OF GREASE REFILL AUTOMATIC STOP SYSTEM 434
OPERATION OF GREASE REFILL AUTOMATIC STOP SYSTEM 434
COMPONENT PARTS OF AUTO-GREASING SYSTEM 435
AUTO-GREASING PUMP 435
AUTO-GREASING INJECTOR 436
SERVICE CENTER 439
LAYOUT DRAWING OF SERVICE CENTER 439
FUNCTION OF SERVICE CENTER 439
UNDERCARRIAGE AND FRAME 440
REAR AXLE SUPPORT 440
STRUCTURE OF REAR AXLE SUPPORT 440
SUSPENSION 441
STRUCTURE OF SUSPENSION 441
FUNCTION OF SUSPENSION 441
FRONT SUSPENSION 442
STRUCTURE OF FRONT SUSPENSION 442
FUNCTION OF FRONT SUSPENSION 442
REAR SUSPENSION 443
STRUCTURE OF REAR SUSPENSION 443
FUNCTION OF REAR SUSPENSION 443
FRONT SUSPENSION CYLINDER 444
STRUCTURE OF FRONT SUSPENSION CYLINDER 444
FUNCTION OF FRONT SUSPENSION CYLINDER 444
OPERATION OF FRONT SUSPENSION CYLINDER 445
REAR SUSPENSION CYLINDER 446
STRUCTURE OF REAR SUSPENSION CYLINDER 446
FUNCTION OF REAR SUSPENSION CYLINDER 446
OPERATION OF REAR SUSPENSION CYLINDER 446
WORK EQUIPMENT 447
STRUCTURE OF WORK EQUIPMENT 447
FUNCTION OF WORK EQUIPMENT 447
CAB AND ITS ATTACHMENTS 448
ROPS CAB 448
STRUCTURE OF ROPS CAB 448
FUNCTION OF ROPS CAB 448
CAB MOUNT 449
STRUCTURE OF CAB MOUNT 449
FUNCTION OF CAB MOUNT 449
LIFTING SYSTEM 450
POWER LADDER SYSTEM 450
LAYOUT DRAWING OF POWER LADDER SYSTEM 450
POWER LADDER SYSTEM DIAGRAM 451
FUNCTION OF POWER LADDER SYSTEM 452
OPERATION OF POWER LADDER SYSTEM 452
POWER LADDER DRIVE PUMP 453
RELIEF VALVE A 454
RELIEF VALVE B 454
SOLENOID VALVE 455
SOLENOID VALVE (FOR POWER LADDER RAISE AND LOWER SWITCH) 456
20 STANDARD VALUE TABLE 457
CONTENTS 458
ABBREVIATIONS 459
STANDARD VALUE TABLE FOR ENGINE 464
STANDARD VALUE TABLE FOR ENGINE: HD1500-8 464
STANDARD VALUE TABLE FOR MACHINE 466
STANDARD VALUE TABLE FOR MACHINE: HD1500-8 466
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 489
30 TEST AND ADJUST 491
CONTENTS 492
PRECAUTIONS BEFORE WORK 496
ABBREVIATIONS 497
RELATED INFORMATION TO TEST AND ADJUST 502
TOOLS TO TEST AND ADJUST 502
ENGINE AND COOLING SYSTEM 509
TEST ENGINE SPEED 509
PROCEDURE TO TEST ENGINE SPEED 509
TEST EXHAUST GAS COLOR 510
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 511
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 512
TEST BLOWBY PRESSURE 513
PROCEDURE TO TEST BLOWBY PRESSURE 513
TEST FUEL PRESSURE 515
PROCEDURE TO TEST FUEL PRESSURE 515
BLEED AIR FROM FUEL CIRCUIT 517
PROCEDURE TO BLEED AIR FROM FUEL CIRCUIT 517
TEST TORQUE CONVERTER STALL SPEED 518
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED 518
POWER TRAIN 520
TEST POWER TRAIN OIL PRESSURE 520
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 523
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 535
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 535
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 536
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 536
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 537
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 537
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 538
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 538
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 539
PROCEDURE TO FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 539
CLEAN FINAL DRIVE CASE MAGNET 541
PROCEDURE TO CLEAN FINAL DRIVE CASE MAGNET 541
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 542
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 542
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 543
STEERING SYSTEM 547
TEST STEERING CIRCUIT OIL PRESSURE 547
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 547
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 547
TEST STEERING CYLINDER PRESSURE 549
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 549
BLEED AIR FROM STEERING CYLINDER CIRCUIT 550
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 550
BRAKE SYSTEM 552
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 552
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 552
TEST WHEEL BRAKE OIL PRESSURE 553
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 553
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE WITH TEST TOOLS 553
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 554
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE WITH TEST TOOLS 555
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE WITH MACHINE MONITOR 556
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE WITH TEST TOOLS 557
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 558
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 558
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 559
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 560
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 561
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (FRONT BRAKE) 561
PROCEDURE TO TEST BRAKE ACCUMULATOR NITROGEN GAS PRESSURE (REAR AND PARKING) 565
PROCEDURE TO PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 568
PROCEDURE TO RELEASE NITROGEN GAS WHEN DISPOSING ACCUMULATOR 572
TEST BRAKE PERFORMANCE 573
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 573
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 574
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 575
BLEED AIR FROM BRAKE CIRCUIT 576
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 576
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT 577
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 578
TEST PARKING BRAKE OIL PRESSURE 580
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE WITH MACHINE MONITOR 580
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE WITH WITH TEST TOOLS 580
RELEASE PARKING BRAKE MANUALLY 582
PROCEDURE TO RELEASE FRONT PARKING BRAKE MANUALLY 582
PROCEDURE TO RELEASE REAR PARKING BRAKE MANUALLY 583
