Komatsu Dump Truck HD465, HD605 Repair Service Manual + Operation & Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Trucks HD465, HD605, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Dump Truck HD465-2, HD465-3, HD465-5, HD465-7, HD465-8, HD605-5, HD605-7, HD465-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 9,971 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM0569C02 - Mechanical Truck HD465-2 Shop Manual.pdf
SEBM0569S308 - Dump Truck HD465-3 Shop Manual.pdf
SEBM015209 - Dump Truck HD465-5, HD605-5 Shop Manual.pdf
SEBM027616 - Dump Truck HD465-7, HD605-7 Shop Manual.pdf
SEBM05690507 - Dump Truck HD465-5 Shop Manual.pdf
SEN06605-04 - Dump Truck HD465-8, HD605-8 Shop Manual.pdf
GEN00010-01 - Dump Truck HD465-7, HD605-7 Field Assembly Instruction.pdf
GEN00026-00 - Dump Truck HD465-5, HD605-5 Field Assembly Instruction.pdf
SEAM0569S300 - Dump Truck HD465-3 Operation & Maintenance Manual.pdf
SEAM0569S301 - Dump Truck HD465-3 Operation & Maintenance Manual.pdf
SEAM0569S303 - Dump Truck HD465-3 Operation & Maintenance Manual.pdf
SEAM05690500 - Dump Truck HD465-5 Operation & Maintenance Manual.pdf
SEAM05690508 - Dump Truck HD465-5, HD605-5 Operation & Maintenance Manual.pdf
SEAM05690513T - Dump Truck HD465-5, HD605-5 Operation & Maintenance Manual.pdf
TEN00017-05 - Dump Truck GALEO HD465-7, HD605-7 Operation & Maintenance Manual.pdf
TEN00271-03 - Dump Truck HD465-7, HD605-7 Operation & Maintenance Manual.pdf
MAIN SECTIONS
COVER...1
00 INDEX AND FOREWORD...3
INDEX...4
ABBREVIATIONS...25
FOREWORD, SAFETY, BASIC INFORMATION...30
HOW TO READ THE SHOP MANUAL...30
Configuration of the shop manual...30
Symbols...30
Signal word...31
Unit...31
SAFETY NOTICE FOR OPERATION...32
Safety matters...32
General precautions...32
Preliminary work precautions...33
Precautions during work...33
Hand signals and use of sling precautions...35
Precautions when using a mobile crane...36
Precautions when using an overhead crane...36
Select wire ropes...37
Precautions when you disconnect air conditioner piping...38
Precautions for air conditioner piping...38
PRECAUTIONS TO PREVENT FIRE...40
Fire caused by fuel, oil, coolant or window washer fluid...40
Fire caused by accumulation or flammable material...40
Fire caused from electrical wires...40
Fire caused by piping...40
Fire around the machine because of hot exhaust gas...40
Explosion caused by lighting equipment...40
ACTIONS IF FIRE OCCURS...41
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS...41
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS...42
PRECAUTIONS FOR DEF...43
GENERAL CHARACTER AND PRECAUTIONS FOR USAGE...43
PRECAUTIONS WHEN YOU ADD DEF...43
PRECAUTIONS WHEN YOU STORE DEF...43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...43
THE OTHER PRECAUTIONS...43
DEF STORAGE PRECAUTIONS...44
How you handle AdBlue/DEF in cold weather...44
PRECAUTIONS WHEN YOU HANDLE HYDRAULIC EQUIPMENT...45
Select an appropriate workplace...45
Disassemble and maintenance work outdoors...45
Seal openings and prevent oil flow...45
Prevent unwanted materials during fill...45
Change hydraulic oil while its temperature is high...46
Flush operation...46
Clean operation...46
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPES...47
