Komatsu DUMP TRUCK HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 PDF
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Komatsu DUMP TRUCK HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 – PDF DOWNLOAD
SERIAL NUMBERS HD325-55001 and up
HD405-55001 and up
Description
Komatsu DUMP TRUCK HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 – PDF DOWNLOAD
FILE DETAILS:
Komatsu DUMP TRUCK HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 – PDF DOWNLOAD
Language : English
Pages :3402
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu DUMP TRUCK HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 – PDF DOWNLOAD
SERIAL NUMBERS HD325-55001 and up
HD405-55001 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 HD325-8E0 HD405-8E0 Shop Manual SEN06745-10 – PDF DOWNLOAD
SERIAL NUMBERS HD325-55001 and up
HD405-55001 and up
Cover 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATIONS 27
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
Composition of the shop manual 32
Symbols 33
Signal word 33
Unit 33
SAFETY NOTICE FOR OPERATION 34
Safety matters 34
General precautions 34
Precautions for preparatory work 35
Precautions during work 36
Precautions for slinging work and making signals 37
Precautions for using mobile crane 39
Precautions for using overhead traveling crane 39
Selecting wire ropes 39
Precautions for disconnecting air conditioner piping 40
Precautions for air conditioner piping 40
PRECAUTIONS TO PREVENT FIRE 42
Fire caused by fuel, oil, coolant or window washer fluid 42
Fire caused by accumulation or attachment of flammable material 42
Fire coming from electric wiring 42
Fire caused by piping 42
Fire around the machine due to highly heated exhaust gas 42
Explosion caused by lighting equipment 43
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 43
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 44
PRECAUTIONS FOR DEF 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 45
THE OTHER PRECAUTIONS 45
STORE DEF 46
Handling DEF in cold weather 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
Select an appropriate workplace 47
Disassembly and maintenance work in the field 47
Sealing of openings (prevention of flowing out of oil) 47
Preventing intrusion of foreign materials during refilling 47
Replacing hydraulic oil while its temperature is high 48
Flushing operation 48
Cleaning operation 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
Precautions for removal and disassembling work 49
Introduction of parts for the disassembly of the face seal type hoses and tubes 49
Introduction of parts for the disconnection of the taper seal type hoses and tubes 50
Introduction of parts for the disconnection of the split flange type hoses and tubes 50
Introduction of parts for the removal of O-ring boss type joint 51
Introduction of parts for the removal of taper pipe thread type joint 52
Precautions for installation and assembling work 52
Precautions at the time of completion of work 53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
Handling wiring harnesses and connectors 55
Main causes of failure in wiring harness 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
Select an appropriate workplace 57
Sealing the opening 57
How to clean parts when dirt is stuck 57
Precautions for replacing fuel filter cartridge 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
Select an appropriate workplace 58
Sealing the opening 58
PRACTICAL USE OF KOMTRAX 59
Merit of using KOMTRAX 59
How to make a full use of KOMTRAX 59
How to operate KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
Disconnecting connectors 64
Connecting connectors 65
Drying wiring harness 66
Handling controller 67
Precautions for troubleshooting electrical circuits 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
Method for disconnecting Deutsch connector 68
Method for connecting Deutsch connector 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 69
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME- 2) 69
Method for disconnecting slide lock type connector (FRAMATOME-24) 69
Method for connecting slide lock type connector (FRAMATOME-24) 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
Method for disconnecting connector with lock to pull 70
Method for connecting connector with lock to pull 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
Method for disconnecting connector with lock to push (BOSCH-3) 71
Method for connecting connector with lock to push (BOSCH-3) 71
Method for disconnecting connector with lock to push (AMP-3) 72
Method for connecting connector with lock to push (AMP-3) 72
Method for disconnecting connector with lock to push (SUMITOMO-3) 72
Method for connecting connector with lock to push (SUMITOMO-3) 72
Method for disconnecting connector with lock to push (SUMITOMO-4) 72
Method for connecting connector with lock to push (SUMITOMO-4) 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
Method for disconnecting connector with housing to rotate 73
Method for connecting connector with housing to rotate 73
HOW TO READ ELECTRICAL WIRE CODE 74
Type, symbol, and material 74
Dimensions 74
Color codes table 76
Types of circuits and color codes 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
Standard dimension and tolerance 78
Standard clearance and standard value 79
Standard interference 79
Repair limit and allowable value or allowable dimension 79
Allowable clearance 79
Allowable interference 79
STANDARD TIGHTENING TORQUE TABLE 80
Table of tightening torque for bolts and nuts 80
Table of tightening torque for O-ring boss piping joints 83
Table of tightening torque for O-ring boss plugs 83
Table of tightening torque for hose (taper seal type and face seal type) 84
Table of tightening torque for face seal joints 85
Tightening torque table for bolts and nuts on 102,107 and 114 series engines 85
Tightening torque table for 102, 107, and 114 series engines (joint bolts) 86
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe thread (NPT)) 86
CONVERSION TABLE 87
Method of using the conversion table 87
Examples of using the conversion table to convert a unit from mm to in 87
mm to in 87
mm to in 87
kg to lb 88
l to USGal 88
l to UKGal 88
kgm to lbft 89
kg/cm2 to lb/in2 89
Temperature 90
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATIONS 95
SPECIFICATIONS 100
SPECIFICATION DRAWING 100
SPECIFICATION DRAWING: HD325-8E0 100
SPECIFICATION DRAWING: HD405-8E0 102
SPECIFICATIONS 104
SPECIFICATIONS: HD325-8E0 104
SPECIFICATIONS: HD405-8E0 109
WEIGHT TABLE 114
WEIGHT TABLE: HD325-8E0 114
WEIGHT TABLE: HD405-8E0 115
FUEL, COOLANT, AND LUBRICATING OIL (EU SPECIFICATION) 116
USAGE OF FUEL, COOLANT, AND LUBRICATING OIL ACCORDING TO AMBIENT TEMPERATURE 116
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATIONS 125
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR STSTEM 130
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF DEF SYSTEM 134
INDUCEMENT STRATEGY 136
COMPONENT PARTS OF UREA SCR SYSTEM 145
DEF MIXING TUBE 145
SCR ASSEMBLY 146
DEF TANK 148
DEF PUMP 150
DEF INJECTOR 151
DEF HOSE 152
DEF TANK HEATING VALVE 153
BOOT-UP SYSTEM 154
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with KOMTRAX terminal) 154
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with KOMTRAX terminal) 156
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with gateway function controller) 158
LAYOUT DRAWING OF BOOT-UP SYSTEM (For machines equipped with emergency engine stop switch) (For machines equipped with gateway function controller) 160
SYSTEM OPERATING LAMP SYSTEM 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with KOMTRAX terminal) 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (For machines equipped with gateway function controller) 163
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (For machines equipped with gateway function controller) 163
BATTERY DISCONNECT SWITCH 164
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with KOMTRAX terminal) 164
FUNCTION OF BATTERY DISCONNECT SWITCH (For machines equipped with gateway function controller) 165
ENGINE SHUTDOWN SECONDARY SWITCH 166
LAYOUT DRAWING OF ENGINE SHUTDOWN SECONDARY SWITCH 166
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 166
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 167
ENGINE SYSTEM 168
LAYOUT DRAWING OF ENGINE SYSTEM 168
FUNCTION OF ENGINE SYSTEM 170
ENGINE CONTROL SYSTEM 171
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 171
ENGINE CONTROL SYSTEM DIAGRAM (For machines equipped with gateway function controller) 172
FUNCTION OF ENGINE CONTROL SYSTEM 173
OPERATION OF ENGINE CONTROL SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM 176
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 176
COMPONENT PARTS OF ENGINE SYSTEM 178