TEST THE AMOUNT OF WHEEL BRAKE DISC WEAR 584
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE DISC WEAR 584
PROCEDURE TO TEST THE AMOUNT OF REAR BRAKE DISC WEAR 585
HYDRAULIC SYSTEM 586
TEST HOIST CIRCUIT OIL PRESSURE 586
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 586
TEST HOIST CYLINDER SUPPLY PRESSURE 588
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 588
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 589
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 589
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 590
TEST AND ADJUST FRONT SUSPENSION CYLINDER 591
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 591
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 592
TEST AND ADJUST REAR SUSPENSION CYLINDER 597
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 597
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 598
BLEED AIR FROM HYDRAULIC CIRCUIT 603
PROCEDURE TO BLEED AIR FROM PISTON PUMP 603
PROCEDURE TO BLEED AIR IN HOIST CYLINDER CIRCUIT 605
PROCEDURE TO BLEED AIR FROM FRONT BRAKE COOLING REMOTE MOTOR 607
PROCEDURE TO BLEED AIR FROM REAR BRAKE COOLING REMOTE MOTOR 608
CALIBRATION OF LADDER POSITION 610
CALIBRATION METHOD OF STOWED POSITION OF LADDER 610
CALIBRATION METHOD OF LOWEST POSITION OF LADDER 610
WORK EQUIPMENT 611
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 611
PROCEDURE TO TEST DUMP BODY POSITIONER SENSOR 611
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 611
PROCEDURE TO CALIBRATE AFTER YOU ADJUST DUMP BODY POSITION SENSOR 611
LOWER THE DUMP BODY MANUALLY 613
PROCEDURE TO LOWER THE DUMP BODY MANUALLY 613
LIFT THE DUMP BODY MANUALLY 614
PROCEDURE TO LIFT THE DUMP BODY MANUALLY 614
LIFT THE DUMP BODY WITH BUDDY SYSTEM 616
PROCEDURE TO LIFT THE DUMP BODY WITH BUDDY SYSTEM 616
CAB AND ITS ATTACHMENTS 619
ADJUST STEERING WHEEL TILT LOCK LEVER 619
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 619
ADJUST RATTLING OPERATOR’S SEAT 620
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 620
ADJUST CLEARANCE OF ESCAPE DOOR 621
PROCEDURE TO ADJUST CLEARANCE OF ESCAPE DOOR 621
LIFTING SYSTEM 623
BLEED AIR FROM POWER LADDER CYLINDER 623
PROCEDURE TO BLEED AIR FROM POWER LADDER CYLINDER 623
ELECTRICAL SYSTEM 624
SET AND ADJUST EACH EQUIPMENT 624
SET AND OPERATE OF MACHINE MONITOR 628
OPERATOR MODE 631
SERVICE MODE 645
ABNORMALITY RECORD MENU 668
DEFAULT MENU 683
ADJUSTMENT MENU 699
PAYLOAD METER SETTING 717
KOMTRAX SETTINGS MENU 736
PROCEDURE TO DISPLAY SERVICE MESSAGE 739
PROCEDURE TO HANDLE MANUAL SNAP SHOT 741
START UP KOMTRAX TERMINAL 744
STOP USE OF KOMTRAX TERMINAL 748
STOP USE OF KOMTRAX TERMINAL (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 750
SETTING DEFAULT OF KOMTRAX Plus CONTROLLER 752
PROCEDURE TO SET WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 752
SETTING DEFAULT OF WIRELESS LAN MODEM 754
PROCEDURE TO SET WITH DEFAULT SETTING OF WIRELESS LAN MODEM 754
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION 755
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 756
PROCEDURE TO DOWNLOAD KOMTRAX Plus CONTROLLER DATA 756
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 760
PROCEDURE TO ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 760
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 763
PROCEDURE TO ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 763
SETTING OF MOBILE COMMUNICATION TERMINAL 765
SETTING OF MOBILE COMMUNICATION TERMINAL 765
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 774
BATTERY DISCONNECT SWITCH WORK 775
BATTERY DISCONNECT SWITCH WORK (MACHINE WITH MOBILE COMMUNICATION TERMINAL) 776
TEST DIODES 777
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 777
PROCEDURE TO TEST DIODE USING ANALOG TESTER 777
Pm CLINIC 778
Pm CLINIC SERVICE 778
Pm CLINIC CHECK SHEET 783
PERFORM QUICK Pm 790
PROCEDURE TO PERFORM QUICK Pm 790
40 TROUBLESHOOTING 795
CONTENTS 796
PRECAUTIONS BEFORE WORK 806
ABBREVIATIONS 807
RELATED INFORMATION ON TROUBLESHOOTING 812
GENERAL TROUBLESHOOTING POINTS 812
SEQUENCE OF EVENTS IN TROUBLESHOOTING 813
CHECKS BEFORE TROUBLESHOOTING 815
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 818
WALK-AROUND CHECK 818
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 819
CHECK FUEL LEVEL 819
CHECK IMPURE INGREDIENT IN FUEL 820
CHECK FUEL FILTER 820
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 822
CHECK COOLANT LEVEL (RESERVOIR TANK) 822
CHECK CLOGGING OF AIR CLEANER 824
OUTER ELEMENT – CLEAN 825
REPLACE ELEMENT 827
CHECK HYDRAULIC OIL LEVEL 829
CHECK HYDRAULIC OIL STRAINER 829
CHECK HYDRAULIC OIL FILTER 830
CHECK OIL LEVEL IN TRANSMISSION CASE 830
CHECK OIL LEVEL IN DIFFERENTIAL CASE 831
CHECK OIL LEVEL IN FINAL DRIVE CASE 831
BLEED AIR FROM FUEL SYSTEM 832
BLEED AIR FROM HYDRAULIC SYSTEM 832
PROCEDURE TO CHECK ELECTRIC EQUIPMENT 832
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 838
PROCEDURE FOR TESTING AND TROUBLESHOOTING 846
SYMPTOM AND TROUBLESHOOTING NUMBERS 848
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 851
CONNECTORS LIST AND LAYOUT 853
CONNECTOR CONTACT IDENTIFICATION 886
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 928
FUSE LOCATION TABLE 934
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 940
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 942
FAILURE CODES TABLE 948
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 976
FAILURE CODE [1500L0] 976
FAILURE CODE [15B0NX] 977
FAILURE CODE [15F0KM] 979
FAILURE CODE [15F0MB] 980
FAILURE CODE [15F7KM] 981
FAILURE CODE [15G0MW] 982
FAILURE CODE [15G7KM] 984
FAILURE CODE [15H0MW] 985
FAILURE CODE [15J0MW] 987
FAILURE CODE [15K0MW] 989
FAILURE CODE [15L0MW] 991
FAILURE CODE [15M0MW] 993
FAILURE CODE [15N0MW] 995
FAILURE CODE [15SBL1] 997
