Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 PDF
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Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 – PDF DOWNLOAD
SERIAL NUMBERS HD325-50001 and up
HD405-50001 and up
Description
Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 – PDF DOWNLOAD
FILE DETAILS:
Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 – PDF DOWNLOAD
Language : English
Pages :3410
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 – PDF DOWNLOAD
SERIAL NUMBERS HD325-50001 and up
HD405-50001 and up
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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the 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 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu DUMP TRUCK HD325-8 HD405-8 Shop Manual SEN06618-16 – PDF DOWNLOAD
SERIAL NUMBERS HD325-50001 and up
HD405-50001 and up
Cover 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATIONS 28
FOREWORD, SAFETY, BASIC INFORMATION 33
HOW TO READ THE SHOP MANUAL 33
Composition of the shop manual 33
Symbols 34
Signal word 34
Unit 34
SAFETY NOTICE FOR OPERATION 35
Safety matters 35
General precautions 35
Precautions for preparatory work 36
Precautions during work 37
Precautions for slinging work and making signals 38
Precautions for using mobile crane 40
Precautions for using overhead traveling crane 40
Selecting wire ropes 40
Precautions for disconnecting air conditioner piping 41
Precautions for air conditioner piping 41
PRECAUTIONS TO PREVENT FIRE 43
Fire caused by fuel, oil, coolant or window washer fluid 43
Fire caused by accumulation or attachment of flammable material 43
Fire coming from electric wiring 43
Fire caused by piping 43
Fire around the machine due to highly heated exhaust gas 43
Explosion caused by lighting equipment 44
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 45
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE DEF 47
Handling DEF in cold weather 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
Select an appropriate workplace 48
Disassembly and maintenance work in the field 48
Sealing of openings (prevention of flowing out of oil) 48
Preventing intrusion of foreign materials during refilling 48
Replacing hydraulic oil while its temperature is high 49
Flushing operation 49
Cleaning operation 49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 50
Precautions for removal and disassembling work 50
Introduction of parts for the disassembly of the face seal type hoses and tubes 50
Introduction of parts for the disconnection of the taper seal type hoses and tubes 51
Introduction of parts for the disconnection of the split flange type hoses and tubes 51
Introduction of parts for the removal of O-ring boss type joint 52
Introduction of parts for the removal of taper pipe thread type joint 53
Precautions for installation and assembling work 53
Precautions at the time of completion of work 54
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
Handling wiring harnesses and connectors 56
Main causes of failure in wiring harness 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
Select an appropriate workplace 58
Sealing the opening 58
How to clean parts when dirt is stuck 58
Precautions for replacing fuel filter cartridge 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
Select an appropriate workplace 59
Sealing the opening 59
PRACTICAL USE OF KOMTRAX 60
Merit of using KOMTRAX 60
How to make a full use of KOMTRAX 60
How to operate KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
Disconnecting connectors 65
Connecting connectors 66
Drying wiring harness 67
Handling controller 68
Precautions for troubleshooting electrical circuits 68
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
Method for disconnecting Deutsch connector 69
Method for connecting Deutsch connector 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 70
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 70
Method for disconnecting slide lock type connector (FRAMATOME-24) 70
Method for connecting slide lock type connector (FRAMATOME-24) 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
Method for disconnecting connector with lock to pull 71
Method for connecting connector with lock to pull 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
Method for disconnecting connector with lock to push (BOSCH-3) 72
Method for connecting connector with lock to push (BOSCH-3) 72
Method for disconnecting connector with lock to push (AMP-3) 73
Method for connecting connector with lock to push (AMP-3) 73
Method for disconnecting connector with lock to push (SUMITOMO-3) 73
Method for connecting connector with lock to push (SUMITOMO-3) 73
Method for disconnecting connector with lock to push (SUMITOMO-4) 73
Method for connecting connector with lock to push (SUMITOMO-4) 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
Method for disconnecting connector with housing to rotate 74
Method for connecting connector with housing to rotate 74
HOW TO READ ELECTRICAL WIRE CODE 75
Type, symbol, and material 75
Dimensions 75
Color codes table 77
Types of circuits and color codes 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
Standard dimension and tolerance 79
Standard clearance and standard value 80
Standard interference 80
Repair limit and allowable value or allowable dimension 80
Allowable clearance 80
Allowable interference 80
STANDARD TIGHTENING TORQUE TABLE 81
Table of tightening torque for bolts and nuts 81
Table of tightening torque for O-ring boss piping joints 84
Table of tightening torque for O-ring boss plugs 84
Table of tightening torque for hose (taper seal type and face seal type) 85
Table of tightening torque for face seal joints 86
Tightening torque table for bolts and nuts on 102,107 and 114 series engines 86
Tightening torque table for 102, 107, and 114 series engines (joint bolts) 87
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) 87
CONVERSION TABLE 88
Method of using the conversion table 88
Examples of using the conversion table to convert a unit from mm to in 88
mm to in 88
mm to in 88
kg to lb 89
l to USGal 89
l to UKGal 89
kgm to lbft 90
kg/cm2 to lb/in2 90
Temperature 91
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATIONS 95
SPECIFICATIONS 100
SPECIFICATION DRAWING 100
SPECIFICATION DRAWING: HD325-8 100
SPECIFICATION DRAWING: HD405-8 102
SPECIFICATIONS 104
SPECIFICATIONS: HD325-8 104
SPECIFICATIONS: HD405-8 109
WEIGHT TABLE 114
WEIGHT TABLE: HD325-8 114
WEIGHT TABLE: HD405-8 115
FUEL, COOLANT, AND LUBRICATING OIL (NORTH AMERICAN SPECIFICATION) 116
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 116
FUEL, COOLANT, AND LUBRICATING OIL (EU SPECIFICATION) 118
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 118
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATIONS 127
UREA SCR SYSTEM 132
LAYOUT DRAWING OF UREA SCR STSTEM 132
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF DEF SYSTEM 136
INDUCEMENT STRATEGY 138
COMPONENT PARTS OF UREA SCR SYSTEM 153
DEF MIXING TUBE 153
SCR ASSEMBLY 154
DEF TANK 156
DEF PUMP 158
DEF INJECTOR 159
DEF HOSE 160
DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with KOMTRAX terminal) 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with KOMTRAX terminal) 164
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with gateway function controller) 166
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with gateway function controller) 168
SYSTEM OPERATING LAMP SYSTEM 170
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 170
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with KOMTRAX terminal) 170
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with gateway function controller) 171
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with gateway function controller) 171
BATTERY DISCONNECT SWITCH 172
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with KOMTRAX terminal) 172
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with gateway function controller) 173
ENGINE SHUTDOWN SECONDARY SWITCH 174
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 174
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 174
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 175
ENGINE SYSTEM 176
LAYOUT DRAWING OF ENGINE SYSTEM 176
FUNCTION OF ENGINE SYSTEM 178
ENGINE CONTROL SYSTEM 179
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 179
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with gateway function controller) 180
FUNCTION OF ENGINE CONTROL SYSTEM 181
OPERATION OF ENGINE CONTROL SYSTEM 182
AUTOMATIC IDLE STOP SYSTEM 184
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 184
COMPONENT PARTS OF ENGINE SYSTEM 186
OUTPUT SHAFT 186
VGT 187