OUTPUT SHAFT 178
VGT 179
EGR SYSTEM 183
EGR VALVE 185
EGR COOLER 187
KCCV SYSTEM 188
KCCV VENTILATOR 190
KDPF 192
COOLING SYSTEM 196
LAYOUT DRAWING OF COOLING SYSTEM 196
SPECIFICATIONS OF COOLING SYSTEM 197
RADIATOR FAN CONTROL SYSTEM 198
RADIATOR FAN CONTROL SYSTEM DIAGRAM 198
FUNCTION OF RADIATOR FAN CONTROL SYSTEM 198
COMPONENT PARTS OF COOLING SYSTEM 200
COOLING FAN AND HOIST PUMP 200
COOLING FAN MOTOR 208
CONTROL SYSTEM 215
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with KOMTRAX terminal) 215
LAYOUT DRAWING OF CONTROL SYSTEM (For machines equipped with gateway function controller) 217
RETARDER AND HOIST CONTROL SYSTEM 219
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM 219
MACHINE MONITOR SYSTEM 221
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 221
MACHINE MONITOR SYSTEM DIAGRAM (For machines equipped with gateway function controller) 223
FUNCTION OF MACHINE MONITOR SYSTEM 224
REARVIEW MONITOR SYSTEM 225
REARVIEW MONITOR SYSTEM DIAGRAM 225
FUNCTION OF REARVIEW MONITOR SYSTEM 225
KOMTRAX SYSTEM 226
KOMTRAX SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 226
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with KOMTRAX terminal) 226
KOMTRAX SYSTEM DIAGRAM (For machines equipped with gateway function controller) 227
FUNCTION OF KOMTRAX SYSTEM (For machines equipped with gateway function controller) 227
PAYLOAD METER SYSTEM 228
LAYOUT DRAWING OF PAYLOAD METER SYSTEM 228
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with KOMTRAX terminal) 229
PAYLOAD METER SYSTEM DIAGRAM (For machines equipped with gateway function controller) 230
FUNCTION OF PAYLOAD METER SYSTEM 230
DROWSINESS DETECTION SYSTEM 240
LAYOUT DRAWING OF DROWSINESS DETECTION SYSTEM 240
SYSTEM DIAGRAM OF DROWSINESS DETECTION SYSTEM 241
FUNCTION OF DROWSINESS DETECTION SYSTEM 243
OPERATION OF DROWSINESS DETECTION SYSTEM 244
COMPONENT PARTS OF CONTROL SYSTEM 245
MACHINE MONITOR 245
SWITCH PANEL 262
REARVIEW MONITOR 263
REARVIEW CAMERA 264
KOMTRAX TERMINAL 265
GATEWAY FUNCTION CONTROLLER 267
INPUT AND OUTPUT SIGNALS OF GATEWAY FUNCTION CONTROLLER 267
COMMUNICATION TERMINAL 270
INPUT AND OUTPUT SIGNALS OF COMMUNICATION TERMINAL FOR MOBILE COMMUNICATION 270
INPUT AND OUTPUT SIGNALS OF COMMUNICATIONTERMINAL FOR IRIDIUM COMMUNICATION 271
TRANSMISSION CONTROLLER 272
RETARDER AND HOIST CONTROLLER 276
MONITOR CONTROLLER 281
ENGINE CONTROLLER 286
PAYLOAD METER CONTROLLER 292
TRANSLATOR CONTROLLER 296
DROWSINESS DETECTION CAMERA 300
DRIVER STATUS MONITOR 301
ACCELERATOR PEDAL 303
GEAR SHIFT LEVER 304
RETARDER CONTROL LEVER 305
HYDRAULIC SYSTEM 306
LAYOUT DRAWING OF HYDRAULIC SYSTEM 306
COMPONENT PARTS OF HYDRAULIC SYSTEM 307
HYDRAULIC TANK 307
STEERING AND HOIST PUMP 308
POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP 318
BRAKE COOLING DUPLEX PUMP 319
HOIST VALVE 320
POWER TRAIN SYSTEM 326
LAYOUT DRAWING OF POWER TRAIN SYSTEM 326
TRANSMISSION CONTROL SYSTEM 329
TRANSMISSION CONTROL SYSTEM DIAGRAM 329
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE 331
GEAR SHIFT CONTROL SYSTEM 335
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM 335
SHIFTING METHOD IN EACH GEAR SHIFT LEVER POSITIONS OF GEAR SHIFT CONTROL SYSTEM 336
GEAR SHIFT DISABLED TIME CONTROL OF GEAR SHIFT CONTROL SYSTEM 337
DIRECTION CONTROL SYSTEM 338
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM 338
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM 338
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 339
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM 339
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 339
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC 340
TRAVEL SPEED LIMITATION SYSTEM 341
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM 341
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM 342
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM 343
COMPONENT PARTS OF POWER TRAIN SYSTEM 345
DRIVE SHAFT 345
TORQUE CONVERTER AND PTO 347
LOCKUP CLUTCH ECMV 351
TRANSMISSION 354
TRANSMISSION CONTROL VALVE 375
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 377
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 382
MAIN RELIEF VALVE 384
TORQUE CONVERTER RELIEF VALVE 386
AXLE 387
DIFFERENTIAL 389
FINAL DRIVE 391
WORK EQUIPMENT SYSTEM 392
WORK EQUIPMENT CONTROL 392
LAYOUT DRAWING OF WORK EQUIPMENT CONTROL 392
FUNCTION OF WORK EQUIPMENT CONTROL 392
HOIST CONTROL 393
HOIST CONTROL SYSTEM DIAGRAM 393
FUNCTION OF HOIST CONTROL 393
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 395
HOIST AND COOLING FAN DIRECTION SELECTOR SOLENOID VALVE 395
DUMP LEVER 396
HOIST EPC VALVE 401
STEERING SYSTEM 402
LAYOUT DRAWING OF STEERING SYSTEM 402
FUNCTION OF STEERING SYSTEM 403
STEERING COLUMN 404
STRUCTURE OF STEERING COLUMN 404
STEERING CONTROL LINKAGE 405
STRUCTURE OF STEERING CONTROL LINKAGE 405
COMPONENT PARTS OF STEERING SYSTEM 406
DEMAND VALVE 406
ORBITROL VALVE 414
STEERING PUMP SELECTOR SOLENOID VALVE 420
CROSS-OVER RELIEF VALVE 421
SECONDARY STEERING PUMP 422
SECONDARY STEERING MOTOR 423
BRAKE SYSTEM 424
LAYOUT DRAWING OF BRAKE SYSTEM 424
RETARDER CONTROL 425
RETARDER CONTROL SYSTEM DIAGRAM 425
FUNCTION OF RETARDER CONTROL 425
ARSC SYSTEM 426
ARSC SYSTEM DIAGRAM 426
FUNCTION OF ARSC SYSTEM 426
COMPONENT PARTS OF BRAKE SYSTEM 427
BRAKE CONTROL PUMP 427
PARKING BRAKE SOLENOID VALVE 428
ACCUMULATOR CHARGE VALVE 429
BRAKE CIRCUIT ACCUMULATOR 433
BRAKE VALVE 434
SECONDARY BRAKE VALVE 438
SECONDARY BRAKE RELAY VALVE 439
FRONT BRAKE CUT SOLENOID VALVE 440
PROPORTIONAL PRESSURE REDUCING VALVE 441
SLACK ADJUSTER 442
BRAKE COOLING OIL CONTROL VALVE 444
BRAKE 445
STRUCTURE OF REAR BRAKE 446
PARKING BRAKE 448
BRAKE SUB-TANK 449
UNDERCARRIAGE AND FRAME 450
REAR AXLE SUPPORT 450
STRUCTURE OF REAR AXLE SUPPORT 450
SUSPENSION 451
STRUCTURE OF SUSPENSION 451
FUNCTION OF SUSPENSION 452
FRONT SUSPENSION 453
STRUCTURE OF FRONT SUSPENSION 453
FUNCTION OF FRONT SUSPENSION 454
REAR SUSPENSION 455
STRUCTURE OF REAR SUSPENSION 455
FUNCTION OF REAR SUSPENSION 456
SUSPENSION CYLINDER 457
STRUCTURE OF SUSPENSION CYLINDER 457
FUNCTION OF SUSPENSION CYLINDER 457
OPERATION OF SUSPENSION CYLINDER 457
WORK EQUIPMENT 458
STRUCTURE OF WORK EQUIPMENT 458
FUNCTION OF WORK EQUIPMENT 458
CAB AND ITS ATTACHMENTS 459
ROPS CAB 459
STRUCTURE OF ROPS CAB 459
FUNCTION OF ROPS CAB 459
CAB MOUNT 460
STRUCTURE OF CAB MOUNT 460
FUNCTION OF CAB MOUNT 460
20 STANDARD VALUE TABLE 461
CONTENTS 462
ABBREVIATIONS 463
STANDARD VALUE TABLE FOR ENGINE 468
STANDARD VALUE TABLE FOR ENGINE: HD325-8E0 468
STANDARD VALUE TABLE FOR ENGINE: HD405-8E0 471
STANDARD VALUE TABLE FOR MACHINE 474
STANDARD VALUE TABLE FOR MACHINE: HD325-8E0 474
STANDARD VALUE TABLE FOR MACHINE: HD405-8E0 488
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 502
30 TESTING AND ADJUSTING 503
CONTENTS 504
PRECAUTIONS BEFORE WORK 509
ABBREVIATIONS 510
RELATED INFORMATION TO TEST AND ADJUST 515
TOOLS TO TEST AND ADJUST 515
DIAGRAM FOR TEST AND ADJUST TOOLS 525
ENGINE AND COOLING SYSTEM 527
TEST ENGINE SPEED 527
PROCEDURE TO TEST ENGINE SPEED 527
TEST BOOST PRESSURE 529
PROCEDURE TO TEST BOOST PRESSURE WITH MACHINE MONITOR 529
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS 531
TEST EXHAUST GAS TEMPERATURE 533
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE 533
TEST EXHAUST GAS COLOR 536
PROCEDURE TO TEST EXHAUST GAS COLOR WITH HANDY SMOKE CHECKER 536
PROCEDURE TO TEST EXHAUST GAS COLOR WITH SMOKE METER 537
TEST AND ADJUST VALVE CLEARANCE 539
PROCEDURE TO TEST VALVE CLEARANCE 539
PROCEDURE TO ADJUST VALVE CLEARANCE 540
TEST COMPRESSION PRESSURE 542
PROCEDURE TO TEST COMPRESSION PRESSURE 542
TEST BLOWBY PRESSURE 545
PROCEDURE TO TEST BLOWBY PRESSURE 545
TEST ENGINE OIL PRESSURE 548
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH MACHINE MONITOR 548
PROCEDURE TO TEST ENGINE OIL PRESSURE WITH TEST TOOLS 548
TEST EGR VALVE AND VGT OIL PRESSURE 550
PROCEDURE TO TEST EGR VALVE AND VGT OIL PRESSURE 550
TEST FUEL PRESSURE 551
PROCEDURE TO TEST FUEL PRESSURE 551
TEST FUEL RETURN RATE AND LEAKAGE 553
PROCEDURE TO TEST FUEL RETURN RATE AND LEAKAGE 554
BLEED AIR FROM FUEL SYSTEM 558
PROCEDURE TO BLEED AIR FROM FUEL SYSTEM 558
TEST FUEL CIRCUIT LEAK 560
PROCEDURE TO TEST FUEL CIRCUIT LEAK 560
CYLINDER CUT-OUT MODE 562
NO-INJECTION CRANKING 563
CLEAN FUEL DOSER 564
PROCEDURE TO CLEAN FUEL DOSER 564
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER 567
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE 568
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER 574
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER 574
TEST SCR RELATED FUNCTIONS 575
TEST DEF PUMP RAISED PRESSURE 578
TEST INJECTION AMOUNT FROM DEF INJECTOR 581
TEST DEF LINE HEATER RELAY 1 586
TEST DEF LINE HEATER RELAY 2 590
TEST DEF PUMP HEATER RELAY 594