FAILURE CODE [15SBMA]1000
FAILURE CODE [15SCL1]1001
FAILURE CODE [15SCMA]1004
FAILURE CODE [15SDL1]1005
FAILURE CODE [15SDMA]1008
FAILURE CODE [15SEL1]1009
FAILURE CODE [15SEMA]1012
FAILURE CODE [15SFL1]1014
FAILURE CODE [15SFMA]1017
FAILURE CODE [15SGL1]1019
FAILURE CODE [15SGMA]1022
FAILURE CODE [15SHL1]1024
FAILURE CODE [15SHMA]1027
FAILURE CODE [15SJMA]1028
FAILURE CODE [2B0QNX]1029
FAILURE CODE [2F00KM]1030
FAILURE CODE [2G42ZG]1032
FAILURE CODE [2G43ZG]1033
FAILURE CODE [2G44ZG]1034
FAILURE CODE [879AKA]1036
FAILURE CODE [879AKB]1037
FAILURE CODE [879BKA]1038
FAILURE CODE [879BKB]1039
FAILURE CODE [879CKA]1041
FAILURE CODE [879CKB]1042
FAILURE CODE [879EMC]1043
FAILURE CODE [879FMC]1044
FAILURE CODE [879GKX]1045
FAILURE CODE [989D00]1046
FAILURE CODE [989X00]1047
FAILURE CODE [989Y00]1048
FAILURE CODE [AA10NX]1049
FAILURE CODE [AB00KE]1051
FAILURE CODE [AB00KY]1053
FAILURE CODE [B@C6NS]1054
FAILURE CODE [B@C7NS]1055
FAILURE CODE [B@CENS]1056
FAILURE CODE [B@JANS]1057
FAILURE CODE [D150KB]1058
FAILURE CODE [D150KZ]1060
FAILURE CODE [D151KB]1062
FAILURE CODE [D151KZ]1064
FAILURE CODE [D164KY]1066
FAILURE CODE [D19HKZ]1067
FAILURE CODE [D19JKZ]1069
FAILURE CODE [D19QKZ]1070
FAILURE CODE [D1EHKA]1072
FAILURE CODE [D1EHKB]1073
FAILURE CODE [D1EHKY]1074
FAILURE CODE [D1ENKZ]1075
FAILURE CODE [D1EPKA]1077
FAILURE CODE [D1EPKB]1079
FAILURE CODE [D1EPKY]1081
FAILURE CODE [D1EQKA]1082
FAILURE CODE [D1EQKB]1084
FAILURE CODE [D1EQKY]1086
FAILURE CODE [D1ERKA]1088
FAILURE CODE [D1ERKB]1090
FAILURE CODE [D1ERKY]1092
FAILURE CODE [D1ESKA]1094
FAILURE CODE [D1ESKB]1096
FAILURE CODE [D1ESKY]1098
FAILURE CODE [D1EWKA]1100
FAILURE CODE [D1EWKB]1102
FAILURE CODE [D1EWKY]1104
FAILURE CODE [D1J0KB]1106
FAILURE CODE [D5ZHL6]1107
FAILURE CODE [D862KA]1109
FAILURE CODE [DAF0KT]1110
FAILURE CODE [DAF0MB]1111
FAILURE CODE [DAF0MC]1112
FAILURE CODE [DAF3KK]1113
FAILURE CODE [DAF8KB]1115
FAILURE CODE [DAFDKB]1116
FAILURE CODE [DAFGMC]1118
FAILURE CODE [DAFLKA]1119
FAILURE CODE [DAFLKB]1121
FAILURE CODE [DAFQKR]1123
FAILURE CODE [DAQ0KK]1124
FAILURE CODE [DAQ0KT]1127
FAILURE CODE [DAQ0MC]1128
FAILURE CODE [DAQ1KA]1129
FAILURE CODE [DAQ2KK]1131
FAILURE CODE [DAQ9KQ]1133
FAILURE CODE [DAQLKA]1134
FAILURE CODE [DAQLKB]1136
FAILURE CODE [DAQQKR]1138
FAILURE CODE [DAQRKR]1139
FAILURE CODE [DAQRMA]1140
FAILURE CODE [DAQV00]1141
FAILURE CODE [DAQW00]1142
FAILURE CODE [DAZ9KQ]1143
FAILURE CODE [DAZQKR]1144
FAILURE CODE [DB10KT]1145
FAILURE CODE [DB10MC]1146
FAILURE CODE [DB11KA]1147
FAILURE CODE [DB12KK]1150
FAILURE CODE [DB13KK]1153
FAILURE CODE [DB19KQ]1155
FAILURE CODE [DB1LKA]1156
FAILURE CODE [DB1LKB]1158
FAILURE CODE [DB1QKR]1160
FAILURE CODE [DB1QMA]1161
FAILURE CODE [DB1RKR]1162
FAILURE CODE [DB2QKR]1168
FAILURE CODE [DBBUKM]1174
FAILURE CODE [DBBUKR]1175
FAILURE CODE [DBP0KM]1177
FAILURE CODE [DBP0KT]1178
FAILURE CODE [DBP0NR]1179
FAILURE CODE [DBP5KP]1180
FAILURE CODE [DBPLKA]1182
FAILURE CODE [DBPLKB]1184
FAILURE CODE [DBPQKR]1186
FAILURE CODE [DBPRKR]1189
FAILURE CODE [DBPRMA]1192
FAILURE CODE [DBPUKR]1193
FAILURE CODE [DBPVKR]1198
FAILURE CODE [DBPWKR]1203
FAILURE CODE [DBPXKR]1204
FAILURE CODE [DBV0MC]1205
FAILURE CODE [DBV1KK]1206
FAILURE CODE [DBV6KB]1208
FAILURE CODE [DBV7KB]1210
FAILURE CODE [DBVLKA]1211
FAILURE CODE [DBVLKB]1213
FAILURE CODE [DBVQKR]1215
FAILURE CODE [DBVRKR]1216
FAILURE CODE [DBVVKR]1217
FAILURE CODE [DBVWKR]1218
FAILURE CODE [DDAAL6]1219
FAILURE CODE [DDD7KX]1221
FAILURE CODE [DDDGL4]1223
FAILURE CODE [DDDHL4]1225
FAILURE CODE [DDTHKA]1227
FAILURE CODE [DDTJKA]1229
FAILURE CODE [DDTKKA]1231
FAILURE CODE [DDTLKA]1233
FAILURE CODE [DDTMKA]1235
FAILURE CODE [DDTNKA]1237
FAILURE CODE [DDTPKA]1239
FAILURE CODE [DDU1KA]1241
FAILURE CODE [DF10KA]1243
FAILURE CODE [DF10KB]1247
FAILURE CODE [DGE5KX]1250
FAILURE CODE [DGF1KX]1252
FAILURE CODE [DGR2KB]1254
FAILURE CODE [DGR2L8]1255
FAILURE CODE [DGR4KB]1257
FAILURE CODE [DGR4L8]1258
FAILURE CODE [DGR6KB]1260
FAILURE CODE [DGR6L8]1261
FAILURE CODE [DGREKB]1263
FAILURE CODE [DGREL8]1264
FAILURE CODE [DGT1KX]1266
FAILURE CODE [DHP4KY]1268
FAILURE CODE [DHP4KZ]1270
FAILURE CODE [DHP5KY]1272
FAILURE CODE [DHP5KZ]1274
FAILURE CODE [DHP6KA]1276
FAILURE CODE [DHP6KX]1278
FAILURE CODE [DHP6KY]1280
FAILURE CODE [DHP6KZ]1282
FAILURE CODE [DHP7KA]1284
FAILURE CODE [DHP7KX]1286
FAILURE CODE [DHP7KY]1288
FAILURE CODE [DHP7KZ]1290
FAILURE CODE [DHQ2KX]1292
FAILURE CODE [DHQ4KX]1294
FAILURE CODE [DHQ6KX]1296
FAILURE CODE [DHT5KX]1298
FAILURE CODE [DHT5L6]1300
FAILURE CODE [DHT7KX]1301
FAILURE CODE [DHT7L6]1303
FAILURE CODE [DHT8KX]1304
FAILURE CODE [DHT8ZG]1306
FAILURE CODE [DHU2KX]1307
FAILURE CODE [DHU3KX]1309
FAILURE CODE [DHUBKX]1311
FAILURE CODE [DHUCKX]1313
FAILURE CODE [DHUDKX]1315
FAILURE CODE [DHUEKX]1317
FAILURE CODE [DHUHKX]1319
FAILURE CODE [DHUJKX]1321
FAILURE CODE [DHUKKX]1323
FAILURE CODE [DHULKX]1325
FAILURE CODE [DHUMKX]1327
FAILURE CODE [DHUQKX]1329
FAILURE CODE [DHUSKX]1331
FAILURE CODE [DJF1KA]1333
FAILURE CODE [DK30KX]1335
FAILURE CODE [DK51L5]1337
FAILURE CODE [DK52KX]1340
FAILURE CODE [DK53L8]1342
FAILURE CODE [DK54KX]1344
FAILURE CODE [DK5VKX]1346
FAILURE CODE [DK5VMA]1348
FAILURE CODE [DK60KX]1349
FAILURE CODE [DKH0KX]1351
FAILURE CODE [DKH1KX]1353
FAILURE CODE [DLF1KA]1355
FAILURE CODE [DLF1LC]1356
FAILURE CODE [DLF2KA]1358
FAILURE CODE [DLF2LC]1359
FAILURE CODE [DLF8LC]1361
FAILURE CODE [DLF9LC]1363
FAILURE CODE [DLFKLC]1365
FAILURE CODE [DLFLLC]1367
FAILURE CODE [DLT3KA]1369
FAILURE CODE [DLT3LC]1370
FAILURE CODE [DPQ1KR]1372
FAILURE CODE [DPQ1LD]1375
FAILURE CODE [DPQ2KR]1378
FAILURE CODE [DPQ3KR]1381
FAILURE CODE [DPQ4KB]1383
FAILURE CODE [DQ11KQ]1384
FAILURE CODE [DQ11KR]1387
FAILURE CODE [DQ11KT]1388
FAILURE CODE [DQ11MA]1389
FAILURE CODE [DQ11NR]1391