EGR SYSTEM 191
EGR VALVE 193
EGR COOLER 195
KCCV SYSTEM 196
KCCV VENTILATOR 198
KDPF 200
COOLING SYSTEM 204
LAYOUT DRAWING OF COOLING SYSTEM 204
SPECIFICATIONS OF COOLING SYSTEM 205
RADIATOR FAN CONTROL SYSTEM 206
RADIATOR FAN CONTROL SYSTEM DIAGRAM 206
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 206
COMPONENT PARTS OF COOLING SYSTEM 208
COOLING FAN AND HOIST PUMP 208
COOLING FAN MOTOR 216
CONTROL SYSTEM 223
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with KOMTRAX terminal) 223
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with gateway function controller) 225
RETARDER AND HOIST CONTROL SYSTEM 227
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 227
MACHINE MONITOR SYSTEM 229
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 229
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with gateway function controller) 231
FUNCTION OF MACHINE MONITOR SYSTEM 232
REARVIEW MONITOR SYSTEM 233
REARVIEW MONITOR SYSTEM DIAGRAM 233
FUNCTION OF REARVIEW MONITOR SYSTEM 233
KOMTRAX SYSTEM 234
KOMTRAX SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 234
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with KOMTRAX terminal) 234
KOMTRAX SYSTEM DIAGRAM (For machines equipped with gateway function controller) 235
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with gateway function controller) 235
PAYLOAD METER SYSTEM 236
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 236
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 237
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with gateway function controller) 238
FUNCTION OF PAYLOAD METER SYSTEM 238
DROWSINESS DETECTION SYSTEM 248
LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM 248
SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM 249
FUNCTION OF DROWSINESS DETECTION SYSTEM 251
OPERATION OF DROWSINESS DETECTION SYSTEM 252
COMPONENT PARTS OF CONTROL SYSTEM 253
MACHINE MONITOR 253
SWITCH PANEL 270
REARVIEW MONITOR 271
REARVIEW CAMERA 272
KOMTRAX TERMINAL 273
GATEWAY FUNCTION CONTROLLER 275
INPUT AND OUTPUT SIGNALS OF GATEWAY FUNCTION CONTROLLER 275
COMMUNICATION TERMINAL 278
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR MOBILE COMMUNICATION 278
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR IRIDIUM COMMUNICATION 279
TRANSMISSION CONTROLLER 280
RETARDER AND HOIST CONTROLLER 284
MONITOR CONTROLLER 289
ENGINE CONTROLLER 294
PAYLOAD METER CONTROLLER 300
TRANSLATOR CONTROLLER 304
DROWSINESS DETECTION CAMERA 308
DRIVER STATUS MONITOR 309
ACCELERATOR PEDAL 311
GEAR SHIFT LEVER 312
RETARDER CONTROL LEVER 313
HYDRAULIC SYSTEM 314
LAYOUT DRAWING OF HYDRAULIC SYSTEM 314
COMPONENT PARTS OF HYDRAULIC SYSTEM 315
HYDRAULIC TANK 315
STEERING AND HOIST PUMP 316
POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 326
BRAKE COOLING DUPLEX PUMP 327
HOIST VALVE 328
POWER TRAIN SYSTEM 334
LAYOUT DRAWING OF POWER TRAIN SYSTEM 334
TRANSMISSION CONTROL SYSTEM 337
TRANSMISSION CONTROL SYSTEM DIAGRAM 337
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 339
GEAR SHIFT CONTROL SYSTEM 343
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 343
SHIFTING METHOD IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT CONTROL SYSTEM 344
GEAR SHIFT DISABLED TIME CONTROL OF GEAR SHIFT CONTROL SYSTEM 345
DIRECTION CONTROL SYSTEM 346
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 346
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 346
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 347
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 347
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 347
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 348
TRAVEL SPEED LIMITATION SYSTEM 349
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 349
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 350
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 351
COMPONENT PARTS OF POWER TRAIN SYSTEM 353
DRIVE SHAFT 353
TORQUE CONVERTER AND PTO 355
LOCKUP CLUTCH ECMV 359
TRANSMISSION 362
TRANSMISSION CONTROL VALVE 383
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 385
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 390
MAIN RELIEF VALVE 392
TORQUE CONVERTER RELIEF VALVE 394
AXLE 395
DIFFERENTIAL 397
FINAL DRIVE 399
WORK EQUIPMENT SYSTEM 400
WORK EQUIPMENT CONTROL 400
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 400
FUNCTION OF WORK EQUIPMENT CONTROL 400
HOIST CONTROL 401
HOIST CONTROL SYSTEM DIAGRAM 401
FUNCTION OF HOIST CONTROL 401
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 403
HOIST AND COOLING FAN DIRECTION SELECTOR SOLENOID VALVE 403
DUMP LEVER 404
HOIST EPC VALVE 409
STEERING SYSTEM 410
LAYOUT DRAWING OF STEERING SYSTEM 410
FUNCTION OF STEERING SYSTEM 411
STEERING COLUMN 412
STRUCTURE OF STEERING COLUMN 412
STEERING CONTROL LINKAGE 413
STRUCTURE OF STEERING CONTROL LINKAGE 413
COMPONENT PARTS OF STEERING SYSTEM 414
DEMAND VALVE 414
ORBITROL VALVE 422
STEERING PUMP SELECTOR SOLENOID VALVE 428
CROSS-OVER RELIEF VALVE 429
SECONDARY STEERING PUMP 430
SECONDARY STEERING MOTOR 431
BRAKE SYSTEM 432
LAYOUT DRAWING OF BRAKE SYSTEM 432
RETARDER CONTROL 433
RETARDER CONTROL SYSTEM DIAGRAM 433
FUNCTION OF RETARDER CONTROL 433
ARSC SYSTEM 434
ARSC SYSTEM DIAGRAM 434
FUNCTION OF ARSC SYSTEM 434
COMPONENT PARTS OF BRAKE SYSTEM 435
BRAKE CONTROL PUMP 435
PARKING BRAKE SOLENOID VALVE 436
ACCUMULATOR CHARGE VALVE 437
BRAKE CIRCUIT ACCUMULATOR 441
BRAKE VALVE 442
SECONDARY BRAKE VALVE 446
SECONDARY BRAKE RELAY VALVE 447
FRONT BRAKE CUT SOLENOID VALVE 448
PROPORTIONAL PRESSURE REDUCING VALVE 449
SLACK ADJUSTER 450
BRAKE COOLING OIL CONTROL VALVE 452
BRAKE 453
STRUCTURE OF REAR BRAKE 454
PARKING BRAKE 456
BRAKE SUB-TANK 457
UNDERCARRIAGE AND FRAME 458
REAR AXLE SUPPORT 458
STRUCTURE OF REAR AXLE SUPPORT 458
SUSPENSION 459
STRUCTURE OF SUSPENSION 459
FUNCTION OF SUSPENSION 460
FRONT SUSPENSION 461
STRUCTURE OF FRONT SUSPENSION 461
FUNCTION OF FRONT SUSPENSION 462
REAR SUSPENSION 463
STRUCTURE OF REAR SUSPENSION 463
FUNCTION OF REAR SUSPENSION 464
SUSPENSION CYLINDER 465
STRUCTURE OF SUSPENSION CYLINDER 465
FUNCTION OF SUSPENSION CYLINDER 465
OPERATION OF SUSPENSION CYLINDER 465
WORK EQUIPMENT 466
STRUCTURE OF WORK EQUIPMENT 466
FUNCTION OF WORK EQUIPMENT 466
CAB AND ITS ATTACHMENTS 467
ROPS CAB 467
STRUCTURE OF ROPS CAB 467
FUNCTION OF ROPS CAB 467
CAB MOUNT 468
STRUCTURE OF CAB MOUNT 468
FUNCTION OF CAB MOUNT 468
20 STANDARD VALUE TABLE 469
CONTENTS 470
ABBREVIATIONS 471
STANDARD VALUE TABLE FOR ENGINE 476
STANDARD VALUE TABLE FOR ENGINE: HD325-8 476
STANDARD VALUE TABLE FOR ENGINE: HD405-8 479
STANDARD VALUE TABLE FOR MACHINE 482
STANDARD VALUE TABLE FOR MACHINE: HD325-8 482
STANDARD VALUE TABLE FOR MACHINE: HD405-8 496
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 510
30 TESTING AND ADJUSTING 511
CONTENTS 512
PRECAUTIONS BEFORE WORK 517
ABBREVIATIONS 518
RELATED INFORMATION TO TEST AND ADJUST 523
TOOLS TO TEST AND ADJUST 523
DIAGRAM FOR TEST AND ADJUST TOOLS 533
ENGINE AND COOLING SYSTEM 535
TEST ENGINE SPEED 535
PROCEDURE TO TEST ENGINE SPEED 535
TEST BOOST PRESSURE 537
PROCEDURE TO TEST BOOST PRESSURE WITH MACHINE MONITOR 537
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 539
TEST EXHAUST GAS TEMPERATURE 541
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 541
TEST EXHAUST GAS COLOR 544
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 544
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 545
TEST AND ADJUST VALVE CLEARANCE 547
PROCEDURE TO TEST VALVE CLEARANCE 547
PROCEDURE TO ADJUST VALVE CLEARANCE 548
TEST COMPRESSION PRESSURE 550
PROCEDURE TO TEST COMPRESSION PRESSURE 550
TEST BLOWBY PRESSURE 553
PROCEDURE TO TEST BLOWBY PRESSURE 553
TEST ENGINE OIL PRESSURE 556
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH MACHINE MONITOR 556
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH TEST TOOLS 556
TEST EGR VALVE AND VGT OIL PRESSURE 558
PROCEDURE TO TEST EGR VALVE AND VGT OIL PRESSURE 558
TEST FUEL PRESSURE 559
PROCEDURE TO TEST FUEL PRESSURE 559
TEST FUEL RETURN RATE AND LEAKAGE 561
PROCEDURE TO TEST FUEL RETURN RATE AND LEAKAGE 562
BLEED AIR FROM FUEL SYSTEM 566
PROCEDURE TO BLEED AIR FROM FUEL SYSTEM 566
TEST FUEL CIRCUIT LEAK 568
PROCEDURE TO TEST FUEL CIRCUIT LEAK 568
CYLINDER CUT-OUT MODE 570
NO-INJECTION CRANKING 571
CLEAN FUEL DOSER 572
PROCEDURE TO CLEAN FUEL DOSER 572
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 575
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 576
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER 582
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 582
TEST SCR RELATED FUNCTIONS 583
TEST DEF PUMP RAISED PRESSURE 586
TEST INJECTION AMOUNT FROM DEF INJECTOR 589
TEST DEF LINE HEATER RELAY 1 594