TEST DEF TANK HEATER VALVE 598
TEST DENITRATION EFFICIENCY OF SCR 602
CLEAN DEF TANK 605
PROCEDURE TO CLEAN DEF TANK 605
CLEAN DEF PUMP 611
PROCEDURE TO CLEAN DEF PUMP 611
TEST TORQUE CONVERTER STALL SPEED 617
PROCEDURE TO TEST TORQUE CONVERTER STALL SPEED 617
TEST RADIATOR FAN SPEED 619
PROCEDURE TO TEST RADIATOR FAN SPEED 619
POWER TRAIN 621
TEST POWER TRAIN OIL PRESSURE 621
PROCEDURE TO TEST POWER TRAIN OIL PRESSURE 624
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 635
PROCEDURE TO ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 635
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 636
PROCEDURE TO ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 636
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 637
PROCEDURE TO ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 637
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 638
PROCEDURE TO CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 638
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 639
PROCEDURE TO MOVE MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS 639
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEMS 639
STEERING SYSTEM 644
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 644
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 644
PROCEDURE TO TEST STEERING CIRCUIT OIL PRESSURE WITH TEST TOOLS 644
PROCEDURE TO ADJUST STEERING CIRCUIT OIL PRESSURE 646
TEST SUPPLY PRESSURE OF ORBITROL VALVE 647
PROCEDURE TO TEST SUPPLY PRESSURE OF ORBITROL VALVE 647
TEST STEERING CYLINDER PRESSURE 649
PROCEDURE TO TEST STEERING CYLINDER PRESSURE 649
BLEED AIR FROM STEERING CYLINDER CIRCUIT 651
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT 651
BRAKE SYSTEM 652
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 652
PROCEDURE TO RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 652
TEST WHEEL BRAKE OIL PRESSURE 653
PROCEDURE TO TEST FRONT BRAKE ACCUATION PRESSURE 653
PROCEDURE TO TEST REAR BRAKE ACCUATION PRESSURE 654
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE 655
PROCEDURE TO TEST RETARDER BRAKE ACCUATION PRESSURE (FOR MACHINE WITH KTCS) 655
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 657
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH MACHINE MONITOR 657
PROCEDURE TO TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS 658
PROCEDURE TO ADJUST BRAKE ACCUMULATOR PRESSURE 659
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR AND CHARGE NITROGEN GAS 660
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR(FRONT) 661
TEST NITROGEN GAS PRESSURE IN BRAKE ACCUMULATOR (REAR BRAKE AND PARKING BRAKE) 665
METHOD FOR CHARGING NITROGEN GAS IN BRAKE ACCUMULATOR 669
METHOD FOR DISCHARGING THE NITROGEN GAS WHEN DISPOSING OF THE ACCUMULATOR 675
TEST BRAKE PERFORMANCE 676
PROCEDURE TO TEST FOOT BRAKE PERFORMANCE 676
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE 677
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE 678
BLEED AIR FROM BRAKE CIRCUIT 679
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT 679
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITHOUT KTCS) 679
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT (FOR MACHINE WITH KTCS) 680
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT 682
TEST PARKING BRAKE OIL PRESSURE 683
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE 683
RELEASE PARKING BRAKE MANUALLY 685
PROCEDURE TO RELEASE PARKING BRAKE MANUALLY 685
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 686
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR 686
PROCEDURE TO TEST THE AMOUNT OF FRONT BRAKE PAD WEAR WITH GUAGE MEASURE 686
TEST THE AMOUNT OF REAR BRAKE DISC WEAR 687
PROCEDURE TO VISUALLY TEST THE AMOUNT OF REAR BRAKE DISC WEAR 687
TEST AND ADJUST PARKING BRAKE PAD 688
PROCEDURE TO TEST PARKING BRAKE PAD CLEARANCE 688
PROCEDURE TO ADJUST PARKING BRAKE PAD CLEARANCE 689
HYDRAULIC SYSTEM 690
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE 690
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE 690
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE 691
TEST HOIST CYLINDER SUPPLY PRESSURE 692
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE 692
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 694
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE 694
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE 695
TEST RADIATOR FAN CIRCUIT OIL PRESSURE 696
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE 696
TEST AND ADJUST FRONT SUSPENSION CYLINDER 698
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER 698
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER 699
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 704
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 704
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION) 705
TEST AND ADJUST REAR SUSPENSION CYLINDER 706
PROCEDURE TO TEST REAR SUSPENSION CYLINDER 706
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER 707
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS) 712
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH MACHINE MONITOR 712
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE WITH TEST TOOLS 712
WORK EQUIPMENT 714
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 714
PROCEDURE TO TEST BODY POSITIONER SENSOR 714
PROCEDURE TO ADJUST DUMP BODY POSITIONER SENSOR 714
PROCEDURE TO CALIBRATE AFTER YOU ADJUST BODY POSITION SENSOR 714
LOWER THE BODY MANUALLY 716
PROCEDURE TO LOWER THE BODY MANUALLY 716
LIFT THE BODY MANUALLY 717
PROCEDURE TO LIFT THE BODY MANUALLY 717
CAB AND ITS ATTACHMENTS 718
ADJUST STEERING WHEEL TILT LOCK LEVER 718
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER 718
ADJUST RATTLING OPERATOR’S SEAT 719
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 719
ELECTRICAL SYSTEM 720
SET AND ADJUST EACH EQUIPMENT 720
SET AND OPERATE OF MACHINE MONITOR 723
OPERATOR MODE 727
SERVICE MODE 740
ABNORMALITY RECORD MENU 768
DEFAULT MENU 783
DIAGNOSTIC TESTS MENU 797
ADJUSTMENT MENU 809
PROCEDURE TO PERFORM NO-INJECTION CRANKING 830
PAYLOAD METER SETTING 832
KOMTRAX SETTINGS MENU 854
PROCEDURE TO DISPLAY SERVICE MESSAGE 859
PROCEDURE TO START UP KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 861
PROCEDURE TO FINISH KOMTRAX TERMINAL (For machines equipped with KOMTRAX terminal) 865
PROCEDURE TO START UP KOMTRAX SYSTEM (For machines equipped with gateway function controller) 867
PROCEDURE TO FINISH KOMTRAX SYSTEM (For machines equipped with gateway function controller) 871
SET DRIVER STATUS MONITOR 873
PREPARATION FOR DRIVER STATUS MONITOR SETTING 873
HOW TO SET DRIVER STATUS MONITOR 879
HOW TO DO OPERATION CHECK OF DRIVER STATUS MONITOR 881
HOW TO ADJUST DROWSINESS DETECTION CAMERA ANGLE 882
ADJUST REARVIEW CAMERA ANGLE 883
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE 883
SET REGION OF BLUETOOTH® COMPATIBLE RADIO 884
HOW TO SET REGION OF BLUETOOTH® COMPATIBLE RADIO 884
ADJUST OPTICAL AXIS OF HEAD LAMP 886
PROCEDURE TO ADJUST OPTICAL AXIS OF HEAD LAMP 886
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 889
BATTERY DISCONNECT SWITCH WORK (For machines equipped with KOMTRAX terminal) 890
BATTERY DISCONNECT SWITCH WORK (For machines equipped with gateway function controller) 891
TEST DIODES 892
PROCEDURE TO TEST DIODE USING DIGITAL TESTER 892
PROCEDURE TO TEST DIODE USING ANALOG TESTER 892
Pm CLINIC 893
Pm CLINIC SERVICE 893
Pm CLINIC CHECK SHEET: HD325-8E0 896
Pm CLINIC CHECK SHEET: HD405-8E0 903
40 TROUBLESHOOTING 911
CONTENTS 912
PRECAUTIONS BEFORE WORK 927
ABBREVIATIONS 928
RELATED INFORMATION ON TROUBLESHOOTING 933
GENERAL TROUBLESHOOTING POINTS 933
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 934
SEQUENCE OF EVENTS IN TROUBLESHOOTING 946
CHECKS BEFORE TROUBLESHOOTING 948
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 951
WALK-AROUND CHECK 951
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 953
CHECK FUEL LEVEL AND TYPE 953
CHECK IMPURE INGREDIENT IN FUEL 953
CHECK DEF LEVEL AND TYPE 953
CHECK FUEL PREFILTER 954
CHECK MAIN FILTER 956
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 958
CHECK COOLANT LEVEL (RESERVOIR TANK) 959
CHECK CLOGGING OF AIR CLEANER 960
CHECK OF AIR CLEANER 961
OUTER ELEMENT – CLEAN 961
REPLACE ELEMENT 963
CHECK HYDRAULIC OIL LEVEL 965
CHECK HYDRAULIC OIL STRAINER 965
CHECK HYDRAULIC FILTER 966
CHECK OIL LEVEL IN TRANSMISSION CASE 966
CHECK OIL LEVEL IN DIFFERENTIAL CASE 967
CHECK OIL LEVEL IN FINAL DRIVE CASE 967
BLEED AIR FROM FUEL SYSTEM 968
BLEED AIR FROM HYDRAULIC SYSTEM 968
METHOD FOR CHECKING ELECTRIC EQUIPMENT METHOD 968
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 974
PROCEDURE FOR TESTING AND TROUBLESHOOTING 984
SYMPTOM AND TROUBLESHOOTING NUMBERS 986
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 991
CONNECTORS LIST AND LAYOUT 994