Precautions for removal and disassemble work...47
Parts for disassemble of the face type seals on hoses and piping...47
Parts for the removal of hoses and piping with taper seals...48
Parts to disconnect split flange type on hoses and piping...48
Parts to remove an o-ring boss type joint...49
Parts to remove taper pipe thread type joint...50
Precautions for installation and assembly work...50
Precaution at the time work is done...51
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT...53
Handle wire harness and connectors...53
Primary causes of failure in wiring harness...53
PRECAUTIONS WHEN YOU HANDLE FUEL SYSTEM EQUIPMENT...55
Select an appropriate workplace...55
Seal opening...55
How to clean parts when dirt is stuck...55
Precautions when you replace fuel filter cartridge...55
PRECAUTIONS WHEN YOU HANDLE INTAKE SYSTEM EQUIPMENT...56
Select an appropriate workplace...56
Seal opening...56
PRACTICAL USEAGE OF KOMTRAX...57
Value of using KOMTRAX...57
How to use KOMTRAX...57
How to operate KOMTRAX...57
DISCONNECT AND CONNECT PUSH PULL TYPE QUICK DISCONNECT...58
PROCEDURE TO DISCONNECT AND CONNECT TYPE 1 PUSH PULL TYPE QUICK DISCONNECT...58
PROCEDURE TO DISCONNECT AND CONNECT TYPE 2 PUSH PULL TYPE QUICK DISCONNECT...59
PROCEDURE TO DISCONNECT AND CONNECT TYPE 3 PUSH PULL TYPE QUICK DISCONNECT...60
PRECAUTIONS FOR DISCONNECT AND CONNECT OF CONNECTORS...62
Disconnect connectors...62
Connect connectors...63
Blow dry wiring harness...64
Handle controller...65
Precautions for when you troubleshoot electrical circuits...65
PROCEDURE TO DISCONNECT AND CONNECT DEUTSCH CONNECTOR...66
Procedure to disconnect Deutsch connector...66
Procedure to connect Deutsch connector...66
PROCEDURE TO DISCONNECT AND CONNECT SLIDE LOCK CONNECTOR...67
Procedure to disconnect slide lock connector (FRAMATOME-3, FRAMATOME-2)...67
Procedure to connect slide lock connector (FRAMATOME-3, FRAMATOME- 2)...67
Procedure to disconnect slide lock connector (FRAMATOME-24)...67
Procedure to connect slide lock connector (FRAMATOME-24)...68
PROCEDURE TO DISCONNECT AND CONNECT PULL TO LOCK TYPE CONNECTOR...69
Procedure to disconnect pull to lock type connector...69
Procedure to connect pull to lock type connector...69
PROCEDURE TO DISCONNECT AND CONNECT PUSH TO LOCK TYPE CONNECTOR...70
Procedure to disconnect push to lock type connector (BOSCH-3)...70
Procedure to connect push to lock type connector (BOSCH-3)...70
Procedure to disconnect push to lock type connector (AMP-3)...71
Procedure to connect push to lock type connector (AMP-3)...71
Procedure to disconnect push to lock type connector (SUMITOMO-3)...71
Procedure to connect push to lock type connector (SUMITOMO-3)...71
Procedure to disconnect push to lock type connector (SUMITOMO-4)...71
Procedure to connect push to lock type connector (SUMITOMO-4)...71
PROCEDURE TO DISCONNECT AND CONNECT TWIST TYPE CONNECTORS...72
Procedure to disconnect twist type connector...72
Procedure to connect twist type connector...72
HOW TO READ ELECTRICAL WIRE CODES...73
Type, symbol, and material...73
Dimensions...73
Color codes table...75
Types of circuits and color codes...76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...77
Standard dimension and tolerance...77
Standard clearance and standard value...78