TEST DEF LINE HEATER RELAY 2 598
TEST DEF PUMP HEATER RELAY 602
TEST DEF TANK HEATER VALVE 606
TEST DENITRATION EFFICIENCY OF SCR 610
CLEAN DEF TANK 613
PROCEDURE TO CLEAN DEF TANK 613
CLEAN DEF PUMP 619
PROCEDURE TO CLEAN DEF PUMP 619
TEST TORQUE CONVERTER STALL SPEED 625
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED 625
TEST RADIATOR FAN SPEED 627
PROCEDURE TO TEST RADIATOR FAN SPEED 627
POWER TRAIN 629
TEST POWER TRAIN OIL PRESSURE 629
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 632
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 643
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 643
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 644
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 644
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 645
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 645
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 646
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 646
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 647
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 647
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 647
STEERING SYSTEM 652
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 652
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 652
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 652
PROCEDURE TO ADJUST STEERING CIRCUIT OIL PRESSURE 654
TEST SUPPLY PRESSURE OF ORBITROL VALVE 655
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 655
TEST STEERING CYLINDER PRESSURE 657
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 657
BLEED AIR FROM STEERING CYLINDER CIRCUIT 659
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 659
BRAKE SYSTEM 660
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 660
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 660
TEST WHEEL BRAKE OIL PRESSURE 661
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE 661
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE 662
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE 663
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE (FOR MACHINE WITH KTCS) 663
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 665
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 665
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 666
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 667
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 668
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 669
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 673
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 677
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 683
TEST BRAKE PERFORMANCE 684
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 684
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 685
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 686
BLEED AIR FROM BRAKE CIRCUIT 687
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 687
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITHOUT KTCS) 687
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 688
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 690
TEST PARKING BRAKE OIL PRESSURE 691
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 691
RELEASE PARKING BRAKE MANUALLY 693
PROCEDURE TO RELEASE PARKING BRAKE MANUALLY 693
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 694
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 694
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE PAD WEAR WITH GUAGE MEASURE 694
TEST THE AMOUNT OF REAR BRAKE DISC WEAR 695
PROCEDURE TO VISUALLY TEST THE AMOUNT OF REAR BRAKE DISC WEAR 695
TEST AND ADJUST PARKING BRAKE PAD 696
PROCEDURE TO TEST PARKING BRAKE PAD CLEARANCE 696
PROCEDURE TO ADJUST PARKING BRAKE PAD CLEARANCE 697
HYDRAULIC SYSTEM 698
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 698
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 698
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 699
TEST HOIST CYLINDER SUPPLY PRESSURE 700
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 700
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 702
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 702
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 703
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 704
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 704
TEST AND ADJUST FRONT SUSPENSION CYLINDER 706
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 706
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 707
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 712
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 712
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 713
TEST AND ADJUST REAR SUSPENSION CYLINDER 714
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 714
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 715
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 720
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 720
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH TEST TOOLS 720
WORK EQUIPMENT 722
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 722
PROCEDURE TO TEST BODY POSITIONER SENSOR 722
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 722
PROCEDURE TO CALIBRATE AFTER YOU ADJUST BODY POSITION SENSOR 722
LOWER THE BODY MANUALLY 724
PROCEDURE TO LOWER THE BODY MANUALLY 724
LIFT THE BODY MANUALLY 725
PROCEDURE TO LIFT THE BODY MANUALLY 725
CAB AND ITS ATTACHMENTS 726
ADJUST STEERING WHEEL TILT LOCK LEVER 726
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 726
ADJUST RATTLING OPERATOR’S SEAT 727
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 727
ELECTRICAL SYSTEM 728
SET AND ADJUST EACH EQUIPMENT 728
SET AND OPERATE OF MACHINE MONITOR 731
OPERATOR MODE 735
SERVICE MODE 748
ABNORMALITY RECORD MENU 776
DEFAULT MENU 791
DIAGNOSTIC TESTS MENU 805
ADJUSTMENT MENU 817
PROCEDURE TO PERFORM NO-INJECTION CRANKING 838
PAYLOAD METER SETTING 840
KOMTRAX SETTINGS MENU 862
PROCEDURE TO DISPLAY SERVICE MESSAGE 867
PROCEDURE TO START UP KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 869
PROCEDURE TO FINISH KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 873
PROCEDURE TO START UP KOMTRAX SYSTEM (For machines equipped with gateway function controller) 875
PROCEDURE TO FINISH KOMTRAX SYSTEM(For machines equipped with gateway function controller) 879
SET DRIVER STATUS MONITOR 881
PREPARATION FOR DRIVER STATUS MONITOR SETTING 881
HOW TO SET DRIVER STATUS MONITOR 887
HOW TO DO OPERATION CHECK OF DRIVER STATUS MONITOR 889
HOW TO ADJUST DROWSINESS DETECTION CAMERA ANGLE 890
ADJUST REARVIEW CAMERA ANGLE 891
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 891
SET REGION OF BLUETOOTH® COMPATIBLE RADIO 892
HOW TO SET REGION OF BLUETOOTH® COMPATIBLE RADIO 892
ADJUST OPTICAL AXIS OF HEAD LAMP 894
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 894
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 897
BATTERY DISCONNECT SWITCH WORK (For machines equipped with KOMTRAX terminal) 898
BATTERY DISCONNECT SWITCH WORK (For machines equipped with gateway function controller) 899
TEST DIODES 900
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 900
PROCEDURE TO TEST DIODE USING ANALOG TESTER 900
Pm CLINIC 901
Pm CLINIC SERVICE 901
Pm CLINIC CHECK SHEET: HD325-8 904
Pm CLINIC CHECK SHEET: HD405-8 911
40 TROUBLESHOOTING 919
CONTENTS 920
PRECAUTIONS BEFORE WORK 935
ABBREVIATIONS 936
RELATED INFORMATION ON TROUBLESHOOTING 941
GENERAL TROUBLESHOOTING POINTS 941
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 942
SEQUENCE OF EVENTS IN TROUBLESHOOTING 954
CHECKS BEFORE TROUBLESHOOTING 956
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 959
WALK-AROUND CHECK 959
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 961
CHECK FUEL LEVEL AND TYPE 961
CHECK IMPURE INGREDIENT IN FUEL 961
CHECK DEF LEVEL AND TYPE 961
CHECK FUEL PREFILTER 962
CHECK MAIN FILTER 964
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 966
CHECK COOLANT LEVEL (RESERVOIR TANK) 967
CHECK CLOGGING OF AIR CLEANER 968
CHECK OF AIR CLEANER 969
OUTER ELEMENT – CLEAN 969
REPLACE ELEMENT 971
CHECK HYDRAULIC OIL LEVEL 973
CHECK HYDRAULIC OIL STRAINER 973
CHECK HYDRAULIC FILTER 974
CHECK OIL LEVEL IN TRANSMISSION CASE 974
CHECK OIL LEVEL IN DIFFERENTIAL CASE 975
CHECK OIL LEVEL IN FINAL DRIVE CASE 975
BLEED AIR FROM FUEL SYSTEM 976
BLEED AIR FROM HYDRAULIC SYSTEM 976
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 976
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 982
PROCEDURE FOR TESTING AND TROUBLESHOOTING 992
SYMPTOM AND TROUBLESHOOTING NUMBERS 994
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 999
CONNECTORS LIST AND LAYOUT1002
CONNECTOR LIST1002