Connector List 994
CONNECTOR LIST (MACHINE WITH DROWSINESS DETECTION SYSTEM)1007
CONNECTOR CONTACT IDENTIFICATION1021
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1061
FUSE LOCATION TABLE (For machines equipped with KOMTRAX terminal)1067
FUSE LOCATION TABLE (For machines equipped with gateway function controller)1073
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1079
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR1082
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT1084
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] and [CA3135])1090
FAILURE CODES TABLE1092
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1119
FAILURE CODE [1500L0]1119
FAILURE CODE [15B0NX]1120
FAILURE CODE [15F0KM]1122
FAILURE CODE [15F0MB]1123
FAILURE CODE [15F7KM]1124
FAILURE CODE [15G0MW]1125
FAILURE CODE [15G7KM]1126
FAILURE CODE [15H0MW]1127
FAILURE CODE [15J0MW]1128
FAILURE CODE [15K0MW]1129
FAILURE CODE [15L0MW]1131
FAILURE CODE [15M0MW]1133
FAILURE CODE [15N0MW]1135
FAILURE CODE [15SBL1]1136
FAILURE CODE [15SBMA]1139
FAILURE CODE [15SCL1]1140
FAILURE CODE [15SCMA]1143
FAILURE CODE [15SDL1]1144
FAILURE CODE [15SDMA]1147
FAILURE CODE [15SEL1]1148
FAILURE CODE [15SEMA]1151
FAILURE CODE [15SFL1]1152
FAILURE CODE [15SFMA]1155
FAILURE CODE [15SGL1]1156
FAILURE CODE [15SGMA]1159
FAILURE CODE [15SHL1]1160
FAILURE CODE [15SHMA]1163
FAILURE CODE [15SJMA]1164
FAILURE CODE [2C4MNX]1165
FAILURE CODE [2F00KM]1166
FAILURE CODE [2G42ZG]1169
FAILURE CODE [2G43ZG]1170
FAILURE CODE [6014NX]1171
FAILURE CODE [879AKA]1172
FAILURE CODE [879AKB]1173
FAILURE CODE [879BKA]1174
FAILURE CODE [879BKB]1175
FAILURE CODE [879CKA]1176
FAILURE CODE [879CKB]1177
FAILURE CODE [879EMC]1178
FAILURE CODE [879FMC]1179
FAILURE CODE [879GKX]1180
FAILURE CODE [989D00]1181
FAILURE CODE [989L00]1182
FAILURE CODE [989M00]1183
FAILURE CODE [989N00]1184
FAILURE CODE [989X00]1185
FAILURE CODE [98A000]1186
FAILURE CODE [98A100]1187
FAILURE CODE [98A200]1188
FAILURE CODE [98A300]1189
FAILURE CODE [98A400]1190
FAILURE CODE [98A500]1191
FAILURE CODE [98A600]1192
FAILURE CODE [A1U0N3]1193
FAILURE CODE [A1U0N4]1194
FAILURE CODE [AA10NX]1195
FAILURE CODE [AB00KE]1197
FAILURE CODE [AB00KY]1199
FAILURE CODE [AQ10N3]1200
FAILURE CODE [AS00N3]1201
FAILURE CODE [AS00R2]1202
FAILURE CODE [AS00R3]1203
FAILURE CODE [AS00R4]1204
FAILURE CODE [AS00R5]1205
FAILURE CODE [AS00R6]1206
FAILURE CODE [AS00ZK]1207
FAILURE CODE [AS10KM]1208
FAILURE CODE [AS10NR]1209
FAILURE CODE [AS10NT]1210
FAILURE CODE [B@BAZG]1211
FAILURE CODE [B@BAZK]1212
FAILURE CODE [B@BCNS]1213
FAILURE CODE [B@BCQA]1214
FAILURE CODE [B@BCZK]1216
FAILURE CODE [B@C7NS]1218
FAILURE CODE [B@CENS]1220
FAILURE CODE [B@JANS]1221
FAILURE CODE [CA115]1222
FAILURE CODE [CA122]1223
FAILURE CODE [CA123]1225
FAILURE CODE [CA131]1227
FAILURE CODE [CA132]1229
FAILURE CODE [CA135]1231
FAILURE CODE [CA141]1233
FAILURE CODE [CA144]1235
FAILURE CODE [CA145]1237
FAILURE CODE [CA153]1239
FAILURE CODE [CA154]1241
FAILURE CODE [CA187]1243
FAILURE CODE [CA221]1245
FAILURE CODE [CA222]1247
FAILURE CODE [CA227]1249
FAILURE CODE [CA234]1250
FAILURE CODE [CA238]1251
FAILURE CODE [CA239]1253
FAILURE CODE [CA249]1255
FAILURE CODE [CA256]1257
FAILURE CODE [CA271]1259
FAILURE CODE [CA272]1261
FAILURE CODE [CA273]1262
FAILURE CODE [CA274]1264
FAILURE CODE [CA322]1265
FAILURE CODE [CA323]1267
FAILURE CODE [CA324]1269
FAILURE CODE [CA325]1271
FAILURE CODE [CA331]1273
FAILURE CODE [CA332]1275
FAILURE CODE [CA343]1277
FAILURE CODE [CA351]1278
FAILURE CODE [CA352]1279
FAILURE CODE [CA356]1281
FAILURE CODE [CA357]1283
FAILURE CODE [CA386]1285
FAILURE CODE [CA431]1286
FAILURE CODE [CA432]1289
FAILURE CODE [CA441]1292
FAILURE CODE [CA442]1295
FAILURE CODE [CA449]1296
FAILURE CODE [CA451]1297
FAILURE CODE [CA452]1299
FAILURE CODE [CA515]1301
FAILURE CODE [CA516]1303
FAILURE CODE [CA553]1305
FAILURE CODE [CA555]1306
FAILURE CODE [CA556]1307
FAILURE CODE [CA559]1308
FAILURE CODE [CA595]1312
FAILURE CODE [CA687]1313
FAILURE CODE [CA689]1315
FAILURE CODE [CA691]1317
FAILURE CODE [CA692]1319
FAILURE CODE [CA697]1321
FAILURE CODE [CA698]1322
FAILURE CODE [CA731]1323
FAILURE CODE [CA778]1324
FAILURE CODE [CA1117]1327
FAILURE CODE [CA1664]1329
FAILURE CODE [CA1669]1331
FAILURE CODE [CA1673]1332
FAILURE CODE [CA1677]1333
FAILURE CODE [CA1678]1334
FAILURE CODE [CA1682]1335
FAILURE CODE [CA1683]1339
FAILURE CODE [CA1684]1341
FAILURE CODE [CA1686]1343
FAILURE CODE [CA1691]1344
FAILURE CODE [CA1694]1346
FAILURE CODE [CA1695]1348
FAILURE CODE [CA1696]1349
FAILURE CODE [CA1712]1351
FAILURE CODE [CA1713]1353
FAILURE CODE [CA1714]1355
FAILURE CODE [CA1715]1356
FAILURE CODE [CA1776]1357
FAILURE CODE [CA1777]1360
FAILURE CODE [CA1843]1363
FAILURE CODE [CA1844]1365
FAILURE CODE [CA1879]1367
FAILURE CODE [CA1881]1369
FAILURE CODE [CA1883]1371
FAILURE CODE [CA1885]1374
FAILURE CODE [CA1887]1376
FAILURE CODE [CA1921]1378
FAILURE CODE [CA1922]1380
FAILURE CODE [CA1923]1383
FAILURE CODE [CA1924]1385
FAILURE CODE [CA1925]1387
FAILURE CODE [CA1927]1389
FAILURE CODE [CA1928]1391
FAILURE CODE [CA1942]1393
FAILURE CODE [CA1963]1394
FAILURE CODE [CA1977]1398
FAILURE CODE [CA1993]1400
FAILURE CODE [CA2185]1402
FAILURE CODE [CA2186]1404
FAILURE CODE [CA2249]1406
FAILURE CODE [CA2265]1407
FAILURE CODE [CA2266]1409
FAILURE CODE [CA2271]1411
FAILURE CODE [CA2272]1413
FAILURE CODE [CA2349]1415
FAILURE CODE [CA2353]1417
FAILURE CODE [CA2357]1419
FAILURE CODE [CA2381]1420
FAILURE CODE [CA2382]1422
FAILURE CODE [CA2383]1424
FAILURE CODE [CA2386]1426
FAILURE CODE [CA2387]1428
FAILURE CODE [CA2555]1429
FAILURE CODE [CA2556]1431
FAILURE CODE [CA2637]1433
FAILURE CODE [CA2639]1435
FAILURE CODE [CA2732]1437
FAILURE CODE [CA2733]1439
FAILURE CODE [CA2741]1441
FAILURE CODE [CA2765]1442
FAILURE CODE [CA2771]1443
FAILURE CODE [CA2777]1448
FAILURE CODE [CA2878]1449
FAILURE CODE [CA2881]1452
FAILURE CODE [CA2976]1456
FAILURE CODE [CA3133]1458
FAILURE CODE [CA3134]1460
FAILURE CODE [CA3135]1462
FAILURE CODE [CA3142]1465
FAILURE CODE [CA3143]1466
FAILURE CODE [CA3144]1467
FAILURE CODE [CA3146]1469
FAILURE CODE [CA3147]1470
FAILURE CODE [CA3148]1471
FAILURE CODE [CA3151]1473
FAILURE CODE [CA3165]1478
FAILURE CODE [CA3167]1480
FAILURE CODE [CA3229]1483
FAILURE CODE [CA3231]1485
FAILURE CODE [CA3232]1487
FAILURE CODE [CA3235]1491
FAILURE CODE [CA3239]1493
FAILURE CODE [CA3241]1496
FAILURE CODE [CA3242]1499
FAILURE CODE [CA3251]1501
FAILURE CODE [CA3253]1503
FAILURE CODE [CA3254]1506
FAILURE CODE [CA3255]1508
FAILURE CODE [CA3256]1510
FAILURE CODE [CA3311]1512
FAILURE CODE [CA3312]1514
FAILURE CODE [CA3313]1516
FAILURE CODE [CA3314]1517
FAILURE CODE [CA3315]1518
FAILURE CODE [CA3316]1521
FAILURE CODE [CA3317]1522
FAILURE CODE [CA3318]1523
FAILURE CODE [CA3319]1526
FAILURE CODE [CA3321]1527
FAILURE CODE [CA3322]1528
FAILURE CODE [CA3419]1531
FAILURE CODE [CA3421]1533
FAILURE CODE [CA3497]1535
FAILURE CODE [CA3498]1536
FAILURE CODE [CA3543]1537
FAILURE CODE [CA3545]1542
FAILURE CODE [CA3547]1544
FAILURE CODE [CA3558]1545
FAILURE CODE [CA3559]1547
FAILURE CODE [CA3562]1549
FAILURE CODE [CA3563]1551
FAILURE CODE [CA3567]1554
FAILURE CODE [CA3568]1556
FAILURE CODE [CA3571]1560
FAILURE CODE [CA3572]1562
FAILURE CODE [CA3574]1564
FAILURE CODE [CA3575]1566
FAILURE CODE [CA3577]1568
FAILURE CODE [CA3578]1570
FAILURE CODE [CA3582]1572
FAILURE CODE [CA3583]1578
FAILURE CODE [CA3596]1580
FAILURE CODE [CA3649]1584
FAILURE CODE [CA3681]1586
FAILURE CODE [CA3682]1590
FAILURE CODE [CA3713]1594
FAILURE CODE [CA3717]1597
FAILURE CODE [CA3718]1598
FAILURE CODE [CA3725]1599
FAILURE CODE [CA3748]1602
FAILURE CODE [CA3751]1604
FAILURE CODE [CA3755]1605
FAILURE CODE [CA3866]1607
FAILURE CODE [CA3867]1610
FAILURE CODE [CA3868]1613
FAILURE CODE [CA3899]1617
FAILURE CODE [CA3911]1619
FAILURE CODE [CA3912]1623
FAILURE CODE [CA3932]1625
FAILURE CODE [CA3933]1627
FAILURE CODE [CA3934]1629
FAILURE CODE [CA3935]1632
FAILURE CODE [CA3936]1634
FAILURE CODE [CA4151]1636
FAILURE CODE [CA4152]1640
FAILURE CODE [CA4155]1644
FAILURE CODE [CA4156]1646
FAILURE CODE [CA4157]1648
FAILURE CODE [CA4158]1650
FAILURE CODE [CA4159]1652
FAILURE CODE [CA4161]1653
FAILURE CODE [CA4162]1655
FAILURE CODE [CA4163]1657
FAILURE CODE [CA4164]1659
FAILURE CODE [CA4165]1661
FAILURE CODE [CA4166]1663
FAILURE CODE [CA4168]1664
FAILURE CODE [CA4169]1669
FAILURE CODE [CA4171]1672
FAILURE CODE [CA4249]1675
FAILURE CODE [CA4251]1678
FAILURE CODE [CA4259]1681
FAILURE CODE [CA4261]1684
FAILURE CODE [CA4277]1686
FAILURE CODE [CA4281]1688
FAILURE CODE [CA4459]1691
FAILURE CODE [CA4461]1693
FAILURE CODE [CA4658]1696
FAILURE CODE [CA4731]1699
FAILURE CODE [CA4732]1700
FAILURE CODE [CA4739]1701
FAILURE CODE [CA4768]1702
FAILURE CODE [CA4769]1704
FAILURE CODE [CA4842]1706
FAILURE CODE [CA4952] (For machines equipped with KOMTRAX terminal)1709