Standard interference...78
Repair limit and approved value or permitted dimension...78
Permitted clearance...78
Permitted interference...78
STANDARD VAULE TIGHTEN TABLE...79
Table of tighten values for bolts and nuts...79
Table of tighten value for o-ring boss piping joints...82
Table of tighten value for o-ring boss plugs...82
Table of tighten value for hoses (Taper seal and face seal type)...83
Table of tighten value for face seal joints...84
Tighten value table for bolts and nuts on 102,107 and 114 engines...84
Tighten value table for 102, 107, and 114 engines (joint bolts)...85
Tighten value table for tapered screws on 102, 107, and 114 engines (NPT)...85
CONVERSION TABLE...86
Procedure for using the conversion table...86
Examples of using the conversion table to convert a unit from mm to in...86
mm to in...86
mm to in...86
kg to lb...87
l to U.S.Gal...87
l to U.K.Gal...87
kgm to lbft...88
kg/cm2 to lb/in2...88
Temperature...89
01 SPECIFICATIONS...91
CONTENTS...92
ABBREVIATIONS...93
SPECIFICATIONS...98
DIAGRAM SPECIFICATION...98
DIAGRAM SPECIFICATION: HD465-8...98
DIAGRAM SPECIFICATION: HD605-8...100
SPECIFICATIONS...102
SPECIFICATIONS: HD465-8...102
SPECIFICATIONS: HD605-8...107
WEIGHT TABLE...112
WEIGHT TABLE: HD465-8...112
WEIGHT TABLE: HD605-8...113
TABLE OF APPROVED FUEL, COOLANT, AND LUBRICANTS...114
10 STRUCTURE AND FUNCTION...117
CONTENTS...118
ABBREVIATIONS...122
BOOT-UP SYSTEM...127
BOOT-UP SYSTEM DIAGRAM...127
SYSTEM IN OPERATION LAMP...128
OPERATION LAMP SYSTEM DIAGRAM...128
FUNCTION OF OPERATION LAMP SYSTEM...128
BATTERY DISCONNECT SWITCH...129
BATTERY DISCONNECT SWITCH DIAGRAM...129
FUNCTION OF BATTERY DISCONNECT SWITCH...130
ENGINE SYSTEM...133
ENGINE SYSTEM DIAGRAM...133
FUNCTION OF ENGINE SYSTEM...134
ENGINE CONTROL SYSTEM...135
ENGINE CONTROL SYSTEM DIAGRAM...135
AUTOMATIC IDLE STOP SYSTEM...139
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...139
ENGINE COMPONENTS...141
OUTPUT SHAFT...141
VGT...142
EGR SYSTEM...146
EGR valve...148
EGR COOLER...150
KCCV SYSTEM...151
KCCV VENTILATOR...153
KDPF...155
COOLING SYSTEM...159
COOLING SYSTEM DIAGRAM...159
SPECIFICATIONS OF COOLING SYSTEM...160
RADIATOR FAN CONTROL SYSTEM...161
RADIATOR FAN CONTROL SYSTEM DIAGRAM...161
FUNCTION OF RADIATOR FAN CONTROL SYSTEM...161
COOLING SYSTEM COMPONENTS...163
COOLING FAN PUMP...163
CONTROL SYSTEM...177
CONTROL SYSTEM DIAGRAM...177
RETARDER AND HOIST CONTROL SYSTEM...178
RETARDER AND HOIST CONTROL SYSTEM DIAGRAM...178
MACHINE MONITOR SYSTEM...180
MACHINE MONITOR SYSTEM DIAGRAM...180
FUNCTION OF MACHINE MONITOR SYSTEM...181
REARVIEW MONITOR SYSTEM...182
REARVIEW MONITOR SYSTEM DIAGRAM...182
FUNCTION OF REARVIEW MONITOR SYSTEM...182
KOMTRAX PLUS SYSTEM...183
KOMTRAX PLUS SYSTEM DIAGRAM...183
FUNCTION OF KOMTRAX PLUS SYSTEM...185
PAYLOAD METER SYSTEM...188
PAYLOAD METER SYSTEM DIAGRAM...188
PAYLOAD METER SYSTEM DIAGRAM...189
FUNCTION OF PAYLOAD METER SYSTEM...189
MEASUREMENT PRINCIPLE OF LOADING MASS...190
CONTROL SYSTEM COMPONENTS...199
MACHINE MONITOR...199
SWITCH PANEL...216
REARVIEW MONITOR...217
REARVIEW CAMERA...218
KOMTRAX TERMINAL...219
KOMTRAX PLUS CONTROLLER...221
STRUCTURE OF KOMTRAX PLUS CONTROLLER...221
INPUT AND OUTPUT SIGNALS OF KOMTRAX PLUS CONTROLLER...221