CONNECTOR LIST (MACHINE WITH DROWSINESS DETECTION SYSTEM)1015
CONNECTOR CONTACT IDENTIFICATION1029
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1069
FUSE LOCATION TABLE (For machines equipped with KOMTRAX terminal)1075
FUSE LOCATION TABLE (For machines equipped with gateway function controller)1082
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1088
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR1091
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT1093
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135])1099
FAILURE CODES TABLE1101
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1128
FAILURE CODE [1500L0]1128
FAILURE CODE [15B0NX]1129
FAILURE CODE [15F0KM]1131
FAILURE CODE [15F0MB]1132
FAILURE CODE [15F7KM]1133
FAILURE CODE [15G0MW]1134
FAILURE CODE [15G7KM]1135
FAILURE CODE [15H0MW]1136
FAILURE CODE [15J0MW]1137
FAILURE CODE [15K0MW]1138
FAILURE CODE [15L0MW]1140
FAILURE CODE [15M0MW]1142
FAILURE CODE [15N0MW]1144
FAILURE CODE [15SBL1]1145
FAILURE CODE [15SBMA]1148
FAILURE CODE [15SCL1]1149
FAILURE CODE [15SCMA]1152
FAILURE CODE [15SDL1]1153
FAILURE CODE [15SDMA]1156
FAILURE CODE [15SEL1]1157
FAILURE CODE [15SEMA]1160
FAILURE CODE [15SFL1]1161
FAILURE CODE [15SFMA]1164
FAILURE CODE [15SGL1]1165
FAILURE CODE [15SGMA]1168
FAILURE CODE [15SHL1]1169
FAILURE CODE [15SHMA]1172
FAILURE CODE [15SJMA]1173
FAILURE CODE [2C4MNX]1174
FAILURE CODE [2F00KM]1175
FAILURE CODE [2G42ZG]1178
FAILURE CODE [2G43ZG]1179
FAILURE CODE [6014NX]1180
FAILURE CODE [879AKA]1181
FAILURE CODE [879AKB]1182
FAILURE CODE [879BKA]1183
FAILURE CODE [879BKB]1184
FAILURE CODE [879CKA]1185
FAILURE CODE [879CKB]1186
FAILURE CODE [879EMC]1187
FAILURE CODE [879FMC]1188
FAILURE CODE [879GKX]1189
FAILURE CODE [989D00]1190
FAILURE CODE [989L00]1191
FAILURE CODE [989M00]1192
FAILURE CODE [989N00]1193
FAILURE CODE [989X00]1194
FAILURE CODE [98A000]1195
FAILURE CODE [98A100]1196
FAILURE CODE [98A200]1197
FAILURE CODE [98A300]1198
FAILURE CODE [98A400]1199
FAILURE CODE [98A500]1200
FAILURE CODE [98A600]1201
FAILURE CODE [A1U0N3]1202
FAILURE CODE [A1U0N4]1203
FAILURE CODE [AA10NX]1204
FAILURE CODE [AB00KE]1206
FAILURE CODE [AB00KY]1208
FAILURE CODE [AQ10N3]1209
FAILURE CODE [AS00N3]1210
FAILURE CODE [AS00R2]1211
FAILURE CODE [AS00R3]1212
FAILURE CODE [AS00R4]1213
FAILURE CODE [AS00R5]1214
FAILURE CODE [AS00R6]1215
FAILURE CODE [AS00ZK]1216
FAILURE CODE [AS10KM]1217
FAILURE CODE [AS10NR]1218
FAILURE CODE [AS10NT]1219
FAILURE CODE [B@BAZG]1220
FAILURE CODE [B@BAZK]1221
FAILURE CODE [B@BCNS]1222
FAILURE CODE [B@BCQA]1223
FAILURE CODE [B@BCZK]1225
FAILURE CODE [B@C7NS]1227
FAILURE CODE [B@CENS]1229
FAILURE CODE [B@JANS]1230
FAILURE CODE [CA115]1231
FAILURE CODE [CA122]1232
FAILURE CODE [CA123]1234
FAILURE CODE [CA131]1236
FAILURE CODE [CA132]1238
FAILURE CODE [CA135]1240
FAILURE CODE [CA141]1242
FAILURE CODE [CA144]1244
FAILURE CODE [CA145]1246
FAILURE CODE [CA153]1248
FAILURE CODE [CA154]1250
FAILURE CODE [CA187]1252
FAILURE CODE [CA221]1254
FAILURE CODE [CA222]1256
FAILURE CODE [CA227]1258
FAILURE CODE [CA234]1259
FAILURE CODE [CA238]1260
FAILURE CODE [CA239]1262
FAILURE CODE [CA249]1264
FAILURE CODE [CA256]1266
FAILURE CODE [CA271]1268
FAILURE CODE [CA272]1270
FAILURE CODE [CA273]1271
FAILURE CODE [CA274]1273
FAILURE CODE [CA322]1274
FAILURE CODE [CA323]1276
FAILURE CODE [CA324]1278
FAILURE CODE [CA325]1280
FAILURE CODE [CA331]1282
FAILURE CODE [CA332]1284
FAILURE CODE [CA343]1286
FAILURE CODE [CA351]1287
FAILURE CODE [CA352]1288
FAILURE CODE [CA356]1290
FAILURE CODE [CA357]1292
FAILURE CODE [CA386]1294
FAILURE CODE [CA431]1295
FAILURE CODE [CA432]1298
FAILURE CODE [CA441]1301
FAILURE CODE [CA442]1304
FAILURE CODE [CA449]1305
FAILURE CODE [CA451]1306
FAILURE CODE [CA452]1308
FAILURE CODE [CA515]1310
FAILURE CODE [CA516]1312
FAILURE CODE [CA553]1314
FAILURE CODE [CA555]1315
FAILURE CODE [CA556]1316
FAILURE CODE [CA559]1317
FAILURE CODE [CA595]1321
FAILURE CODE [CA687]1322
FAILURE CODE [CA689]1324
FAILURE CODE [CA691]1326
FAILURE CODE [CA692]1328
FAILURE CODE [CA697]1330
FAILURE CODE [CA698]1331
FAILURE CODE [CA731]1332
FAILURE CODE [CA778]1333
FAILURE CODE [CA1117]1336
FAILURE CODE [CA1664]1338
FAILURE CODE [CA1669]1340
FAILURE CODE [CA1673]1341
FAILURE CODE [CA1677]1342
FAILURE CODE [CA1678]1343
FAILURE CODE [CA1682]1344
FAILURE CODE [CA1683]1348
FAILURE CODE [CA1684]1350
FAILURE CODE [CA1686]1352
FAILURE CODE [CA1691]1353
FAILURE CODE [CA1694]1355
FAILURE CODE [CA1695]1357
FAILURE CODE [CA1696]1358
FAILURE CODE [CA1712]1360
FAILURE CODE [CA1713]1362
FAILURE CODE [CA1714]1364
FAILURE CODE [CA1715]1365
FAILURE CODE [CA1776]1366
FAILURE CODE [CA1777]1369
FAILURE CODE [CA1843]1372
FAILURE CODE [CA1844]1374
FAILURE CODE [CA1879]1376
FAILURE CODE [CA1881]1378
FAILURE CODE [CA1883]1380
FAILURE CODE [CA1885]1383
FAILURE CODE [CA1887]1385
FAILURE CODE [CA1921]1387
FAILURE CODE [CA1922]1389
FAILURE CODE [CA1923]1392
FAILURE CODE [CA1924]1394
FAILURE CODE [CA1925]1396
FAILURE CODE [CA1927]1398
FAILURE CODE [CA1928]1400
FAILURE CODE [CA1942]1402
FAILURE CODE [CA1963]1403
FAILURE CODE [CA1977]1407
FAILURE CODE [CA1993]1409
FAILURE CODE [CA2185]1411
FAILURE CODE [CA2186]1413
FAILURE CODE [CA2249]1415
FAILURE CODE [CA2265]1416
FAILURE CODE [CA2266]1418
FAILURE CODE [CA2271]1420
FAILURE CODE [CA2272]1422
FAILURE CODE [CA2349]1424
FAILURE CODE [CA2353]1426
FAILURE CODE [CA2357]1428
FAILURE CODE [CA2381]1429
FAILURE CODE [CA2382]1431
FAILURE CODE [CA2383]1433
FAILURE CODE [CA2386]1435
FAILURE CODE [CA2387]1437
FAILURE CODE [CA2555]1438
FAILURE CODE [CA2556]1440
FAILURE CODE [CA2637]1442
FAILURE CODE [CA2639]1444
FAILURE CODE [CA2732]1446
FAILURE CODE [CA2733]1448
FAILURE CODE [CA2741]1450
FAILURE CODE [CA2765]1451
FAILURE CODE [CA2771]1452
FAILURE CODE [CA2777]1457
FAILURE CODE [CA2878]1458
FAILURE CODE [CA2881]1461
FAILURE CODE [CA2976]1465
FAILURE CODE [CA3133]1467
FAILURE CODE [CA3134]1469
FAILURE CODE [CA3135]1471
FAILURE CODE [CA3142]1474
FAILURE CODE [CA3143]1475
FAILURE CODE [CA3144]1476
FAILURE CODE [CA3146]1478
FAILURE CODE [CA3147]1479
FAILURE CODE [CA3148]1480
FAILURE CODE [CA3151]1482
FAILURE CODE [CA3165]1487
FAILURE CODE [CA3167]1489
FAILURE CODE [CA3229]1492
FAILURE CODE [CA3231]1494
FAILURE CODE [CA3232]1496
FAILURE CODE [CA3235]1500
FAILURE CODE [CA3239]1502
FAILURE CODE [CA3241]1505
FAILURE CODE [CA3242]1508
FAILURE CODE [CA3251]1510
FAILURE CODE [CA3253]1512
FAILURE CODE [CA3254]1515
FAILURE CODE [CA3255]1517
FAILURE CODE [CA3256]1519
FAILURE CODE [CA3311]1521
FAILURE CODE [CA3312]1523
FAILURE CODE [CA3313]1525
FAILURE CODE [CA3314]1526
FAILURE CODE [CA3315]1527
FAILURE CODE [CA3316]1530
FAILURE CODE [CA3317]1531
FAILURE CODE [CA3318]1532
FAILURE CODE [CA3319]1535
FAILURE CODE [CA3321]1536
FAILURE CODE [CA3322]1537
FAILURE CODE [CA3419]1540
FAILURE CODE [CA3421]1542
FAILURE CODE [CA3497]1544
FAILURE CODE [CA3498]1545
FAILURE CODE [CA3543]1546
FAILURE CODE [CA3545]1551
FAILURE CODE [CA3547]1553
FAILURE CODE [CA3558]1554
FAILURE CODE [CA3559]1556
FAILURE CODE [CA3562]1558
FAILURE CODE [CA3563]1560
FAILURE CODE [CA3567]1563
FAILURE CODE [CA3568]1565
FAILURE CODE [CA3571]1569
FAILURE CODE [CA3572]1571
FAILURE CODE [CA3574]1573
FAILURE CODE [CA3575]1575
FAILURE CODE [CA3577]1577
FAILURE CODE [CA3578]1579
FAILURE CODE [CA3582]1581
FAILURE CODE [CA3583]1587
FAILURE CODE [CA3596]1589
FAILURE CODE [CA3649]1593
FAILURE CODE [CA3681]1595
FAILURE CODE [CA3682]1599
FAILURE CODE [CA3713]1603
FAILURE CODE [CA3717]1606
FAILURE CODE [CA3718]1607
FAILURE CODE [CA3725]1608
FAILURE CODE [CA3748]1611
FAILURE CODE [CA3751]1613
FAILURE CODE [CA3755]1614
FAILURE CODE [CA3866]1616
FAILURE CODE [CA3867]1619
FAILURE CODE [CA3868]1622
FAILURE CODE [CA3899]1626
FAILURE CODE [CA3911]1628
FAILURE CODE [CA3912]1632
FAILURE CODE [CA3932]1634
FAILURE CODE [CA3933]1636
FAILURE CODE [CA3934]1638
FAILURE CODE [CA3935]1641
FAILURE CODE [CA3936]1643
FAILURE CODE [CA4151]1645
FAILURE CODE [CA4152]1649
FAILURE CODE [CA4155]1653
FAILURE CODE [CA4156]1655
FAILURE CODE [CA4157]1657
FAILURE CODE [CA4158]1659
FAILURE CODE [CA4159]1661
FAILURE CODE [CA4161]1662
FAILURE CODE [CA4162]1664
FAILURE CODE [CA4163]1666
FAILURE CODE [CA4164]1668
FAILURE CODE [CA4165]1670
FAILURE CODE [CA4166]1672
FAILURE CODE [CA4168]1673
FAILURE CODE [CA4169]1678
FAILURE CODE [CA4171]1681
FAILURE CODE [CA4249]1684
FAILURE CODE [CA4251]1687
FAILURE CODE [CA4259]1690
FAILURE CODE [CA4261]1693
FAILURE CODE [CA4277]1695
FAILURE CODE [CA4281]1697
FAILURE CODE [CA4459]1700
FAILURE CODE [CA4461]1702
FAILURE CODE [CA4658]1705
FAILURE CODE [CA4731]1708
FAILURE CODE [CA4732]1709
FAILURE CODE [CA4739]1710
FAILURE CODE [CA4768]1711
FAILURE CODE [CA4769]1713
FAILURE CODE [CA4842]1715
FAILURE CODE [CA4952] (For machines equipped with KOMTRAX terminal)1718