FAILURE CODE [CA4952] (For machines equipped with gateway function controller)1711
FAILURE CODE [CA5115]1713
FAILURE CODE [CA5179]1716
FAILURE CODE [CA5181]1718
FAILURE CODE [CA5383]1720
FAILURE CODE [D018KB]1721
FAILURE CODE [D018KY]1723
FAILURE CODE [D019KB]1725
FAILURE CODE [D019KY]1727
FAILURE CODE [D150KB]1729
FAILURE CODE [D150KZ]1730
FAILURE CODE [D164KY]1731
FAILURE CODE [D19HKZ]1732
FAILURE CODE [D19JKZ]1734
FAILURE CODE [D19QKZ]1735
FAILURE CODE [D1EHKA]1737
FAILURE CODE [D1EHKB]1738
FAILURE CODE [D1EHKY]1739
FAILURE CODE [D1EMKA]1740
FAILURE CODE [D1EMKB]1741
FAILURE CODE [D1EMKY]1742
FAILURE CODE [D1FBKB]1743
FAILURE CODE [D5WNKZ]1744
FAILURE CODE [D5ZHL6]1746
FAILURE CODE [D5ZKKZ]1748
FAILURE CODE [D811MC] (For machines equipped with KOMTRAX terminal)1750
FAILURE CODE [D811MC] (For machines equipped with gateway function controller)1751
FAILURE CODE [D862KA] (For machines equipped with KOMTRAX terminal)1752
FAILURE CODE [D862KA] (For machines equipped with gateway function controller)1753
FAILURE CODE [D8ALKA] (For machines equipped with KOMTRAX terminal)1754
FAILURE CODE [D8ALKA] (For machines equipped with gateway function controller)1756
FAILURE CODE [D8ALKB] (For machines equipped with KOMTRAX terminal)1758
FAILURE CODE [D8ALKB] (For machines equipped with gateway function controller)1760
FAILURE CODE [D8AQK4] (For machines equipped with KOMTRAX terminal)1762
FAILURE CODE [D8AQK4] (For machines equipped with gateway function controller)1763
FAILURE CODE [D8AQKR] (For machines equipped with KOMTRAX terminal)1764
FAILURE CODE [D8AQKR] (For machines equipped with gateway function controller)1765
FAILURE CODE [D8G1KT]1766
FAILURE CODE [D8G6KT]1767
FAILURE CODE [DAF0KT]1768
FAILURE CODE [DAF0MB]1769
FAILURE CODE [DAF0MC]1770
FAILURE CODE [DAF3KK]1771
FAILURE CODE [DAF8KB]1773
FAILURE CODE [DAFDKB]1774
FAILURE CODE [DAFGMC] (For machines equipped with KOMTRAX terminal)1776
FAILURE CODE [DAFGMC] (For machines equipped with gateway function controller)1777
FAILURE CODE [DAFLKA] (For machines equipped with KOMTRAX terminal)1778
FAILURE CODE [DAFLKA] (For machines equipped with gateway function controller)1780
FAILURE CODE [DAFLKB] (For machines equipped with KOMTRAX terminal)1782
FAILURE CODE [DAFLKB] (For machines equipped with gateway function controller)1784
FAILURE CODE [DAFQKR] (For machines equipped with KOMTRAX terminal)1786
FAILURE CODE [DAFQKR] (For machines equipped with gateway function controller)1787
FAILURE CODE [DAQ0KK]1788
FAILURE CODE [DAQ0KT]1791
FAILURE CODE [DAQ0MC]1792
FAILURE CODE [DAQ1KA]1793
FAILURE CODE [DAQ2KK]1796
FAILURE CODE [DAQ9KQ]1799
FAILURE CODE [DAQLKA] (For machines equipped with KOMTRAX terminal)1800
FAILURE CODE [DAQLKA] (For machines equipped with gateway function controller)1802
FAILURE CODE [DAQLKB] (For machines equipped with KOMTRAX terminal)1804
FAILURE CODE [DAQLKB] (For machines equipped with gateway function controller)1806
FAILURE CODE [DAQQKR]1808
FAILURE CODE [DAQRKR]1809
FAILURE CODE [DAQRMA]1810
FAILURE CODE [DAQV00]1811
FAILURE CODE [DAQW00]1812
FAILURE CODE [DAZ9KQ]1813
FAILURE CODE [DAZQKR]1814
FAILURE CODE [DB10KT]1816
FAILURE CODE [DB10MC]1817
FAILURE CODE [DB11KA]1818
FAILURE CODE [DB11KA] (For machines equipped with emergency engine stop switch)1821
FAILURE CODE [DB12KK]1824
FAILURE CODE [DB13KK]1827
FAILURE CODE [DB19KQ]1830
FAILURE CODE [DB1LKA] (For machines equipped with KOMTRAX terminal)1831
FAILURE CODE [DB1LKA] (For machines equipped with gateway function controller)1833
FAILURE CODE [DB1LKB] (For machines equipped with KOMTRAX terminal)1835
FAILURE CODE [DB1LKB] (For machines equipped with gateway function controller)1837
FAILURE CODE [DB1QKR]1839
FAILURE CODE [DB1QMA]1840
FAILURE CODE [DB1RKR]1841
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal)1842
FAILURE CODE [DB2QKR] (For machines equipped with KOMTRAX terminal and Drowsiness Detection system)1848
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller)1854
FAILURE CODE [DB2QKR] (For machines equipped with gateway function controller and Drowsiness Detection system)1860
FAILURE CODE [DB2RKR]1866
FAILURE CODE [DB2RKR] (For machines equipped with Drowsiness Detection system)1871
FAILURE CODE [DBS0KK]1878
FAILURE CODE [DBS6KP]1881
FAILURE CODE [DBSQKQ]1883
FAILURE CODE [DBSQKR]1884
FAILURE CODE [DBSRKR]1885
FAILURE CODE [DCR0MC]1886
FAILURE CODE [DCR2KK]1887
FAILURE CODE [DCR8L4]1891
FAILURE CODE [DCR9KQ]1895
FAILURE CODE [DCRLKA]1896
FAILURE CODE [DCRLKB]1899
FAILURE CODE [DCRQKR]1901
FAILURE CODE [DCRRKR]1912
FAILURE CODE [DDAAL6]1921
FAILURE CODE [DDAAL6] (For machines equipped with emergency engine stop switch)1923
FAILURE CODE [DDD7KX]1925
FAILURE CODE [DDTHKA]1927
FAILURE CODE [DDTJKA]1929
FAILURE CODE [DDTKKA]1931
FAILURE CODE [DDTLKA]1933
FAILURE CODE [DDTMKA]1935
FAILURE CODE [DDTNKA]1937
FAILURE CODE [DDTPKA]1939
FAILURE CODE [DF10KA]1941
FAILURE CODE [DF10KB]1945
FAILURE CODE [DGF1KX]1950
FAILURE CODE [DGR2KB]1952
FAILURE CODE [DGR6KB]1954
FAILURE CODE [DGR6L8]1955
FAILURE CODE [DGT1KX]1957
FAILURE CODE [DHA4KA]1959
FAILURE CODE [DHAAMA]1961
FAILURE CODE [DHACMA]1962
FAILURE CODE [DHP4KY]1963
FAILURE CODE [DHP4KZ]1965
FAILURE CODE [DHP5KY]1967
FAILURE CODE [DHP5KZ]1969
FAILURE CODE [DHP6KA]1971
FAILURE CODE [DHP6KX]1973
FAILURE CODE [DHP6KY]1975
FAILURE CODE [DHP6KZ]1977
FAILURE CODE [DHP7KA]1979
FAILURE CODE [DHP7KX]1981
FAILURE CODE [DHP7KY]1983
FAILURE CODE [DHP7KZ]1985
FAILURE CODE [DHQ4KX]1987
FAILURE CODE [DHT5KX]1989
FAILURE CODE [DHT5L6]1991
FAILURE CODE [DHT8KX]1993
FAILURE CODE [DHT8ZG]1995
FAILURE CODE [DHU2KX]1996
FAILURE CODE [DHU3KX]1998
FAILURE CODE [DHUCKX]2000
FAILURE CODE [DHUDKX]2003
FAILURE CODE [DHUHKX]2005
FAILURE CODE [DHULKX]2007
FAILURE CODE [DHUMKX]2009
FAILURE CODE [DHUPKX]2011
FAILURE CODE [DJF1KA]2013
FAILURE CODE [DK30KX]2015
FAILURE CODE [DK51L5]2017
FAILURE CODE [DK52KX]2020
FAILURE CODE [DK53L8]2022
FAILURE CODE [DK54KX]2024
FAILURE CODE [DK60KX]2026
FAILURE CODE [DKD0L6]2028
FAILURE CODE [DKH0KX]2030
FAILURE CODE [DKH1KX]2033
FAILURE CODE [DLF1KA]2035
FAILURE CODE [DLF1LC]2036
FAILURE CODE [DLF2KA]2038
FAILURE CODE [DLF2LC]2039
FAILURE CODE [DLF8KA]2041
FAILURE CODE [DLF8LC]2043
FAILURE CODE [DLF9KA]2045
FAILURE CODE [DLF9LC]2047
FAILURE CODE [DLM3KA]2049
FAILURE CODE [DLM3LC]2050
FAILURE CODE [DLM3MB]2052
FAILURE CODE [DLT3KA]2053
FAILURE CODE [DLT3LC]2054
FAILURE CODE [DPQ1KR]2056
FAILURE CODE [DPQ2KR]2059
FAILURE CODE [DPQ3KR]2062
FAILURE CODE [DR81KR]2066
FAILURE CODE [DR81MA]2074
FAILURE CODE [DSJ0KR]2075
FAILURE CODE [DV00KB]2076
FAILURE CODE [DV03KB]2078
FAILURE CODE [DV03KY]2080
FAILURE CODE [DW2AKA]2082
FAILURE CODE [DW2AKB]2083
FAILURE CODE [DW2AKY]2085
FAILURE CODE [DW2AL1]2086
FAILURE CODE [DW2ALH]2087
FAILURE CODE [DW35KZ]2088
FAILURE CODE [DW36KZ]2090
FAILURE CODE [DW4BK4]2092
FAILURE CODE [DW4BMA]2095
FAILURE CODE [DW72KZ]2098
FAILURE CODE [DW73KA]2100
FAILURE CODE [DW73KB]2102
FAILURE CODE [DW73KY]2104
FAILURE CODE [DW78KZ]2105
FAILURE CODE [DW7BKB]2107
FAILURE CODE [DW7BKY]2108
FAILURE CODE [DW7BKZ]2109
FAILURE CODE [DW7MKB]2110
FAILURE CODE [DW7MKY]2112
FAILURE CODE [DW7MKZ]2113
FAILURE CODE [DW7NKZ]2115
FAILURE CODE [DWNMKZ]2117
FAILURE CODE [DX11K4]2119
FAILURE CODE [DX11KA]2121
FAILURE CODE [DX11KB]2123
FAILURE CODE [DX11KY]2125
FAILURE CODE [DX11MA]2126
FAILURE CODE [DX13KA]2128
FAILURE CODE [DX13KB]2130
FAILURE CODE [DX13KY]2132
FAILURE CODE [DX16KA]2133
FAILURE CODE [DX16KB]2134
FAILURE CODE [DX16KY]2136
FAILURE CODE [DX37K4]2137
FAILURE CODE [DX37KA]2139
FAILURE CODE [DX37KB]2141
FAILURE CODE [DX37KY]2143
FAILURE CODE [DX37MA]2144
FAILURE CODE [DX38K4]2146
FAILURE CODE [DX38KA]2148
FAILURE CODE [DX38KB]2150
FAILURE CODE [DX38KY]2152
FAILURE CODE [DX38MA]2153
FAILURE CODE [DXH1KA]2155
FAILURE CODE [DXH1KB]2157
FAILURE CODE [DXH1KY]2159
FAILURE CODE [DXH2KA]2161
FAILURE CODE [DXH2KB]2163
FAILURE CODE [DXH2KY]2165
FAILURE CODE [DXH3KA]2168
FAILURE CODE [DXH3KB]2170
FAILURE CODE [DXH3KY]2172
FAILURE CODE [DXH4KA]2175
FAILURE CODE [DXH4KB]2177
FAILURE CODE [DXH4KY]2179
FAILURE CODE [DXH5KA]2182
FAILURE CODE [DXH5KB]2184
FAILURE CODE [DXH5KY]2186
FAILURE CODE [DXH6KA]2189
FAILURE CODE [DXH6KB]2191
FAILURE CODE [DXH6KY]2193
FAILURE CODE [DXH7KA]2196
FAILURE CODE [DXH7KB]2198
FAILURE CODE [DXH7KY]2200
FAILURE CODE [DXHHKA]2202
FAILURE CODE [DXHHKB]2204
FAILURE CODE [DXHHKY]2206
FAILURE CODE [DY30MA]2208
FAILURE CODE [DY30MC]2210
FAILURE CODE [DY30ME]2213
FAILURE CODE [F313KA]2215
FAILURE CODE [F313KB]2217
FAILURE CODE [F318KB]2218
FAILURE CODE [F318KY]2219
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2220
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2220
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2227
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2230