WIRELESS LAN UNIT...225
STRUCTURE OF WIRELESS LAN UNIT...225
FUNCTION OF WIRELESS LAN UNIT...225
INPUT AND OUTPUT SIGNALS OF WIRELESS LAN UNIT...225
TRANSMISSION CONTROLLER...226
RETARDER AND HOIST CONTROLLER...230
MONITOR CONTROLLER...234
ENGINE CONTROLLER...239
ACCELERATOR PEDAL...251
GEAR SHIFT LEVER...252
RETARDER CONTROL LEVER...253
HYDRAULIC SYSTEM...254
HYDRAULIC SYSTEM DIAGRAM...254
HYDRAULIC SYSTEM COMPONENTS...255
HYDRAULIC TANK...255
STEERING AND HOIST PUMP...256
LS VALVE...262
CO VALVE...263
POWER TRAIN AND BRAKE COOLING DUPLEX PUMP...266
BRAKE COOLING, CONTROL TRIPLE PUMP...267
HOIST VALVE...269
POWER TRAIN SYSTEM...275
POWER TRAIN DIAGRAM...275
TRANSMISSION CONTROL SYSTEM...276
TRANSMISSION CONTROL SYSTEM DIAGRAM...276
GEAR SHIFT LEVER POSITIONS AND AUTOMATIC GEAR SHIFT RANGE...278
GEAR SHIFT CONTROL SYSTEM...282
AUTOMATIC GEAR SHIFT CONTROL OF GEAR SHIFT CONTROL SYSTEM...282
DIRECTION CONTROL SYSTEM...284
RIM PULL LIMIT FUNCTION FOR OVERLOAD PREVENTION OF DIRECTION CONTROL SYSTEM...284
FUNCTION OF THROTTLE LIMIT FUNCTION AT F1 START AT D POSITION SETTING OF DIRECTION CONTROL SYSTEM...284
KOMATSU TRACTION CONTROL SYSTEM (KTCS)...285
KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM DIAGRAM...285
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)...285
OPERATION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) SYSTEM LOGIC...286
TRAVEL SPEED LIMITATION SYSTEM...287
SYSTEM DIAGRAM OF TRAVEL SPEED LIMITATION SYSTEM...287
FUNCTION OF TRAVEL SPEED LIMITATION SYSTEM...288
OPERATION OF TRAVEL SPEED LIMITATION SYSTEM...289
POWER TRAIN COMPONENTS...291
DRIVE SHAFT...291
TORQUE CONVERTER AND PTO...293
LOCKUP CLUTCH ECMV...297
TRANSMISSION...300
TRANSMISSION CONTROL VALVE...317
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV...319
AXLE...328
DIFFERENTIAL...330
FINAL DRIVE...332
WORK EQUIPMENT SYSTEM...333
WORK EQUIPMENT CONTROL...333
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM...333
FUNCTION OF WORK EQUIPMENT CONTROL...333
HOIST CONTROL...334
HOIST CONTROL SYSTEM DIAGRAM...334
FUNCTION OF HOIST CONTROL...334
WORK EQUIPMENT SYSTEM COMPONENTS...336
DUMP LEVER...336
HOIST EPC VALVE...341
STEERING SYSTEM...342
STEERING SYSTEM DIAGRAM...342
STEERING SYSTEM FUNCTION...343
STEERING COLUMN...344
STRUCTURE OF STEERING COLUMN...344
STEERING LINKAGE...345
STRUCTURE OF STEERING LINKAGE...345
STEERING SYSTEM COMPONENTS...346
DEMAND VALVE...346
STEERING RELIEF VALVE...353
STRUCTURE OF STEERING RELIEF VALVE...353
FUNCTION OF STEERING RELIEF VALVE...353
OPERATION OF STEERING RELIEF VALVE...353
ORBITAL VALVE...354
STEERING PUMP SELECTOR SOLENOID VALVE...360
CROSS-OVER RELIEF VALVE...361
SECONDARY STEERING PUMP...362
SECONDARY STEERING MOTOR...363
BRAKE SYSTEM...364
BRAKE SYSTEM DIAGRAM...364
RETARDER CONTROL...366
RETARDER CONTROL SYSTEM DIAGRAM...366
FUNCTION OF RETARDER CONTROL...366
ARSC SYSTEM...367
ARSC SYSTEM DIAGRAM...367
FUNCTION OF ARSC SYSTEM...367
BRAKE SYSTEM COMPONENTS...368
BRAKE CHARGE PUMP...368
PARKING BRAKE SOLENOID VALVE...369
ACCUMULATOR CHARGE VALVE...370
BRAKE CIRCUIT ACCUMULATOR...374
BRAKE VALVE...375
SECONDARY BRAKE VALVE...378
SECONDARY BRAKE RELAY VALVE...379
PROPORTION PRESSURE REDUCING VALVE...380
SLACK ADJUSTER...381
BRAKE...383
PARKING BRAKE...386