FAILURE CODE [DQ12KQ]1392
FAILURE CODE [DQ12KR]1395
FAILURE CODE [DQ12KT]1396
FAILURE CODE [DQ12MA]1397
FAILURE CODE [DQ12NR]1399
FAILURE CODE [DQ13KQ]1400
FAILURE CODE [DQ13KR]1403
FAILURE CODE [DQ13KT]1404
FAILURE CODE [DQ13MA]1405
FAILURE CODE [DQ13NR]1407
FAILURE CODE [DQ14KQ]1408
FAILURE CODE [DQ14KR]1411
FAILURE CODE [DQ14KT]1412
FAILURE CODE [DQ14MA]1413
FAILURE CODE [DQ14NR]1415
FAILURE CODE [DQ15KQ]1416
FAILURE CODE [DQ15KR]1419
FAILURE CODE [DQ15KT]1420
FAILURE CODE [DQ15MA]1421
FAILURE CODE [DQ15NR]1423
FAILURE CODE [DQ16KQ]1424
FAILURE CODE [DQ16KR]1427
FAILURE CODE [DQ16KT]1428
FAILURE CODE [DQ16MA]1429
FAILURE CODE [DQ16NR]1431
FAILURE CODE [DQ17KQ]1432
FAILURE CODE [DQ17KR]1435
FAILURE CODE [DQ17KT]1436
FAILURE CODE [DQ17MA]1437
FAILURE CODE [DQ17NR]1439
FAILURE CODE [DQ18KQ]1440
FAILURE CODE [DQ18KR]1443
FAILURE CODE [DQ18KT]1444
FAILURE CODE [DQ18MA]1445
FAILURE CODE [DQ18NR]1447
FAILURE CODE [DR10KA]1448
FAILURE CODE [DR20KA]1450
FAILURE CODE [DR30KA]1452
FAILURE CODE [DR40KA]1454
FAILURE CODE [DR50KA]1456
FAILURE CODE [DR60KA]1458
FAILURE CODE [DSJ0KR]1460
FAILURE CODE [DUMBKB]1461
FAILURE CODE [DV00KB]1462
FAILURE CODE [DV01KB]1464
FAILURE CODE [DW2AKA]1466
FAILURE CODE [DW2AKB]1467
FAILURE CODE [DW2AKY]1469
FAILURE CODE [DW2AL1]1470
FAILURE CODE [DW2ALH]1471
FAILURE CODE [DW2BKA]1472
FAILURE CODE [DW2BKB]1473
FAILURE CODE [DW2BKY]1474
FAILURE CODE [DW2BL1]1475
FAILURE CODE [DW2BLH]1476
FAILURE CODE [DW2CKA]1477
FAILURE CODE [DW2CKB]1478
FAILURE CODE [DW2CKY]1480
FAILURE CODE [DW2CL1]1481
FAILURE CODE [DW2CLH]1482
FAILURE CODE [DW4BK4]1483
FAILURE CODE [DW4BMA]1485
FAILURE CODE [DW72KZ]1488
FAILURE CODE [DW73KA]1490
FAILURE CODE [DW73KB]1492
FAILURE CODE [DW73KY]1494
FAILURE CODE [DW7NKZ]1495
FAILURE CODE [DW7SKZ]1497
FAILURE CODE [DWNJKZ]1499
FAILURE CODE [DWNMKZ]1501
FAILURE CODE [DX13KA]1503
FAILURE CODE [DX13KB]1505
FAILURE CODE [DX13KY]1507
FAILURE CODE [DX30K4]1508
FAILURE CODE [DX30KA]1510
FAILURE CODE [DX30KB]1512
FAILURE CODE [DX30KY]1514
FAILURE CODE [DX30MA]1516
FAILURE CODE [DX33K4]1518
FAILURE CODE [DX33KA]1520
FAILURE CODE [DX33KB]1522
FAILURE CODE [DX33KY]1524
FAILURE CODE [DX33MA]1526
FAILURE CODE [DX37K4]1528
FAILURE CODE [DX37KA]1530
FAILURE CODE [DX37KB]1532
FAILURE CODE [DX37KY]1534
FAILURE CODE [DX37MA]1535
FAILURE CODE [DX38K4]1537
FAILURE CODE [DX38KA]1539
FAILURE CODE [DX38KB]1541
FAILURE CODE [DX38KY]1543
FAILURE CODE [DX38MA]1544
FAILURE CODE [DX42KZ]1546
FAILURE CODE [DX43KZ]1548
FAILURE CODE [DXH1KA]1550
FAILURE CODE [DXH1KB]1552
FAILURE CODE [DXH1KY]1554
FAILURE CODE [DXH2KA]1555
FAILURE CODE [DXH2KB]1558
FAILURE CODE [DXH2KY]1561
FAILURE CODE [DXH3KA]1564
FAILURE CODE [DXH3KB]1567
FAILURE CODE [DXH3KY]1570
FAILURE CODE [DXH4KA]1573
FAILURE CODE [DXH4KB]1576
FAILURE CODE [DXH4KY]1579
FAILURE CODE [DXH5KA]1582
FAILURE CODE [DXH5KB]1585
FAILURE CODE [DXH5KY]1588
FAILURE CODE [DXH6KA]1591
FAILURE CODE [DXH6KB]1594
FAILURE CODE [DXH6KY]1597
FAILURE CODE [DXH7KA]1600
FAILURE CODE [DXH7KB]1603
FAILURE CODE [DXH7KY]1606
FAILURE CODE [DXHHKA]1609
FAILURE CODE [DXHHKB]1611
FAILURE CODE [DXHHKY]1613
FAILURE CODE [DY30MA]1616
FAILURE CODE [DY30MC]1619
FAILURE CODE [DY30ME]1622
FAILURE CODE [DY32MC]1624
FAILURE CODE [F9A1KK]1627
FAILURE CODE [F9A2KK]1630
FAILURE CODE [F9ALKA]1633
FAILURE CODE [F9ALKB]1635
FAILURE CODE [F9AUKA]1637
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1640
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1640
E-2 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING1648
E-3 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING1651
E-4 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)1653
E-5 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY1655
E-6 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL1657
E-7 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL1660
E-8 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL1663
E-9 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY1665
E-10 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION1667
E-11 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL1669
E-12 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY1671
E-13 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS1672
E-14 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY1674
E-15 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED1677
E-16 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL1680
E-17 REARVIEW MONITOR IS NOT DISPLAYED IN CONJUNCTION WITH REVERSE WHEN THE CONSTANT DISPLAY SETTING IS DISABLED1682
E-18 REARVIEW MONITOR REFERENCE LINE IS NOT DISPLAYED WHEN THE REFERENCE LINE DISPLAY SETTING IS ENABLED1685
E-19 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1687
E-20 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL1689
E-21 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION1691
E-22 ALARM BUZZER DOES NOT SOUND1692
E-23 ALARM BUZZER DOES NOT STOP SOUNDING1694
E-24 AISS FUNCTION DOES NOT OPERATE PROPERLY1696
E-25 HOIST LEVER DOES NOT OPERATE PROPERLY1698
E-26 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY1700
E-27 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS1704
E-28 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP1707
E-29 TAIL LAMP DOES NOT LIGHT UP1710
E-30 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP1713
E-31 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP1716
E-32 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEADLAMPS LIGHTS UP1719
E-33 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED1721
E-34 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1723
E-35 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED1725
E-36 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS1726