FAILURE CODE [CA4952] (For machines equipped with gateway function controller)1720
FAILURE CODE [CA5115]1722
FAILURE CODE [CA5179]1725
FAILURE CODE [CA5181]1727
FAILURE CODE [CA5383]1729
FAILURE CODE [D018KB]1730
FAILURE CODE [D018KY]1732
FAILURE CODE [D019KB]1734
FAILURE CODE [D019KY]1736
FAILURE CODE [D150KB]1738
FAILURE CODE [D150KZ]1739
FAILURE CODE [D164KY]1740
FAILURE CODE [D19HKZ]1741
FAILURE CODE [D19JKZ]1743
FAILURE CODE [D19QKZ]1744
FAILURE CODE [D1EHKA]1746
FAILURE CODE [D1EHKB]1747
FAILURE CODE [D1EHKY]1748
FAILURE CODE [D1EMKA]1749
FAILURE CODE [D1EMKB]1750
FAILURE CODE [D1EMKY]1751
FAILURE CODE [D1FBKB]1752
FAILURE CODE [D5WNKZ]1753
FAILURE CODE [D5ZHL6]1755
FAILURE CODE [D5ZKKZ]1757
FAILURE CODE [D811MC] (For machines equipped with KOMTRAX terminal)1759
FAILURE CODE [D811MC] (For machines equipped with gateway function controller)1760
FAILURE CODE [D862KA] (For machines equipped with KOMTRAX terminal)1761
FAILURE CODE [D862KA] (For machines equipped with gateway function controller)1762
FAILURE CODE [D8ALKA] (For machines equipped with KOMTRAX terminal)1763
FAILURE CODE [D8ALKA] (For machines equipped with gateway function controller)1765
FAILURE CODE [D8ALKB] (For machines equipped with KOMTRAX terminal)1767
FAILURE CODE [D8ALKB] (For machines equipped with gateway function controller)1769
FAILURE CODE [D8AQK4] (For machines equipped with KOMTRAX terminal)1771
FAILURE CODE [D8AQK4] (For machines equipped with gateway function controller)1772
FAILURE CODE [D8AQKR] (For machines equipped with KOMTRAX terminal)1773
FAILURE CODE [D8AQKR] (For machines equipped with gateway function controller)1774
FAILURE CODE [D8G1KT]1775
FAILURE CODE [D8G6KT]1776
FAILURE CODE [DAF0KT]1777
FAILURE CODE [DAF0MB]1778
FAILURE CODE [DAF0MC]1779
FAILURE CODE [DAF3KK]1780
FAILURE CODE [DAF8KB]1782
FAILURE CODE [DAFDKB]1783
FAILURE CODE [DAFGMC] (For machines equipped with KOMTRAX terminal)1785
FAILURE CODE [DAFGMC] (For machines equipped with gateway function controller)1786
FAILURE CODE [DAFLKA] (For machines equipped with KOMTRAX terminal)1787
FAILURE CODE [DAFLKA] (For machines equipped with gateway function controller)1789
FAILURE CODE [DAFLKB] (For machines equipped with KOMTRAX terminal)1791
FAILURE CODE [DAFLKB] (For machines equipped with gateway function controller)1793
FAILURE CODE [DAFQKR] (For machines equipped with KOMTRAX terminal)1795
FAILURE CODE [DAFQKR] (For machines equipped with gateway function controller)1796
FAILURE CODE [DAQ0KK]1797
FAILURE CODE [DAQ0KT]1800
FAILURE CODE [DAQ0MC]1801
FAILURE CODE [DAQ1KA]1802
FAILURE CODE [DAQ2KK]1805
FAILURE CODE [DAQ9KQ]1808
FAILURE CODE [DAQLKA] (For machines equipped with KOMTRAX terminal)1809
FAILURE CODE [DAQLKA] (For machines equipped with gateway function controller)1811
FAILURE CODE [DAQLKB] (For machines equipped with KOMTRAX terminal)1813
FAILURE CODE [DAQLKB] (For machines equipped with gateway function controller)1815
FAILURE CODE [DAQQKR]1817
FAILURE CODE [DAQRKR]1818
FAILURE CODE [DAQRMA]1819
FAILURE CODE [DAQV00]1820
FAILURE CODE [DAQW00]1821
FAILURE CODE [DAZ9KQ]1822
FAILURE CODE [DAZQKR]1823
FAILURE CODE [DB10KT]1825
FAILURE CODE [DB10MC]1826
FAILURE CODE [DB11KA]1827
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch)1830
FAILURE CODE [DB12KK]1833
FAILURE CODE [DB13KK]1836
FAILURE CODE [DB19KQ]1839
FAILURE CODE [DB1LKA] (For machines equipped with KOMTRAX terminal)1840
FAILURE CODE [DB1LKA] (For machines equipped with gateway function controller)1842
FAILURE CODE [DB1LKB] (For machines equipped with KOMTRAX terminal)1844
FAILURE CODE [DB1LKB] (For machines equipped with gateway function controller)1846
FAILURE CODE [DB1QKR]1848
FAILURE CODE [DB1QMA]1849
FAILURE CODE [DB1RKR]1850
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal)1851
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal and Drowsiness Detection system)1857
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller)1863
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller and Drowsiness Detection system)1869
FAILURE CODE [DB2RKR]1875
FAILURE CODE [DB2RKR] (For machines equipped with Drowsiness Detection system)1880
FAILURE CODE [DBS0KK]1887
FAILURE CODE [DBS6KP]1890
FAILURE CODE [DBSQKQ]1892
FAILURE CODE [DBSQKR]1893
FAILURE CODE [DBSRKR]1894
FAILURE CODE [DCR0MC]1895
FAILURE CODE [DCR2KK]1896
FAILURE CODE [DCR8L4]1900
FAILURE CODE [DCR9KQ]1904
FAILURE CODE [DCRLKA]1905
FAILURE CODE [DCRLKB]1908
FAILURE CODE [DCRQKR]1910
FAILURE CODE [DCRRKR]1921
FAILURE CODE [DDAAL6]1930
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch)1932
FAILURE CODE [DDD7KX]1934
FAILURE CODE [DDTHKA]1936
FAILURE CODE [DDTJKA]1938
FAILURE CODE [DDTKKA]1940
FAILURE CODE [DDTLKA]1942
FAILURE CODE [DDTMKA]1944
FAILURE CODE [DDTNKA]1946
FAILURE CODE [DDTPKA]1948
FAILURE CODE [DF10KA]1950
FAILURE CODE [DF10KB]1954
FAILURE CODE [DGF1KX]1959
FAILURE CODE [DGR2KB]1961
FAILURE CODE [DGR6KB]1963
FAILURE CODE [DGR6L8]1964
FAILURE CODE [DGT1KX]1966
FAILURE CODE [DHA4KA]1968
FAILURE CODE [DHAAMA]1970
FAILURE CODE [DHACMA]1971
FAILURE CODE [DHP4KY]1972
FAILURE CODE [DHP4KZ]1974
FAILURE CODE [DHP5KY]1976
FAILURE CODE [DHP5KZ]1978
FAILURE CODE [DHP6KA]1980
FAILURE CODE [DHP6KX]1982
FAILURE CODE [DHP6KY]1984
FAILURE CODE [DHP6KZ]1986
FAILURE CODE [DHP7KA]1988
FAILURE CODE [DHP7KX]1990
FAILURE CODE [DHP7KY]1992
FAILURE CODE [DHP7KZ]1994
FAILURE CODE [DHQ4KX]1996
FAILURE CODE [DHT5KX]1998
FAILURE CODE [DHT5L6]2000
FAILURE CODE [DHT8KX]2002
FAILURE CODE [DHT8ZG]2004
FAILURE CODE [DHU2KX]2005
FAILURE CODE [DHU3KX]2007
FAILURE CODE [DHUCKX]2009
FAILURE CODE [DHUDKX]2012
FAILURE CODE [DHUHKX]2014
FAILURE CODE [DHULKX]2016
FAILURE CODE [DHUMKX]2018
FAILURE CODE [DHUPKX]2020
FAILURE CODE [DJF1KA]2022
FAILURE CODE [DK30KX]2024
FAILURE CODE [DK51L5]2026
FAILURE CODE [DK52KX]2029
FAILURE CODE [DK53L8]2031
FAILURE CODE [DK54KX]2033
FAILURE CODE [DK60KX]2035
FAILURE CODE [DKD0L6]2037
FAILURE CODE [DKH0KX]2039
FAILURE CODE [DKH1KX]2042
FAILURE CODE [DLF1KA]2044
FAILURE CODE [DLF1LC]2045
FAILURE CODE [DLF2KA]2047
FAILURE CODE [DLF2LC]2048
FAILURE CODE [DLF8KA]2050
FAILURE CODE [DLF8LC]2052
FAILURE CODE [DLF9KA]2054
FAILURE CODE [DLF9LC]2056
FAILURE CODE [DLM3KA]2058
FAILURE CODE [DLM3LC]2059
FAILURE CODE [DLM3MB]2061
FAILURE CODE [DLT3KA]2062
FAILURE CODE [DLT3LC]2063
FAILURE CODE [DPQ1KR]2065
FAILURE CODE [DPQ2KR]2068
FAILURE CODE [DPQ3KR]2071
FAILURE CODE [DR81KR]2075
FAILURE CODE [DR81MA]2083
FAILURE CODE [DSJ0KR]2084
FAILURE CODE [DV00KB]2085
FAILURE CODE [DV03KB]2087
FAILURE CODE [DV03KY]2089
FAILURE CODE [DW2AKA]2091
FAILURE CODE [DW2AKB]2092
FAILURE CODE [DW2AKY]2094
FAILURE CODE [DW2AL1]2095
FAILURE CODE [DW2ALH]2096
FAILURE CODE [DW35KZ]2097
FAILURE CODE [DW36KZ]2099
FAILURE CODE [DW4BK4]2101
FAILURE CODE [DW4BMA]2104
FAILURE CODE [DW72KZ]2107
FAILURE CODE [DW73KA]2109
FAILURE CODE [DW73KB]2111
FAILURE CODE [DW73KY]2113
FAILURE CODE [DW78KZ]2114
FAILURE CODE [DW7BKB]2116
FAILURE CODE [DW7BKY]2117
FAILURE CODE [DW7BKZ]2118
FAILURE CODE [DW7MKB]2119
FAILURE CODE [DW7MKY]2121
FAILURE CODE [DW7MKZ]2122
FAILURE CODE [DW7NKZ]2124
FAILURE CODE [DWNMKZ]2126
FAILURE CODE [DX11K4]2128
FAILURE CODE [DX11KA]2130
FAILURE CODE [DX11KB]2132
FAILURE CODE [DX11KY]2134
FAILURE CODE [DX11MA]2135
FAILURE CODE [DX13KA]2137
FAILURE CODE [DX13KB]2139
FAILURE CODE [DX13KY]2141
FAILURE CODE [DX16KA]2142
FAILURE CODE [DX16KB]2143
FAILURE CODE [DX16KY]2145
FAILURE CODE [DX37K4]2146
FAILURE CODE [DX37KA]2148
FAILURE CODE [DX37KB]2150
FAILURE CODE [DX37KY]2152
FAILURE CODE [DX37MA]2153
FAILURE CODE [DX38K4]2155
FAILURE CODE [DX38KA]2157
FAILURE CODE [DX38KB]2159
FAILURE CODE [DX38KY]2161
FAILURE CODE [DX38MA]2162
FAILURE CODE [DXH1KA]2164
FAILURE CODE [DXH1KB]2166
FAILURE CODE [DXH1KY]2168
FAILURE CODE [DXH2KA]2170
FAILURE CODE [DXH2KB]2172
FAILURE CODE [DXH2KY]2174
FAILURE CODE [DXH3KA]2177
FAILURE CODE [DXH3KB]2179
FAILURE CODE [DXH3KY]2181
FAILURE CODE [DXH4KA]2184
FAILURE CODE [DXH4KB]2186
FAILURE CODE [DXH4KY]2188
FAILURE CODE [DXH5KA]2191
FAILURE CODE [DXH5KB]2193
FAILURE CODE [DXH5KY]2195
FAILURE CODE [DXH6KA]2198
FAILURE CODE [DXH6KB]2200
FAILURE CODE [DXH6KY]2202
FAILURE CODE [DXH7KA]2205
FAILURE CODE [DXH7KB]2207
FAILURE CODE [DXH7KY]2209
FAILURE CODE [DXHHKA]2211
FAILURE CODE [DXHHKB]2213
FAILURE CODE [DXHHKY]2215
FAILURE CODE [DY30MA]2217
FAILURE CODE [DY30MC]2219
FAILURE CODE [DY30ME]2222
FAILURE CODE [F313KA]2224
FAILURE CODE [F313KB]2226
FAILURE CODE [F318KB]2227
FAILURE CODE [F318KY]2228
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2229
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2229
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2236
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2239