BRAKE SUB-TANK...388
UNDERCARRIAGE AND FRAME...389
SUSPENSION...389
STRUCTURE OF SUSPENSION...389
FUNCTION OF SUSPENSION...389
FRONT SUSPENSION...390
STRUCTURE OF FRONT SUSPENSION...390
FUNCTION OF FRONT SUSPENSION...391
REAR SUSPENSION...392
STRUCTURE OF REAR SUSPENSION...392
FUNCTION OF REAR SUSPENSION...393
SUSPENSION CYLINDER...394
STRUCTURE OF SUSPENSION CYLINDER...394
FUNCTION OF SUSPENSION CYLINDER...394
OPERATION OF SUSPENSION CYLINDER...394
WORK EQUIPMENT...396
STRUCTURE OF WORK EQUIPMENT...396
FUNCTION OF WORK EQUIPMENT...396
CAB AND ATTACHMENTS...397
ROPS CAB...397
STRUCTURE OF ROPS CAB...397
FUNCTION OF ROPS CAB...397
CAB MOUNT...398
STRUCTURE OF CAB MOUNT...398
FUNCTION OF CAB MOUNT...398
20 STANDARD VALUE TABLE...399
CONTENTS...400
ABBREVIATIONS...401
STANDARD VALUE TABLE FOR ENGINE...406
STANDARD VALUE TABLE FOR ENGINE: HD465-8...406
STANDARD VALUE TABLE FOR ENGINE: HD605-8...409
STANDARD VALUE TABLE FOR MACHINE...412
STANDARD VALUE TABLE FOR MACHINE: HD465-8...412
STANDARD VALUE TABLE FOR MACHINE: HD605-8...425
MACHINE SETTING AND PROCEDURE TO MEASURE PERFORMANCE...438
30 TEST AND ADJUST...439
CONTENTS...440
ABBREVIATIONS...444
RELATED INFORMATION TO TEST AND ADJUST...449
TOOLS TO TEST AND ADJUST...449
DIAGRAM FOR TEST AND ADJUST TOOLS...459
ENGINE AND COOLING SYSTEM...460
TEST ENGINE SPEED...460
PROCEDURE TO TEST ENGINE SPEED...460
TEST BOOST PRESSURE...462
BOOST PRESSURE TEST BY MACHINE MONITOR...462
PROCEDURE TO TEST BOOST PRESSURE WITH TEST TOOLS...464
TEST EXHAUST GAS TEMPERATURE...466
EXHAUST GAS TEMPERATURE TEST BY THE MACHINE MONITOR...466
PROCEDURE TO TEST EXHAUST GAS TEMPERATURE...468
TEST EXHAUST GAS COLOR...470
TEST EXHAUST GAS COLOR WITH THE HANDY SMOKE CHECKER...470
TEST EXHAUST GAS COLOR WITH SMOKE METER...471
TEST AND ADJUST VALVE CLEARANCE...473
TEST VALVE CLEARANCE...473
ADJUST VALVE CLEARANCE...474
COMPRESSION TEST...476
COMPRESSION PRESSURE TEST...476
BLOWBY PRESSURE TEST...480
BLOWBY PRESSURE TEST...480
TEST ENGINE OIL PRESSURE...483
ENGINE OIL PRESSURE TEST BY MACHINE MONITOR...483
TEST ENGINE OIL PRESSURE...483
EGR VALVE AND VGT OIL PRESSURE TEST...485
EGR VALVE AND VGT OIL PRESSURE TEST...485
FUEL PRESSURE TEST...486
FUEL PRESSURE TEST...486
FUEL RETURN RATE AND LEAKAGE TEST...488
FUEL RETURN RATE AND LEAKAGE TEST...489
BLEED AIR FROM FUEL SYSTEM...492
BLEED AIR FROM FUEL SYSTEM...492
FUEL CIRCUIT LEAK TEST...494
FUEL CIRCUIT LEAK TEST...494
SUPPLY PUMP TEST...496
SUPPLY PUMP TEST...496
CYLINDER CUT-OUT MODE...499
NO-INJECTION CRANKING...500
CLEAN FUEL DOSER...501
CLEAN FUEL DOSER...501
PROGRAM INJECTOR TRIM CODE VALUE TO ENGINE CONTROLLER...503
PROCEDURE TO PROGRAM INJECTOR TRIM CODE VALUE...504
PROGRAM ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLER...510
PROCEDURE TO PROGRAM SOOT ASH ACCUMULATION CORRECTION TO ENGINE CONTROLLER...510
TEST TORQUE CONVERTER STALL SPEED...511
TEST TORQUE CONVERTER STALL SPEED...511
RADIATOR FAN SPEED TEST...513
RADIATOR FAN SPEED TEST...513
POWER TRAIN...515
TEST POWER TRAIN OIL PRESSURE...515
POWER TRAIN OIL PRESSURE TEST...518
ADJUST TRANSMISSION INPUT SPEED SENSOR...529
ADJUST TRANSMISSION INPUT SPEED SENSOR...529
ADJUST TRANSMISSION INTERMEDIATE SPEED SENSOR...530
ADJUST THE TRANSMISSION INTERMEDIATE SPEED SENSOR...530