E-37 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY1729
E-38 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED1734
E-39 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL1737
E-40 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR1740
E-41 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION1742
E-42 EXTERNAL POWER SUPPLY ENGINE OIL PAN HEATER DOES NOT OPERATE1743
E-43 EXTERNAL POWER SUPPLY BRAKE TANK HEATER DOES NOT OPERATE1745
E-44 EXTERNAL POWER SUPPLY TRANSMISSION OIL PAN HEATER DOES NOT OPERATE1747
E-45 EXTERNAL POWER SUPPLY HYDRAULIC TANK HEATER DOES NOT OPERATE1749
E-46 BUZZER DOES NOT SOUND WHEN POWER LADDER IS OPERATED1751
E-47 POWER LADDER PUMP DOES NOT OPERATE1753
E-48 CANNOT ACCESS TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION1755
E-49 CANNOT LOG IN TO THE SETTING SCREEN OF THE MOBILE COMMUNICATION TERMINAL BECAUSE THE LOG IN PASSWORD IS UNKNOWN1761
E-50 KOMTRAX Plus CONTROLLER IS NOT DETECTED1764
E-51 KOMTRAX Plus CONTROLLER DOES NOT BECOME ACTIVE1765
E-52 COMMUNICATION BETWEEN MOBILE COMMUNICATION TERMINAL AND KOMTRAX Plus SERVER FAILS1766
E-53 DATA IS NOT SENT TO KOMTRAX Plus SERVER1769
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1771
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1771
FAILURE MODE AND CAUSE TABLE1772
H-1 MACHINE DOES NOT START1785
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)1788
H-3 LOCKUP IS NOT RELEASED1789
H-4 ABNORMALLY STRONG SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING1790
H-5 GEAR IS NOT UPSHIFTED1792
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS1795
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE1796
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT PARTICULAR GEAR SPEED1797
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED1799
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH1802
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW1803
H-12 STEERING WHEEL IS HEAVY TO OPERATE1804
H-13 STEERING WHEEL CANNOT BE OPERATED1805
H-14 STEERING WHEEL WAGGLES1806
H-15 FRONT BRAKE DOES NOT APPLY SUFFICIENTLY1807
H-16 REAR BRAKE DOES NOT APPLY SUFFICIENTLY1809
H-17 DUMP BODY RISING SPEED IS LOW1811
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE1813
H-19 DUMP BODY DOES NOT MOVE1814
H-20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)1816
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN1817
H-22 POWER LADDER DOES NOT MOVE OR ITS SPEED IS LOW1818
50 DISASSEMBLY AND ASSEMBLY1819
CONTENTS1820
PRECAUTIONS BEFORE WORK1824
ABBREVIATIONS1825
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION1830
HOW TO READ THIS MANUAL1830
COATING MATERIALS LIST1832
SPECIAL TOOL LIST1835
DIAGRAMS OF SPECIAL TOOLS1852
ENGINE AND COOLING SYSTEM1863
REMOVE AND INSTALL RADIATOR ASSEMBLY1863
PROCEDURE TO REMOVE RADIATOR ASSEMBLY1863
PROCEDURE TO INSTALL RADIATOR ASSEMBLY1877
REMOVE AND INSTALL OIL COOLER ASSEMBLY1890
PROCEDURE TO REMOVE OIL COOLER ASSEMBLY1890
PROCEDURE TO INSTALL OIL COOLER ASSEMBLY1897
REMOVE AND INSTALL ENGINE ASSEMBLY1905
PROCEDURE TO REMOVE ENGINE ASSEMBLY1906
PROCEDURE TO INSTALL ENGINE ASSEMBLY1933
REMOVE AND INSTALL DAMPER ASSEMBLY1964
PROCEDURE TO REMOVE DAMPER ASSEMBLY1964
PROCEDURE TO INSTALL DAMPER ASSEMBLY1966
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY1968
PROCEDURE TO DISASSEMBLE DAMPER ASSEMBLY1968
PROCEDURE TO ASSEMBLE DAMPER ASSEMBLY1970
DISASSEMBLE AND ASSEMBLE OF RADIATOR ASSEMBLY1975
PROCEDURE TO DISASSEMBLE RADIATOR ASSEMBLY1977
PROCEDURE TO ASSEMBLE RADIATOR ASSEMBLY1981
POWER TRAIN1987
REMOVE AND INSTALL FRONT DRIVE SHAFT1987
PROCEDURE TO REMOVE FRONT DRIVE SHAFT1987
PROCEDURE TO INSTALL FRONT DRIVE SHAFT1993
REMOVE AND INSTALL REAR DRIVE SHAFT ASSEMBLY1999
PROCEDURE TO REMOVE REAR DRIVE SHAFT ASSEMBLY1999
PROCEDURE TO INSTALL REAR DRIVE SHAFT ASSEMBLY2002
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2005
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2005
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2023
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2041
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2041
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2051
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER AND PTO ASSEMBLY2066
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER AND PTO ASSEMBLY2068
PROCEDURE TO ASSEMBLE TORQUE CONVERTER AND PTO ASSEMBLY2084
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY2103
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY2106
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY2135
REMOVE AND INSTALL DIFFERENCIAL ASSEMBLY2164
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY2164
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY2166
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY2170
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY2170
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY2180
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY2199
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY2199
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY2201
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY2204
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2204
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2207
BRAKE SYSTEM2218
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY2218
PROCEDURE TO REMOVE FRONT WHEEL HUB AND BRAKE ASSEMBLY2218
PROCEDURE TO INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY2225
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB AND BRAKE ASSEMBLY2233
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB AND BRAKE ASSEMBLY2233
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB AND BRAKE ASSEMBLY2242
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2256