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2232
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2233
E-6 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING (For machines equipped with emergency engine stop switch)2236
E-7 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2239
E-8 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2241
E-9 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2243
E-10 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2245
E-11 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2248
E-12 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2251
E-13 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2254
E-14 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2256
E-15 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2258
E-16 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2260
E-17 DEF LEVEL IS NOT DISPLAYED PROPERLY2261
E-18 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2264
E-19 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2268
E-20 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2272
E-21 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2275
E-22 REARVIEW MONITOR DOES NOT DISPLAY IMAGES WHILE REVERSE LINKED DISPLAY FUNCTION IS ENABLED2277
E-23 GUIDE LINE ON REARVIEW MONITOR IS NOT DISPLAYED WHILE GUIDE LINE IS SET2280
E-24 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2282
E-25 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2284
E-26 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION2286
E-27 ALARM BUZZER DOES NOT SOUND2287
E-28 ALARM BUZZER DOES NOT STOP SOUNDING2289
E-29 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE PROPERLY2291
E-30 AISS FUNCTION DOES NOT OPERATE PROPERLY2293
E-31 HOIST LEVER DOES NOT OPERATE PROPERLY2295
E-32 FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY2297
E-33 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY2300
E-34 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2304
E-35 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP2307
E-36 TAIL LAMP DOES NOT LIGHT UP2310
E-37 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP2313
E-38 (HIGH BEAM) HEAD LAMP DOES NOT LIGHT UP2315
E-39 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS LIGHTS UP2317
E-40 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED2319
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with KOMTRAX terminal)2321
E-41 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY (For machines equipped with gateway function controller)2323
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2325
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2325
FAILURE MODE AND CAUSE TABLE2326
H-1 MACHINE DOES NOT START2334
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS)2338
H-3 LOCKUP IS NOT RELEASED2339
H-4 ABNORMALLY LARGE SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING2340
H-5 GEAR IS NOT SHIFTED UP2342
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS2345
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE2346
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT SOME GEAR SPEED2347
H-9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2349
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2352
H-11 OIL PRESSURE OF TORQUE CONVERTER IS LOW2353
H-12 STEERING WHEEL IS HEAVY TO OPERATE2354
H-13 STEERING WHEEL CANNOT BE OPERATED2355
H-14 STEERING WHEEL WAGGLES2356
H-15 FRONT BRAKE DOES NOT WORK ENOUGH2357
H-16 REAR BRAKE DOES NOT WORK ENOUGH2358
H-17 DUMP BODY RISING SPEED IS LOW2359
H-18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE2361
H-19 DUMP BODY DOES NOT MOVE2362
H-20 RADIATOR FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS)2364
H-21 UNUSUAL NOISE IS HEARD FROM AROUND RADIATOR FAN2365
TROUBLESHOOTING OF ENGINE (S-MODE)2366
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2366
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2367
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2368
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2369
S-4 ENGINE STARTABILITY IS POOR2370
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2372
S-6 ENGINE STOPS DURING OPERATION2374
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2376
S-8 ENGINE LACKS POWER2377
S-9 KDPF GETS CLOGGED IN A SHORT TIME2379
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2381
S-11 OIL BECOMES CONTAMINATED QUICKLY2382
S-12 FUEL CONSUMPTION IS EXCESSIVE2383
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2384
S-14 OIL PRESSURE DROPS2385
S-15 FUEL MIXES INTO ENGINE OIL2386
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2387
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2388
S-18 UNUSUAL NOISE IS HEARD2389
S-19 VIBRATION IS EXCESSIVE2390
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2391
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2392
S-22 ACTIVE REGENERATION TAKES TIME2394
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2395
S-24 DEF CONSUMPTION IS EXCESSIVE2396
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2398
S-26 FOREIGN MATERIALS ENTER DEF (DEF INCREASES)2399
50 DISASSEMBLY AND ASSEMBLY2401
CONTENTS2402
PRECAUTIONS BEFORE WORK2408
ABBREVIATIONS2409
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION2414
HOW TO READ THIS MANUAL2414
COATING MATERIALS LIST2416
SPECIAL TOOL LIST2419
DIAGRAMS OF SPECIAL TOOLS2435
ENGINE AND COOLING SYSTEM2440
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2440
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY2440
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY2441
REMOVE AND INSTALL INJECTOR ASSEMBLY2445
PROCEDURE TO REMOVE INJECTOR ASSEMBLY2445
PROCEDURE TO INSTALL INJECTOR ASSEMBLY2459
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2477
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY2477
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY2479
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2481
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY2482
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY2497
REMOVE AND INSTALL EGR VALVE ASSEMBLY2520
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY2520
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY2523
REMOVE AND INSTALL EGR COOLER ASSEMBLY2526
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY2526
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY2532
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2538
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY2538
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY2539
REMOVE AND INSTALL ALTERNATOR BELT2540
PROCEDURE TO REMOVE ALTERNATOR BELT2540
PROCEDURE TO INSTALL ALTERNATOR BELT2541
REMOVE AND INSTALL RADIATOR2544
PROCEDURE TO REMOVE RADIATOR2545
PROCEDURE TO INSTALL RADIATOR2549
REMOVE AND INSTALL COOLER ASSEMBLY2553
PROCEDURE TO REMOVE COOLER ASSEMBLY2553
PROCEDURE TO INSTALL COOLER ASSEMBLY2564
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2576
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2576
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2580
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2585
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY2585
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY2586
REMOVE AND INSTALL GRILLE GUARD ASSEMBLY2588
PROCEDURE TO REMOVE GRILLE GUARD ASSEMBLY2588
PROCEDURE TO INSTALL GRILLE GUARD ASSEMBLY2592
REMOVE AND INSTALL ENGINE ASSEMBLY2596
PROCEDURE TO REMOVE ENGINE ASSEMBLY2597
PROCEDURE TO INSTALL ENGINE ASSEMBLY2606
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2621
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL2621
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL2622
REMOVE AND INSTALL ENGINE REAR OIL SEAL2624
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL2624
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL2626
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY2632
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY2632
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY2633
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY2635
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY2635
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY2636
REMOVE AND INSTALL DEF TANK ASSEMBLY2638
PROCEDURE TO REMOVE DEF TANK ASSEMBLY2639
PROCEDURE TO INSTALL DEF TANK ASSEMBLY2646
REMOVE AND INSTALL DEF TANK SENSOR FLANGE ASSEMBLY2651
PROCEDURE TO REMOVE DEF TANK SENSOR FLANGE ASSEMBLY2652
PROCEDURE TO INSTALL DEF TANK SENSOR FLANGE ASSEMBLY2659
REMOVE AND INSTALL DEF TANK SENSOR2664
PROCEDURE TO REMOVE DEF TANK SENSOR2664
PROCEDURE TO INSTALL DEF TANK SENSOR2665
REMOVE AND INSTALL DEF TANK STRAINER2667
PROCEDURE TO REMOVE DEF TANK STRAINER2667
PROCEDURE TO INSTALL DEF TANK STRAINER2667
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2668