ADJUST TRANSMISSION OUTPUT SPEED SENSOR...531
ADJUST TRANSMISSION OUTPUT SPEED SENSOR...531
CHECK AFTER ADJUSTMENT OF TRANSMISSION SPEED SENSORS...532
PROCEDURE TO CHECK AFTER ADJUSTMENT THE TRANSMISSION SPEED SENSORS...532
MOVE A MACHINE WITH ELECTRICAL SYSTEM PROBLEMS...533
MOVE A MACHINE WITH ENGINE CONTROL SYSTEM PROBLEMS...533
PROCEDURE TO MOVE MACHINE WITH TRANSMISSION CONTROL SYSTEM PROBLEM...534
STEERING SYSTEM...538
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE...538
EST STEERING CIRCUIT OIL PRESSURE WITH THE MACHINE MONITOR...538
TEST STEERING CIRCUIT PRESSURE WITH TEST TOOLS...538
PROCEDURE FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE...539
TEST SUPPLY PRESSURE OF ORBITAL VALVE...541
TEST SUPPLY PRESSURE FOR THE ORBITAL VALVE...541
TEST STEERING CYLINDER PRESSURE...543
PROCEDURE TO TEST STEERING CYLINDER PRESSURE...543
BLEED AIR FROM STEERING CYLINDER CIRCUIT...545
PROCEDURE TO BLEED AIR FROM STEERING CYLINDER CIRCUIT...545
BRAKE SYSTEM...546
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...546
RELEASE THE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...546
TEST WHEEL BRAKE OIL PRESSURE...547
FRONT BRAKE ACCUATION PRESSURE TEST...547
REAR BRAKE ACTUATON PRESSURE TEST...548
RETARDER BRAKE PRESSURE TEST...549
RETARDER BRAKE ACTUATOIN PRESSURE TEST (FOR MACHINE WITH KTCS)...550
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE...551
MEASURE BRAKE ACCUMULATOR PRESSURE USING THE MONITOR...551
TEST BRAKE ACCUMULATOR PRESSURE WITH TEST TOOLS...551
ADJUST BRAKE ACCUMULATOR PRESSURE...553
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS...554
FRONT BRAKE ACCUMULATOR NITROGEN GAS PRESSURE TEST...554
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE (REAR BRAKE AND PARKING BRAKE)...558
PROCEDURE TO PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS...561
TEST BRAKE PERFORMANCE...563
TEST FOOT BRAKE PERFORMANCE...563
PROCEDURE TO TEST RETARDER BRAKE PERFORMANCE...564
PROCEDURE TO TEST PARKING BRAKE PERFORMANCE...565
BLEED AIR FROM BRAKE CIRCUIT...566
PROCEDURE TO BLEED AIR FROM FRONT BRAKE CIRCUIT...566
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT...567
(FOR MACHINE WITHOUT KTCS)...567
PROCEDURE TO BLEED AIR FROM REAR BRAKE CIRCUIT...568
(FOR MACHINE WITH KTCS)...568
PROCEDURE TO BLEED AIR FROM PARKING BRAKE CIRCUIT...570
TEST PARKING BRAKE OIL PRESSURE...572
PROCEDURE TO TEST PARKING BRAKE OIL PRESSURE...572
RELEASE PARKING BRAKE MANUALLY...573
PROCEDURE TO RELEASE THE PARKING BRAKE MANUALLY...573
TEST THE AMOUNT OF FRONT BRAKE PAD WEAR...574
PROCEDURE TO VISUALLY TEST THE AMOUNT OF FRONT BRAKE PAD WEAR...574
PROCEDURE TO TEST FRONT BRAKE PAD WEAR WITH GAUGE MEASURE...575
TEST THE QUANTITY OF REAR BRAKE DISC WEAR...576
PROCEDURE TO TEST THE QUANTITY OF REAR BRAKE DISC WEAR...576
HYDRAULIC SYSTEM...577
TEST AND ADJUST HOIST CIRCUIT OIL PRESSURE...577
PROCEDURE TO TEST HOIST CIRCUIT OIL PRESSURE...577
PROCEDURE TO ADJUST HOIST CIRCUIT OIL PRESSURE...578
TEST HOIST CYLINDER SUPPLY PRESSURE...579
PROCEDURE TO TEST HOIST CYLINDER SUPPLY PRESSURE...579
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT...581
PROCEDURE TO TEST HOIST EPC VALVE SUPPLY PRESSURE...581
PROCEDURE TO TEST HOIST EPC VALVE OUTLET PRESSURE...582