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2241
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2242
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch)2245
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2248
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2250
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2252
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2254
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2257
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2260
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2263
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2265
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2267
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2269
E-17 DEF LEVEL IS NOT DISPLAYED PROPERLY2270
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2273
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2277
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2281
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2284
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED2286
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET2289
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2291
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2293
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION2295
E-27 ALARM BUZZER DOES NOT SOUND2296
E-28 ALARM BUZZER DOES NOT STOP SOUNDING2298
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY2300
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY2302
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY2304
E-32 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY2306
E-33 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY2309
E-34 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2313
E-35 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP2316
E-36 TAIL LAMP DOES NOT LIGHT UP2319
E-37 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP2322
E-38 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP2324
E-39 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP2326
E-40 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED2328
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with KOMTRAX terminal)2330
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with gateway function controller)2332
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2334
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2334
FAILURE MODE AND CAUSE TABLE2335
H-1 MACHINE DOES NOT START2343
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)2347
H-3 LOCKUP IS NOT RELEASED2348
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING2349
H-5 GEAR IS NOT SHIFTED UP2351
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS2354
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE2355
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED2356
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2358
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2361
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW2362
H-12 STEERING WHEEL IS HEAVY TO OPERATE2363
H-13 STEERING WHEEL CANNOT BE OPERATED2364
H-14 STEERING WHEEL WAGGLES2365
H-15 FRONT BRAKE DOES NOT WORK ENOUGH2366
H-16 REAR BRAKE DOES NOT WORK ENOUGH2367
H-17 DUMP BODY RISING SPEED IS LOW2368
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE2370
H-19 DUMP BODY DOES NOT MOVE2371
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)2373
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN2374
TROUBLESHOOTING OF ENGINE (S-MODE)2375
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2375
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2376
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2377
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2378
S-4 ENGINE STARTABILITY IS POOR2379
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2381
S-6 ENGINE STOPS DURING OPERATION2383
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2385
S-8 ENGINE LACKS POWER2386
S-9 KDPF GETS CLOGGED IN A SHORT TIME2388
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2390
S-11 OIL BECOMES CONTAMINATED QUICKLY2391
S-12 FUEL CONSUMPTION IS EXCESSIVE2392
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2393
S-14 OIL PRESSURE DROPS2394
S-15 FUEL MIXES INTO ENGINE OIL2395
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2396
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2397
S-18 UNUSUAL NOISE IS HEARD2398
S-19 VIBRATION IS EXCESSIVE2399
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2400
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2401
S-22 ACTIVE REGENERATION TAKES TIME2403
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2404
S-24 DEF CONSUMPTION IS EXCESSIVE2405
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2407
S-26 FOREIGN MATERIALS ENTER DEF (DEF INCREASES)2408
50 DISASSEMBLY AND ASSEMBLY2409
CONTENTS2410
PRECAUTIONS BEFORE WORK2416
ABBREVIATIONS2417
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION2422
HOW TO READ THIS MANUAL2422
COATING MATERIALS LIST2424
SPECIAL TOOL LIST2427
DIAGRAMS OF SPECIAL TOOLS2443
ENGINE AND COOLING SYSTEM2448
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2448
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY2448
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY2449
REMOVE AND INSTALL INJECTOR ASSEMBLY2453
PROCEDURE TO REMOVE INJECTOR ASSEMBLY2453
PROCEDURE TO INSTALL INJECTOR ASSEMBLY2467
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2485
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY2485
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY2487
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2489
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY2490
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY2505
REMOVE AND INSTALL EGR VALVE ASSEMBLY2528
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY2528
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY2531
REMOVE AND INSTALL EGR COOLER ASSEMBLY2534
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY2534
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY2540
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2546
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY2546
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY2547
REMOVE AND INSTALL ALTERNATOR BELT2548
PROCEDURE TO REMOVE ALTERNATOR BELT2548
PROCEDURE TO INSTALL ALTERNATOR BELT2549
REMOVE AND INSTALL RADIATOR2552
PROCEDURE TO REMOVE RADIATOR2553
PROCEDURE TO INSTALL RADIATOR2557
REMOVE AND INSTALL COOLER ASSEMBLY2561
PROCEDURE TO REMOVE COOLER ASSEMBLY2561
PROCEDURE TO INSTALL COOLER ASSEMBLY2572
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2584
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2584
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2588
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2593
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY2593
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY2594
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY2596
PROCEDURE TO REMOVE GRILLE GUARD ASSEMBLY2596
PROCEDURE TO INSTALL GRILLE GUARD ASSEMBLY2600
REMOVE AND INSTALL ENGINE ASSEMBLY2604
PROCEDURE TO REMOVE ENGINE ASSEMBLY2605
PROCEDURE TO INSTALL ENGINE ASSEMBLY2614
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2629
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL2629
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL2630
REMOVE AND INSTALL ENGINE REAR OIL SEAL2632
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL2632
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL2634
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY2640
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY2640
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY2641
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY2643
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY2643
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY2644
REMOVE AND INSTALL DEF TANK ASSEMBLY2646
PROCEDURE TO REMOVE DEF TANK ASSEMBLY2647
PROCEDURE TO INSTALL DEF TANK ASSEMBLY2654
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY2659
PROCEDURE TO REMOVE DEF TANK SENSOR FLANGE ASSEMBLY2660
PROCEDURE TO INSTALL DEF TANK SENSOR FLANGE ASSEMBLY2667
REMOVE AND INSTALL DEF TANK SENSOR2672
PROCEDURE TO REMOVE DEF TANK SENSOR2672
PROCEDURE TO INSTALL DEF TANK SENSOR2673
REMOVE AND INSTALL DEF TANK STRAINER2675
PROCEDURE TO REMOVE DEF TANK STRAINER2675
PROCEDURE TO INSTALL DEF TANK STRAINER2675
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2676
PROCEDURE TO REMOVE KDPF, SCR ASSEMBLY2677
PROCEDURE TO INSTALL KDPF, SCR ASSEMBLY2687
REMOVE AND INSTALL KDPF ASSEMBLY2697
PROCEDURE TO REMOVE KDPF ASSEMBLY2698