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY2256
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2256
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE AND REAR BRAKE ASSEMBLY2258
PROCEDURE TO DISASSEMBLE FINAL DRIVE AND REAR BRAKE ASSEMBLY2258
PROCEDURE TO ASSEMBLE FINAL DRIVE AND REAR BRAKE ASSEMBLY2272
STEERING SYSTEM2294
REMOVE AND INSTALL STEERING VALVE ASSEMBLY2294
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY2294
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY2297
REMOVE AND INSTALL O-RING OF STEERING VALVE ASSEMBLY2300
PROCEDURE TO REMOVE O-RING OF STEERING VALVE ASSEMBLY2300
PROCEDURE TO INSTALL O-RING OF STEERING VALVE ASSEMBLY2302
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY2306
PROCEDURE TO REMOVE STEERING CYLINDER ASSEMBLY2306
PROCEDURE TO INSTALL STEERING CYLINDER ASSEMBLY2313
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY2320
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY2320
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY2322
UNDERCARRIAGE AND FRAME2325
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY2325
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY2325
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY2328
REMOVE AND INSTALL REAR WHEEL ASSEMBLY2331
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY2331
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY2335
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2339
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY2339
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2346
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2353
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2353
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2355
REMOVE AND INSTALL KING PIN2357
PROCEDURE TO REMOVE KING PIN2357
PROCEDURE TO INSTALL KING PIN2358
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2360
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY2360
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2364
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2367
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2367
PROCEDURE TOASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2369
INSTALL AUTOMATIC FIRE EXTINGUISHER2372
INSTALL AUTOMATIC FIRE EXTINGUISHER2372
HYDRAULIC SYSTEM2378
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY2378
PROCEDURE TO REMOVE FLOW AMPLIFIER VALVE ASSEMBLY2378
PROCEDURE TO INSTALL FLOW AMPLIFIER VALVE ASSEMBLY2385
REMOVE AND INSTALL O-RING of FLOW AMPLIFIER VALVE ASSEMBLY2393
PROCEDURE TO REMOVE O-RING OF FLOW AMPLIFIER VALVE ASSEMBLY2393
PROCEDURE TO INSTALL O-RING OF FLOW AMPLIFIER VALVE ASSEMBLY2396
REMOVE AND INSTALL HOIST VALVE ASSEMBLY2399
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY2399
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY2406
REMOVE AND INSTALL HOIST CYLINDER HEAD ASSEMBLY2414
PROCEDURE TO REMOVE HOIST CYLINDER HEAD ASSEMBLY2414
PROCEDURE TO INSTALL HOIST CYLINDER ASSEMBLY2415
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY2417
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY2417
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY2422
WORK EQUIPMENT2429
REMOVE AND INSTALL DUMP BODY ASSEMBLY2429
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY2429
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY2433
CAB AND ITS ATTACHMENTS2439
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY2439
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY2439
PROCEDURE TO INSTALL AIR CONDITIONER ASSEMBLY2448
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY2456
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY2456
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY2458
REMOVE AND INSTALL SEAT BELT2461
PROCEDURE TO REMOVE SEAT BELT2461
PROCEDURE TO INSTALL SEAT BELT2461
ELECTRICAL SYSTEM2463
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY2463
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY2463
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY2464
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY2465
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY2465
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY2466
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY2467
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY2467
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY2467
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2469
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY2469
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY2471
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY2474
PROCEDURE TO REMOVE KOMTRAX Plus CONTROLLER ASSEMBLY2474
PROCEDURE TO INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY2475
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL2476
PROCEDURE TO REMOVE MOBILE COMMUNICATION TERMINAL2476
PROCEDURE TO INSTALL MOBILE COMMUNICATION TERMINAL2477
REMOVE AND INSTALL DC-DC CONVERTER2479
PROCEDURE TO REMOVE DC-DC CONVERTER2479
PROCEDURE TO INSTALL DC-DC CONVERTER2479
REMOVE AND INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS2480
PROCEDURE TO REMOVE MOBILE COMMUNICATION TERMINAL WIRING HARNESS2480
PROCEDURE TO INSTALL MOBILE COMMUNICATION TERMINAL WIRING HARNESS2485
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2491
PROCEDURE TO REMOVE KOMTRAX TERMINAL ASSEMBLY2491
PROCEDURE TO INSTALL KOMTRAX TERMINAL ASSEMBLY2492
REMOVE AND INSTALL REARVIEW CAMERA2493
PROCEDURE TO REMOVE REARVIEW CAMERA2493
PROCEDURE TO INSTALL REARVIEW CAMERA2493
REMOVE AND INSTALL KomVision CAMERA2495
PROCEDURE TO REMOVE KomVision CAMERA2495
PROCEDURE TO INSTALL KomVision CAMERA2498
REMOVE AND INSTALL KomVision RADAR2500
PROCEDURE TO REMOVE KomVision RADAR2501