PROCEDURE TO REMOVE KDPF, SCR ASSEMBLY2669
PROCEDURE TO INSTALL KDPF, SCR ASSEMBLY2679
REMOVE AND INSTALL KDPF ASSEMBLY2689
PROCEDURE TO REMOVE KDPF ASSEMBLY2690
PROCEDURE TO INSTALL KDPF ASSEMBLY2694
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2699
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY2700
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY2705
REMOVE AND INSTALL SCR ASSEMBLY2710
PROCEDURE TO REMOVE SCR ASSEMBLY2710
PROCEDURE TO INSTALL SCR ASSEMBLY2713
REMOVE AND INSTALL KCCV ASSEMBLY2718
PROCEDURE TO REMOVE KCCV ASSEMBLY2718
PROCEDURE TO INSTALL KCCV ASSEMBLY2722
REMOVE AND INSTALL DEF MIXING TUBE2726
PROCEDURE TO REMOVE DEF MIXING TUBE2727
PROCEDURE TO INSTALL DEF MIXING TUBE2735
REMOVE AND INSTALL DEF INJECTOR2746
PROCEDURE TO REMOVE DEF INJECTOR2747
PROCEDURE TO INSTALL DEF INJECTOR2753
REMOVE AND INSTALL DEF PUMP2758
PROCEDURE TO REMOVE DEF PUMP2758
PROCEDURE TO INSTALL DEF PUMP2763
REMOVE AND INSTALL DEF HOSE2767
PROCEDURE TO REMOVE DEF HOSE2768
PROCEDURE TO INSTALL DEF HOSE2779
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2790
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY2790
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY2792
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2795
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2795
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2796
POWER TRAIN2797
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2797
PROCEDURE TO REMOVE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2798
PROCEDURE TO INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2810
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2825
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2825
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2837
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY2851
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY2852
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY2858
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY2868
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY2869
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY2886
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY2907
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY2907
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY2909
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY2911
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY2912
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY2917
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD2928
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD2928
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD2928
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY2929
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY2929
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY2929
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY2931
PROCEDURE TO DISASSEMBLE FRONT BRAKE CALIPER ASSEMBLY2931
PROCEDURE TO ASSEMBLE FRONT BRAKE CALIPER ASSEMBLY2932
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2934
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY2934
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY2935
REMOVE AND INSTALL PARKING BRAKE PAD ASSEMBLY2937
PROCEDURE TO REMOVE PARKING BRAKE PAD ASSEMBLY2937
PROCEDURE TO INSTALL PARKING BRAKE PAD ASSEMBLY2938
REMOVE AND INSTALL PARKING BRAKE CALIPER ASSEMBLY2940
PROCEDURE TO REMOVE PARKING BRAKE CALIPER ASSEMBLY2940
PROCEDURE TO INSTALL PARKING BRAKE CALIPER ASSEMBLY2940
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY2941
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2941
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY2942
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE ASSEMBLY2944
PROCEDURE TO DISASSEMBLE FINAL DRIVE ASSEMBLY2944
PROCEDURE TO ASSEMBLE FINAL DRIVE ASSEMBLY2948
REMOVE AND INSTALL SLACK ADJUSTER ASSEMBLY2953
PROCEDURE TO REMOVE SLACK ADJUSTER ASSEMBLY2953
PROCEDURE TO INSTALL SLACK ADJUSTER ASSEMBLY2954
STEERING SYSTEM2956
REMOVE AND INSTALL STEERING VALVE ASSEMBLY2956
PROCEDURE TO REMOVE STEERING VALVE ASSEMBLY2956
PROCEDURE TO INSTALL STEERING VALVE ASSEMBLY2959
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY2962
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY2962
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY2964
REMOVE AND INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY2967
PROCEDURE TO REMOVE SECONDARY STEERING MOTOR PUMP ASSEMBLY2967
PROCEDURE TO INSTALL SECONDARY STEERING MOTOR PUMP ASSEMBLY2970
UNDERCARRIAGE AND FRAME2973
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY2973
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY2973
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY2974
REMOVE AND INSTALL REAR WHEEL ASSEMBLY2976
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY2976
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY2978
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2980
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY2980
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY2981
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2984
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2984
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY2986
REMOVE AND INSTALL KING PIN2988
PROCEDURE TO REMOVE KING PIN2988
PROCEDURE TO INSTALL KING PIN2989
DISASSEMBLE AND ASSEMBLE OF VARIABLE DAMPING SELECTOR VALVE ASSEMBLY2990
PROCEDURE TO DISASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY2992
PROCEDURE TO ASSEMBLE VARIABLE DAMPING SELECTOR VALVE ASSEMBLY2992
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2994
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY2994
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY2994
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)2995
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY2995
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY2997
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY3000
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY3000
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY3001
HYDRAULIC SYSTEM3005
REMOVE AND INSTALL HOIST VALVE ASSEMBLY3005
PROCEDURE TO REMOVE HOIST VALVE ASSEMBLY3005
PROCEDURE TO INSTALL HOIST VALVE ASSEMBLY3008
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY3012
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY3013
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY3016
WORK EQUIPMENT3023
REMOVE AND INSTALL DUMP BODY ASSEMBLY3023
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY3023
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY3024
CAB AND ITS ATTACHMENTS3027
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY3027
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY3027
PROCEDURE TO INSTALL AIR CONDITIONER UNIT ASSEMBLY3035
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY3042
PROCEDURE TO REMOVE OPERATOR’S SEAT ASSEMBLY3042
PROCEDURE TO INSTALL OPERATOR’S SEAT ASSEMBLY3044
REMOVE AND INSTALL SEAT BELT3047
PROCEDURE TO REMOVE SEAT BELT3047
PROCEDURE TO INSTALL SEAT BELT3048
ELECTRICAL SYSTEM3049
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3049
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY3049
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY3050
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY3053
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY3053
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY3054
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY3055
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY3055
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY3056
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3057
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY3057
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY3059
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY3062
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY3062
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY3063
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3064
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR3064
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3065
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3067
PROCEDURE TO REMOVE SCR TEMPERATURE SENSOR3067
PROCEDURE TO INSTALL SCR TEMPERATURE SENSOR3069
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY3071
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY3071
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY3072
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3073
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY3073
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3077
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS3081
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS3081