PROCEDURE TO INSTALL KDPF ASSEMBLY2702
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2707
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY2708
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY2713
REMOVE AND INSTALL SCR ASSEMBLY2718
PROCEDURE TO REMOVE SCR ASSEMBLY2718
PROCEDURE TO INSTALL SCR ASSEMBLY2721
REMOVE AND INSTALL KCCV ASSEMBLY2726
PROCEDURE TO REMOVE KCCV ASSEMBLY2726
PROCEDURE TO INSTALL KCCV ASSEMBLY2730
REMOVE AND INSTALL DEF MIXING TUBE2734
PROCEDURE TO REMOVE DEF MIXING TUBE2735
PROCEDURE TO INSTALL DEF MIXING TUBE2743
REMOVE AND INSTALL DEF INJECTOR2754
PROCEDURE TO REMOVE DEF INJECTOR2755
PROCEDURE TO INSTALL DEF INJECTOR2761
REMOVE AND INSTALL DEF PUMP2766
PROCEDURE TO REMOVE DEF PUMP2766
PROCEDURE TO INSTALL DEF PUMP2771
REMOVE AND INSTALL DEF HOSE2775
PROCEDURE TO REMOVE DEF HOSE2776
PROCEDURE TO INSTALL DEF HOSE2787
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2798
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY2798
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY2800
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2803
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2803
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2804
POWER TRAIN2805
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2805
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2806
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2818
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2833
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2833
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2845
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY2859
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY2860
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY2866
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY2876
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY2877
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY2894
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY2915
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY2915
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY2917
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY2919
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY2920
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY2925
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD2936
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD2936
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD2936
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY2937
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY2937
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY2937
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY2939
PROCEDURE TO DISASSEMBLE FRONT BRAKE CALIPER ASSEMBLY2939
PROCEDURE TO ASSEMBLE FRONT BRAKE CALIPER ASSEMBLY2940
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2942
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY2942
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2943
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY2945
PROCEDURE TO REMOVE PARKING BRAKE PAD ASSEMBLY2945
PROCEDURE TO INSTALL PARKING BRAKE PAD ASSEMBLY2946
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY2948
PROCEDURE TO REMOVE PARKING BRAKE CALIPER ASSEMBLY2948
PROCEDURE TO INSTALL PARKING BRAKE CALIPER ASSEMBLY2948
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY2949
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2949
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2950
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY2952
PROCEDURE TO DISASSEMBLE FINAL DRIVE ASSEMBLY2952
PROCEDURE TO ASSEMBLE FINAL DRIVE ASSEMBLY2956
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY2961
PROCEDURE TO REMOVE SLACK ADJUSTER ASSEMBLY2961
PROCEDURE TO INSTALL SLACK ADJUSTER ASSEMBLY2962
STEERING SYSTEM2964
REMOVE AND INSTALL STEERING VALVE ASSEMBLY2964
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY2964
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY2967
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY2970
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY2970
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY2972
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY2975
PROCEDURE TO REMOVE SECONDARY STEERING MOTOR PUMP ASSEMBLY2975
PROCEDURE TO INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY2978
UNDERCARRIAGE AND FRAME2981
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY2981
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY2981
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY2982
REMOVE AND INSTALL REAR WHEEL ASSEMBLY2984
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY2984
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY2986
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2988
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY2988
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2989
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2992
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2992
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2994
REMOVE AND INSTALL KING PIN2996
PROCEDURE TO REMOVE KING PIN2996
PROCEDURE TO INSTALL KING PIN2997
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY2998
PROCEDURE TO DISASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY3000
PROCEDURE TO ASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY3000
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY3002
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY3002
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY3002
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)3003
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY3003
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY3005
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY3008
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY3008
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY3009
HYDRAULIC SYSTEM3013
REMOVE AND INSTALL HOIST VALVE ASSEMBLY3013
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY3013
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY3016
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY3020
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY3021
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY3024
WORK EQUIPMENT3031
REMOVE AND INSTALL DUMP BODY ASSEMBLY3031
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY3031
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY3032
CAB AND ITS ATTACHMENTS3035
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY3035
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY3035
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY3043
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY3050
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY3050
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY3052
REMOVE AND INSTALL SEAT BELT3055
PROCEDURE TO REMOVE SEAT BELT3055
PROCEDURE TO INSTALL SEAT BELT3056
ELECTRICAL SYSTEM3057
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3057
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY3057
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY3058
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY3061
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY3061
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY3062
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY3063
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY3063
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY3064
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3065
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY3065
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY3067
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY3070
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY3070
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY3071
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3072
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR3072
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3073
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3075
PROCEDURE TO REMOVE SCR TEMPERATURE SENSOR3075
PROCEDURE TO INSTALL SCR TEMPERATURE SENSOR3077
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY3079
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY3079
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY3080
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3081
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY3081
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3085
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS3089
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS3089
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS3097