TEST RADIATOR FAN CIRCUIT OIL PRESSURE...583
PROCEDURE TO TEST RADIATOR FAN CIRCUIT OIL PRESSURE...583
TEST AND ADJUST FRONT SUSPENSION CYLINDER...585
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER...585
PROCEDURE TO ADJUST FRONT SUSPENSION CYLINDER...586
TEST AND ADJUST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)...590
PROCEDURE TO TEST FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)...590
PROCEDURE FOR ADJUSTING FRONT SUSPENSION CYLINDER (AUTOMATIC SUSPENSION SPECIFICATION)...591
TEST AND ADJUST REAR SUSPENSION CYLINDER...593
PROCEDURE TO TEST REAR SUSPENSION CYLINDER...593
PROCEDURE TO ADJUST REAR SUSPENSION CYLINDER...594
TEST KTCS CIRCUIT OIL PRESSURE (FOR MACHINE WITH KTCS)...598
PROCEDURE TO TEST KTCS CIRCUIT OIL PRESSURE USING THE MACHINE MONITOR...598
PROCEDURE TO TEST THE OIL PRESSURE OF KTCS CIRCUIT WITH TEST TOOLS...598
WORK EQUIPMENT...600
TEST AND ADJUST DUMP BODY POSITION SENSOR...600
PROCEDURE TO TEST THE BODY POSITION SENSOR...600
PROCEDURE TO ADJUST DUMP BODY POSITION SENSOR...600
PROCEDURE TO CALIBRATION AFTER YOU ADJUST BODY POSITION SENSOR...600
LOWER THE BODY MANUALLY...602
PROCEDURE TO LOWER THE BODY MANUALLY...602
LIFT THE BODY MANUALLY...603
PROCEDURE TO RAISE THE BODY MANUALLY...603
CAB AND ATTACHMENTS...604
ADJUST STEERING WHEEL TILT LOCK LEVER...604
PROCEDURE TO ADJUST STEERING WHEEL TILT LOCK LEVER...604
ELECTRICAL SYSTEM...606
SET AND ADJUST EACH EQUIPMENT...606
SET AND OPERATE OF MACHINE MONITOR...609
OPERATOR MODE...612
SERVICE MODE...625
ABNORMALITY RECORD MENU...650
DEFAULT MENU...665
DIAGNOSTIC TESTS...682
ADJUSTMENT MENU...693
PROCEDURE TO CRANK WITH NO-INJECTION...720
PAYLOAD METER SETTING...722
PROCEDURE FOR MANUAL SNAP SHOT...741
KOMTRAX SETTINGS MENU...744
PROCEDURE TO DISPLAY SERVICE MESSAGE...746
PROCEDURE FOR STARTING UP KOMTRAX TERMINAL...748
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER...753
PROCEDURE FOR SETTING WITH DEFAULT SETTING OF KOMTRAX Plus CONTROLLER...753
SETTING DEFAULT OF WIRELESS LAN MODEM...755
PROCEDURE FOR SETTING DEFAULT OF WIRELESS LAN MODEM...755
PROCEDURE TO CHECK WIRELESS LAN MODEM COMMUNICATION...756
DOWNLOAD KOMTRAX Plus CONTROLLER DATA...758
PROCEDURE FOR DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA...758
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED...762
PROCEDURE TO ADJUST KOMTRAX Plus CONTROLLER WHEN REPLACED...762
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED...765
PROCEDURE FOR ADJUSTMENT WHEN WIRELESS LAN MODEM IS REPLACED...765
ADJUST REARVIEW CAMERA ANGLE...767
PROCEDURE TO ADJUST REARVIEW CAMERA ANGLE...767
ENGINE CONTROLLER VOLTAGE CIRCUIT WORK...768
BATTERY DISCONNECT SWITCH WORK...769
TEST DIODES...770
PROCEDURE TO TEST DIODE USING DIGITAL TESTER...770
PROCEDURE TO TEST DIODE USING ANALOG TESTER...770
Pm CLINIC...771
Pm CLINIC SERVICE...771
Pm CLINIC CHECK SHEET: HD465-8...774
Pm CLINIC CHECK SHEET: HD605-8...781
PERFORM QUICK Pm...788
PROCEDURE TO PERFORM QUICK Pm...788
40 TROUBLESHOOTING...793
CONTENTS...794
ABBREVIATIONS...807
RELATED INFORMATION ON TROUBLESHOOTING...812
GENERAL TROUBLESHOOTING POINTS...812
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEMS...813
SEQUENCE OF EVENTS IN TROUBLESHOOTING...819