PROCEDURE TO INSTALL KomVision RADAR2508
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2514
PROCEDURE TO REMOVE KomVision CONTROLLER ASSEMBLY2514
PROCEDURE TO INSTALL KomVision CONTROLLER ASSEMBLY2515
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY2516
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY2516
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY2517
60 MAINTENANCE STANDARD2519
CONTENTS2520
ABBREVIATIONS2522
ENGINE AND COOLING SYSTEM2527
MAINTENANCE STANDARD OF ENGINE MOUNT2527
MAINTENANCE STANDARD OF OUTPUT SHAFT2528
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE MOTOR2530
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE MOTOR2532
POWER TRAIN2534
MAINTENANCE STANDARD OF DRIVE SHAFT2534
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT2536
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO2537
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE2541
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE2543
MAINTENANCE STANDARD OF TRANSMISSION2544
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE2550
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV2551
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV2552
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION SELECTOR VALVE2553
MAINTENANCE STANDARD OF FRONT AXLE2554
MAINTENANCE STANDARD OF REAR AXLE2555
MAINTENANCE STANDARD OF DIFFERENTIAL2556
MAINTENANCE STANDARD OF FINAL DRIVE2557
STEERING SYSTEM2558
MAINTENANCE STANDARD OF STEERING COLUMN2558
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE2559
MAINTENANCE STANDARD OF STEERING CYLINDER2562
BRAKE SYSTEM2563
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER2563
MAINTENANCE STANDARD OF REAR SLACK ADJUSTER2564
MAINTENANCE STANDARD OF FRONT BRAKE AND PARKING BRAKE2565
MAINTENANCE STANDARD OF REAR BRAKE AND PARKING BRAKE2566
UNDERCARRIAGE AND FRAME2567
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER2567
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER2569
MAINTENANCE STANDARD OF REAR AXLE SUPPORT2570
HYDRAULIC SYSTEM2571
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP2571
MAINTENANCE STANDARD OF DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR2575
MAINTENANCE STANDARD OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR2577
MAINTENANCE STANDARD OF SERVO VALVE OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR2579
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP2580
MAINTENANCE STANDARD OF FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP2582
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE PUMP2584
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE TRIPLEX PUMP2586
WORK EQUIPMENT2588
MAINTENANCE STANDARD OF HOIST CYLINDER2588
CAB AND ITS ATTACHMENTS2589
MAINTENANCE STANDARD OF CAB MOUNT2589
80 THE OTHER INFORMATION2591
CONTENTS2592
PRECAUTIONS BEFORE WORK2596
ABBREVIATIONS2597
AIR CONDITIONER SYSTEM2602
PRECAUTIONS FOR REFRIGERANT2602
AIR CONDITIONER COMPONENT2603
SPECIFICATIONS OF AIR CONDITIONER2605
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2606
OUTLINE OF REFRIGERATION CYCLE2607
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2609
AIR CONDITIONER UNIT2609
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2609
FUNCTION OF AIR CONDITIONER UNIT2610
COMPONENT PARTS OF AIR CONDITIONER UNIT2612
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2613
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2613
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2613
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2613
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2614
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2614
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2614
FUNCTION OF TRIPLE PRESSURE SWITCH2615
AIR CONDITIONER CONTROLLER2616
STRUCTURE OF AIR CONDITIONER CONTROLLER2616
COMPRESSOR2617
STRUCTURE OF COMPRESSOR2617
SPECIFICATIONS OF COMPRESSOR2617
FUNCTION OF COMPRESSOR2617
CONDENSER2618
STRUCTURE OF CONDENSER2618
SPECIFICATIONS OF CONDENSER2618
FUNCTION OF CONDENSER2618
SENSORS FOR AIR CONDITIONER SYSTEM2619
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2619
FUNCTION OF AMBIENT TEMPERATURE SENSOR2619
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2620
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2622
AIR CONDITIONER SYSTEM DIAGRAM2624
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2625
FUNCTION OF AIR CONDITIONER CONTROLLER2626
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2627
TESTING AIR LEAKAGE (DUCT)2630
METHOD FOR TESTING AIR LEAKAGE (DUCT)2630
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2633
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2634
TEST VENT (MODE) CHANGEOVER2636
METHOD FOR TESTING VENT (MODE) CHANGEOVER2636
TESTING FRESH/RECIRC AIR CHANGEOVER2637
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2637
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT2638
PROCEDURE TO TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT2638
TEST RELAYS2640
METHOD FOR TESTING RELAYS2640
AIR CONDITIONER TROUBLESHOOTING CHART 12641
AIR CONDITIONER TROUBLESHOOTING CHART 22642
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2645
FAILURE CODE [879AKA]2646
FAILURE CODE [879AKB]2647
FAILURE CODE [879BKA]2648
FAILURE CODE [879BKB]2649
FAILURE CODE [879CKA]2650
FAILURE CODE [879CKB]2651
FAILURE CODE [879EMC]2652
FAILURE CODE [879FMC]2653
FAILURE CODE [879GKX]2654
A-1 TROUBLESHOOT POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2655
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2657
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2660
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2662
TROUBLESHOOTING USING GAUGE PRESSURE2664
CONNECTION OF SERVICE TOOL2666