REMOVE AND INSTALL COMMUNICATION TERMINAL3104
METHOD FOR REMOVING COMMUNICATION TERMINAL3104
METHOD FOR INSTALLING COMMUNICATION TERMINAL3112
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3119
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR3119
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR3120
REMOVE AND INSTALL DRIVER STATUS MONITOR3121
HOW TO REMOVE DRIVER STATUS MONITOR3121
HOW TO INSTALL DRIVER STATUS MONITOR3122
REMOVE AND INSTALL TRANSLATOR CONTROLLER3124
HOW TO REMOVE TRANSLATOR CONTROLLER3124
HOW TO INSTALL TRANSLATOR CONTROLLER3125
REMOVE AND INSTALL DROWSINESS DETECTION CAMERA3127
HOW TO REMOVE DROWSINESS DETECTION CAMERA3127
HOW TO INSTALL DROWSINESS DETECTION CAMERA3128
REMOVE AND INSTALL DROWSINESS ALARM BUZZER3130
HOW TO REMOVE DROWSINESS ALARM BUZZER3130
HOW TO INSTALL DROWSINESS ALARM BUZZER3131
REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS3133
HOW TO REMOVE DROWSINESS DETECTION WIRING HARNESS3133
HOW TO INSTALL DROWSINESS DETECTION WIRING HARNESS3145
60 MAINTENANCE STANDARD3157
CONTENTS3158
ABBREVIATIONS3159
ENGINE AND COOLING SYSTEM3164
MAINTENANCE STANDARD OF ENGINE MOUNT3164
MAINTENANCE STANDARD OF OUTPUT SHAFT3165
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP3167
MAINTENANCE STANDARD OF SERVO VALVE OF COOLING FAN AND HOIST PUMP3168
MAINTENANCE STANDARD OF COOLING FAN MOTOR3169
POWER TRAIN3171
MAINTENANCE STANDARD OF DRIVE SHAFT3171
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT3172
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO3173
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE3176
MAINTENANCE STANDARD OF TRANSMISSION3177
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE3182
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV3183
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV3184
MAINTENANCE STANDARD OF FRONT AXLE3185
MAINTENANCE STANDARD OF REAR AXLE3186
MAINTENANCE STANDARD OF DIFFERENTIAL3187
MAINTENANCE STANDARD OF FINAL DRIVE3188
STEERING SYSTEM3189
MAINTENANCE STANDARD OF STEERING COLUMN3189
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE3190
MAINTENANCE STANDARD OF DEMAND VALVE3193
MAINTENANCE STANDARD OF STEERING CYLINDER3195
BRAKE SYSTEM3196
MAINTENANCE STANDARD OF SLACK ADJUSTER3196
MAINTENANCE STANDARD OF FRONT BRAKE3197
MAINTENANCE STANDARD OF REAR BRAKE3198
MAINTENANCE STANDARD OF PARKING BRAKE3199
UNDERCARRIAGE AND FRAME3201
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER3201
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER3203
MAINTENANCE STANDARD OF REAR AXLE SUPPORT3205
HYDRAULIC SYSTEM3206
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP3206
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP3207
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP3209
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP3211
MAINTENANCE STANDARD OF HOIST VALVE3213
WORK EQUIPMENT3215
MAINTENANCE STANDARD OF HOIST CYLINDER3215
CAB AND ITS ATTACHMENTS3216
MAINTENANCE STANDARD OF CAB MOUNT3216
80 THE OTHER INFORMATION3217
CONTENTS3218
PRECAUTIONS BEFORE WORK3220
ABBREVIATIONS3221
AIR CONDITIONER SYSTEM3226
PRECAUTIONS FOR REFRIGERANT3226
AIR CONDITIONER COMPONENT3227
SPECIFICATIONS OF AIR CONDITIONER3229
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3230
OUTLINE OF REFRIGERATION CYCLE3231
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3233
AIR CONDITIONER UNIT3233
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3233
FUNCTION OF AIR CONDITIONER UNIT3234
COMPONENT PARTS OF AIR CONDITIONER UNIT3236
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3236
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3237
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3237
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3237
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3238
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3238
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3238
FUNCTION OF DUAL PRESSURE SWITCH3239
AIR CONDITIONER CONTROLLER3240
STRUCTURE OF AIR CONDITIONER CONTROLLER3240
COMPRESSOR3241
STRUCTURE OF COMPRESSOR3241
SPECIFICATIONS OF COMPRESSOR3241
FUNCTION OF COMPRESSOR3241
CONDENSER3242
STRUCTURE OF CONDENSER3242
SPECIFICATIONS OF CONDENSER3242
FUNCTION OF CONDENSER3242
SENSORS FOR AIR CONDITIONER SYSTEM3244
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3244
FUNCTION OF AMBIENT TEMPERATURE SENSOR3244
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3245
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3247
AIR CONDITIONER SYSTEM DIAGRAM3249
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3250
FUNCTION OF AIR CONDITIONER CONTROLLER3251
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3252
TESTING AIR LEAKAGE (DUCT)3255
METHOD FOR TESTING AIR LEAKAGE (DUCT)3255
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3258
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3260
TEST VENT (MODE) CHANGEOVER3262
METHOD FOR TESTING VENT (MODE) CHANGEOVER3262
TESTING FRESH/RECIRC AIR CHANGEOVER3263
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3263
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3264
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3264
TEST RELAYS3265
METHOD FOR TESTING RELAYS3265
AIR CONDITIONER TROUBLESHOOTING CHART 13266
AIR CONDITIONER TROUBLESHOOTING CHART 23267
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3270
FAILURE CODE [879AKA]3271
FAILURE CODE [879AKB]3272
FAILURE CODE [879BKA]3273
FAILURE CODE [879BKB]3274
FAILURE CODE [879CKA]3275
FAILURE CODE [879CKB]3276
FAILURE CODE [879EMC]3277
FAILURE CODE [879FMC]3278
FAILURE CODE [879GKX]3279
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3280
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3282
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3285
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3287
TROUBLESHOOTING USING GAUGE PRESSURE3289
CONNECTION OF SERVICE TOOL3292
METHOD FOR CONNECTING SERVICE TOOL3292
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3293
HANDLE COMPRESSOR OIL3295
METHOD FOR REPLACING DESICCANT3297
90 CIRCUIT DIAGRAMS3299
CONTENTS3300
ABBREVIATIONS3301
HYDRAULIC CIRCUIT DIAGRAM3306
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3306
HYDRAULIC CIRCUIT DIAGRAM3311
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM3313
ELECTRICAL CIRCUIT DIAGRAM3315
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3315
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/9)3319
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/9)3321
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/9)3323
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/9)3325
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/9)3327
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/9)3329
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/9)3331
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/9)3333
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (9/9)3335
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/10)3337
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/10)3339
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/10)3341
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/10)3343
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/10)3345
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/10)3347
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/10)3349
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/10)3351
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (9/10)3353
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (10/10)3355
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/8)3357
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/8)3359
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/8)3361
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/8)3363
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/8)3365
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/8)3367
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/8)3369
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/8)3371
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/8)3373
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/8)3375
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/8)3377
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/8)3379
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/8)3381
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/8)3383
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/8)3385
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/8)3387
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE3389
ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS))3391
INDEX3393
S.M 30/12/24