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS3089
REMOVE AND INSTALL COMMUNICATION TERMINAL3096
METHOD FOR REMOVING COMMUNICATION TERMINAL3096
METHOD FOR INSTALLING COMMUNICATION TERMINAL3104
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3111
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR3111
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR3112
REMOVE AND INSTALL DRIVER STATUS MONITOR3113
HOW TO REMOVE DRIVER STATUS MONITOR3113
HOW TO INSTALL DRIVER STATUS MONITOR3114
REMOVE AND INSTALL TRANSLATOR CONTROLLER3116
HOW TO REMOVE TRANSLATOR CONTROLLER3116
HOW TO INSTALL TRANSLATOR CONTROLLER3117
REMOVE AND INSTALL DROWSINESS DETECTION CAMERA3119
HOW TO REMOVE DROWSINESS DETECTION CAMERA3119
HOW TO INSTALL DROWSINESS DETECTION CAMERA3120
REMOVE AND INSTALL DROWSINESS ALARM BUZZER3122
HOW TO REMOVE DROWSINESS ALARM BUZZER3122
HOW TO INSTALL DROWSINESS ALARM BUZZER3123
REMOVE AND INSTALL DROWSINESS DETECTION WIRING HARNESS3125
HOW TO REMOVE DROWSINESS DETECTION WIRING HARNESS3125
HOW TO INSTALL DROWSINESS DETECTION WIRING HARNESS3137
60 MAINTENANCE STANDARD3149
CONTENTS3150
ABBREVIATIONS3151
ENGINE AND COOLING SYSTEM3156
MAINTENANCE STANDARD OF ENGINE MOUNT3156
MAINTENANCE STANDARD OF OUTPUT SHAFT3157
MAINTENANCE STANDARD OF COOLING FAN AND HOIST PUMP3159
MAINTENANCE STANDARD OF SERVO VALVE OF COOLING FAN AND HOIST PUMP3160
MAINTENANCE STANDARD OF COOLING FAN MOTOR3161
POWER TRAIN3163
MAINTENANCE STANDARD OF DRIVE SHAFT3163
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT3164
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO3165
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE3168
MAINTENANCE STANDARD OF TRANSMISSION3169
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE3174
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV3175
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV3176
MAINTENANCE STANDARD OF FRONT AXLE3177
MAINTENANCE STANDARD OF REAR AXLE3178
MAINTENANCE STANDARD OF DIFFERENTIAL3179
MAINTENANCE STANDARD OF FINAL DRIVE3180
STEERING SYSTEM3181
MAINTENANCE STANDARD OF STEERING COLUMN3181
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE3182
MAINTENANCE STANDARD OF DEMAND VALVE3185
MAINTENANCE STANDARD OF STEERING CYLINDER3187
BRAKE SYSTEM3188
MAINTENANCE STANDARD OF SLACK ADJUSTER3188
MAINTENANCE STANDARD OF FRONT BRAKE3189
MAINTENANCE STANDARD OF REAR BRAKE3190
MAINTENANCE STANDARD OF PARKING BRAKE3191
UNDERCARRIAGE AND FRAME3193
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER3193
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER3195
MAINTENANCE STANDARD OF REAR AXLE SUPPORT3197
HYDRAULIC SYSTEM3198
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP3198
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND HOIST PUMP3199
MAINTENANCE STANDARD OF POWER TRAIN AND BRAKE CONTROL DUPLEX PUMP3201
MAINTENANCE STANDARD OF BRAKE COOLING DUPLEX PUMP3203
MAINTENANCE STANDARD OF HOIST VALVE3205
WORK EQUIPMENT3207
MAINTENANCE STANDARD OF HOIST CYLINDER3207
CAB AND ITS ATTACHMENTS3208
MAINTENANCE STANDARD OF CAB MOUNT3208
80 THE OTHER INFORMATION3209
CONTENTS3210
PRECAUTIONS BEFORE WORK3212
ABBREVIATIONS3213
AIR CONDITIONER SYSTEM3218
PRECAUTIONS FOR REFRIGERANT3218
AIR CONDITIONER COMPONENT3219
SPECIFICATIONS OF AIR CONDITIONER3221
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3222
OUTLINE OF REFRIGERATION CYCLE3223
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3225
AIR CONDITIONER UNIT3225
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3225
FUNCTION OF AIR CONDITIONER UNIT3226
COMPONENT PARTS OF AIR CONDITIONER UNIT3228
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3228
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3229
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3229
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3229
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3230
FUNCTION OF DUAL PRESSURE SWITCH3231
AIR CONDITIONER CONTROLLER3232
STRUCTURE OF AIR CONDITIONER CONTROLLER3232
COMPRESSOR3233
STRUCTURE OF COMPRESSOR3233
SPECIFICATIONS OF COMPRESSOR3233
FUNCTION OF COMPRESSOR3233
CONDENSER3234
STRUCTURE OF CONDENSER3234
SPECIFICATIONS OF CONDENSER3234
FUNCTION OF CONDENSER3234
SENSORS FOR AIR CONDITIONER SYSTEM3236
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3236
FUNCTION OF AMBIENT TEMPERATURE SENSOR3236
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3237
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3239
AIR CONDITIONER SYSTEM DIAGRAM3241
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3242
FUNCTION OF AIR CONDITIONER CONTROLLER3243
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3244
TESTING AIR LEAKAGE (DUCT)3247
METHOD FOR TESTING AIR LEAKAGE (DUCT)3247
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3250
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3252
TEST VENT (MODE) CHANGEOVER3254
METHOD FOR TESTING VENT (MODE) CHANGEOVER3254
TESTING FRESH/RECIRC AIR CHANGEOVER3255
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3255
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3256
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3256
TEST RELAYS3257
METHOD FOR TESTING RELAYS3257
AIR CONDITIONER TROUBLESHOOTING CHART 13258
AIR CONDITIONER TROUBLESHOOTING CHART 23259
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3262
FAILURE CODE [879AKA]3263
FAILURE CODE [879AKB]3264
FAILURE CODE [879BKA]3265
FAILURE CODE [879BKB]3266
FAILURE CODE [879CKA]3267
FAILURE CODE [879CKB]3268
FAILURE CODE [879EMC]3269
FAILURE CODE [879FMC]3270
FAILURE CODE [879GKX]3271
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3272
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3274
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3277
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3279
TROUBLESHOOTING USING GAUGE PRESSURE3281
CONNECTION OF SERVICE TOOL3284
METHOD FOR CONNECTING SERVICE TOOL3284
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3285
HANDLE COMPRESSOR OIL3287
METHOD FOR REPLACING DESICCANT3289
90 CIRCUIT DIAGRAMS3291
CONTENTS3292
ABBREVIATIONS3293
HYDRAULIC CIRCUIT DIAGRAM3298
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3298
HYDRAULIC CIRCUIT DIAGRAM3303
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM3305
ELECTRICAL CIRCUIT DIAGRAM3307
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3307
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/9)3311
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/9)3313
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/9)3315
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/9)3317
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/9)3319
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/9)3321
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/9)3323
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/9)3325
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (9/9)3327
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/10)3329
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/10)3331
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/10)3333
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/10)3335
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/10)3337
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/10)3339
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/10)3341
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/10)3343
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (9/10)3345
INTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (10/10)3347
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (1/8)3349
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (2/8)3351
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (3/8)3353
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (4/8)3355
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (5/8)3357
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (6/8)3359
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (7/8)3361
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with KOMTRAX terminal) (8/8)3363
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (1/8)3365
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (2/8)3367
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (3/8)3369
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (4/8)3371
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (5/8)3373
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (6/8)3375
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (7/8)3377
EXTERNAL CAB ELECTRICAL DIAGRAM (For machines equipped with gateway function controller) (8/8)3379
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE3381
ELECTRICAL CIRCUIT DIAGRAM (DROWSINESS DETECTION SYSTEM (DDS))3383
INDEX3385
S.M 30/12/24