METHOD FOR CONNECTING SERVICE TOOL2666
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2667
HANDLE COMPRESSOR OIL2669
METHOD FOR REPLACING DESICCANT2671
KomVision SYSTEM2673
STRUCTURE AND OPERATION OF KomVision SYSTEM2673
PRECAUTIONS FOR KomVision SYSTEM2673
LAYOUT DRAWING OF KomVision SYSTEM2674
LAYOUT DRAWING OF KomVision SWITCHES AND MONITORS2676
KomVision SYSTEM DIAGRAM2677
FUNCTION OF KomVision SYSTEM2679
COMPONENT PARTS OF KomVision SYSTEM2681
KomVision CONTROLLER2681
KomVision MONITOR2686
KomVision CAMERA2689
KomVision RADAR2690
TESTING AND ADJUSTING KomVision SYSTEM2691
SET AND OPERATE KomVision MONITOR2691
MAINTENANCE MODE2693
CAMERA CALIBRATION2713
6 CAMERAS CALIBRATION2714
1 CAMERA CALIBRATION2742
RADAR ADJUSTMENT (ONLY FOR MACHINE WITH RADAR)2749
METHOD FOR ADJUSTING RADAR2749
METHOD FOR ADJUSTING RADAR SEPARATELY2757
TROUBLESHOOTING OF KomVision SYSTEM2765
RELATED INFORMATION ON TROUBLESHOOTING2765
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION2765
KomVision SYSTEM TROUBLESHOOTING PROCEDURE2768
SYMPTOM AND TROUBLESHOOTING NUMBERS2771
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2772
CONNECTORS LIST AND LAYOUT2774
FAILURE CODES TABLE2779
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)2782
FAILURE CODE [D1J0KB]2782
FAILURE CODE [DBP0KM]2783
FAILURE CODE [DBP0KT]2784
FAILURE CODE [DBP0NR]2785
FAILURE CODE [DBP5KP]2786
FAILURE CODE [DBPLKA]2788
FAILURE CODE [DBPLKB]2790
FAILURE CODE [DBPQKR]2792
FAILURE CODE [DBPRKR]2795
FAILURE CODE [DBPRMA]2798
FAILURE CODE [DBPUKR]2799
FAILURE CODE [DBPVKR]2804
FAILURE CODE [DBPWKR]2809
FAILURE CODE [DBPXKR]2810
FAILURE CODE [DPQ1LD]2811
FAILURE CODE [DPQ4KB]2814
FAILURE CODE [DQ11KQ]2815
FAILURE CODE [DQ11KR]2817
FAILURE CODE [DQ11KT]2818
FAILURE CODE [DQ11MA]2819
FAILURE CODE [DQ11NR]2821
FAILURE CODE [DQ12KQ]2822
FAILURE CODE [DQ12KR]2824
FAILURE CODE [DQ12KT]2825
FAILURE CODE [DQ12MA]2826
FAILURE CODE [DQ12NR]2828
FAILURE CODE [DQ13KQ]2829
FAILURE CODE [DQ13KR]2831
FAILURE CODE [DQ13KT]2832
FAILURE CODE [DQ13MA]2833
FAILURE CODE [DQ13NR]2835
FAILURE CODE [DQ14KQ]2836
FAILURE CODE [DQ14KR]2838
FAILURE CODE [DQ14KT]2839
FAILURE CODE [DQ14MA]2840
FAILURE CODE [DQ14NR]2842
FAILURE CODE [DQ15KQ]2843
FAILURE CODE [DQ15KR]2845
FAILURE CODE [DQ15KT]2846
FAILURE CODE [DQ15MA]2847
FAILURE CODE [DQ15NR]2849
FAILURE CODE [DQ16KQ]2850
FAILURE CODE [DQ16KR]2852
FAILURE CODE [DQ16KT]2853
FAILURE CODE [DQ16MA]2854
FAILURE CODE [DQ16NR]2856
FAILURE CODE [DQ17KQ]2857
FAILURE CODE [DQ17KR]2859
FAILURE CODE [DQ17KT]2860
FAILURE CODE [DQ17MA]2861
FAILURE CODE [DQ17NR]2863
FAILURE CODE [DQ18KQ]2864
FAILURE CODE [DQ18KR]2866
FAILURE CODE [DQ18KT]2867
FAILURE CODE [DQ18MA]2868
FAILURE CODE [DQ18NR]2870
FAILURE CODE [DR10KA]2871
FAILURE CODE [DR20KA]2873
FAILURE CODE [DR30KA]2875
FAILURE CODE [DR40KA]2877
FAILURE CODE [DR50KA]2879
FAILURE CODE [DR60KA]2881
FAILURE CODE [DUMBKB]2883
FAILURE CODE [DV01KB]2884
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2886
E-1 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2886
E-2 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2889
E-3 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED2894
E-4 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL2897
E-5 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR2900
E-6 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION2902
90 CIRCUIT DIAGRAMS2903
CONTENTS2904
ABBREVIATIONS2905
HYDRAULIC CIRCUIT DIAGRAM2910
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2910
HYDRAULIC CIRCUIT DIAGRAM2915
HYDRAULIC CIRCUIT DIAGRAM (Rear axle oil circulation specifications)2917
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM2919
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (Only for machine – 40 °C specification)2921
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM2923
HYDRAULIC CIRCUIT DIAGRAM FOR POWER LADDER2925
ELECTRICAL CIRCUIT DIAGRAM2927
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2927
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/11)2931
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/11)2933
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/11)2935
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/11)2937
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/11)2939
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/11)2941
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/11)2943
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/11)2945
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (9/11)2947
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (10/11)2949
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (11/11)2951
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (1/9)2953
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (2/9)2955
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (3/9)2957
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (4/9)2959
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (5/9)2961
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (6/9)2963
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (7/9)2965
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (8/9)2967
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (9/9)2969
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8)2971
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8)2973
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8)2975
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8)2977
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8)2979
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8)2981
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8)2983
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8)2985
INDEX2987

S.M 30/12/24