CHECKS BEFORE TROUBLESHOOTING...821
INSPECTION PROCEDURE BEFORE YOU TROUBLESHOOT...824
WALK AROUND INSPECTION...824
TEST, REFER TO THE TEST PROCEDURE...825
CHECK FUEL LEVEL AND TYPE...825
EXAMINE FOR UNWANTED MATERIAL IN FUEL...825
INSPECT INITIAL FUEL FILTER...825
EXAMINE PRIMARY FILTER...827
ENGINE OIL PAN - INSPECT ENGINE OIL LEVEL AND TYPE...829
CHECK COOLANT LEVEL (RESERVE TANK)...829
EXAMINE BLOCKAGE OF AIR CLEANER...831
OUTER ELEMENT - CLEAN...832
REPLACE ELEMENT...834
INSPECT HYDRAULIC OIL LEVEL...835
INSPECT HYDRAULIC OIL SCREEN FILTER...836
INSPECT THE HYDRAULIC FILTER...836
CHECK OIL LEVEL IN TRANSMISSION CASE...837
CHECK OIL LEVEL IN DIFFERENTIAL CASE...837
CHECK OIL LEVEL IN FINAL DRIVE CASE...837
BLEED AIR FROM FUEL SYSTEM...838
BLEED AIR FROM HYDRAULIC SYSTEM...838
PROCEDURE TO INSPECT ELECTRICAL EQUIPMENT...838
ELECTRICAL SYSTEM TROUBLESHOOT - PREPARATION...844
PROCEDURE TO TEST AND TROUBLESHOOT...854
SYMPTOM AND TROUBLESHOOT NUMBERS...856
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...860
CONNECTORS LIST AND LAYOUT...862
CONNECTOR CONTACT IDENTIFICATION...883
T-BOX AND T-ADAPTER TABLE...923
FUSE LOCATION TABLE...929
PRECAUTIONS TO CLEAN AND REPLACE KDPF (KCSF and KDOC)...935
PREPARE TO TROUBLESHOOT THE MACHINE MONITOR...939
PROCEDURE TO CREATE A CHECK HARNESS FOR THE MACHINE MONITOR LCD UNIT...941
PREPARE THE SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883], [CB1883], [CA3135], AND [CB3135])...947
FAILURE CODES TABLE...949
TROUBLESHOOT BY FAILURE CODE (DISPLAY OF CODE)...971
FAILURE CODE [1500L0]...971
FAILURE CODE [15B0NX]...972
FAILURE CODE [15F0KM]...974
FAILURE CODE [15F0MB]...975
FAILURE CODE [15F7KM]...976
FAILURE CODE [15G0MW]...977
FAILURE CODE [15G7KM]...978
FAILURE CODE [15H0MW]...979
FAILURE CODE [15J0MW]...980
FAILURE CODE [15K0MW]...981
FAILURE CODE [15L0MW]...983
FAILURE CODE [15M0MW]...985
FAILURE CODE [15N0MW]...987
FAILURE CODE [15SBL1]...989
FAILURE CODE [15SBMA]...992
FAILURE CODE [15SCL1]...993
FAILURE CODE [15SCMA]...996
FAILURE CODE [15SDL1]...997
FAILURE CODE [15SDMA]...1000
FAILURE CODE [15SEL1]...1001
FAILURE CODE [15SEMA]...1004
FAILURE CODE [15SFL1]...1005
FAILURE CODE [15SFMA]...1008
FAILURE CODE [15SGL1]...1009
FAILURE CODE [15SGMA]...1012
FAILURE CODE [15SHL1]...1013
FAILURE CODE [15SHMA]...1016
FAILURE CODE [15SJMA]...1017
FAILURE CODE [2C4MNX]...1018
FAILURE CODE [2F00KM]...1019
FAILURE CODE [2G42ZG]...1023
FAILURE CODE [2G43ZG]...1024
FAILURE CODE [6014NX]...1025
FAILURE CODE [879AKA]...1026
FAILURE CODE [879AKB]...1027
FAILURE CODE [879BKA]...1028
FAILURE CODE [879BKB]...1029
FAILURE CODE [879CKA]...1031
FAILURE CODE [879CKB]...1032
FAILURE CODE [879EMC]...1033
FAILURE CODE [879FMC]...1034
FAILURE CODE [879GKX]...1035
FAILURE CODE [989D00]...1036
FAILURE CODE [989L00]...1037
FAILURE CODE [989M00]...1038
FAILURE CODE [989N00]...1039
FAILURE CODE [989X00]...1040
FAILURE CODE [989Y00]...1041
FAILURE CODE [A1U0N3]...1042
FAILURE CODE [A1U0N4]...1043
FAILURE CODE [AA10NX]...1045
FAILURE CODE [AB00KE]...1047
FAILURE CODE [AB00KY]...1049
FAILURE CODE [AQ00N3]...1050
FAILURE CODE [AQ00N4]...1051
FAILURE CODE [AQ10N3]...1052
FAILURE CODE [B@BAZG]...1053
FAILURE CODE [B@BAZK]...1054
FAILURE CODE [B@BCNS]...1055
FAILURE CODE [B@BCZK]...1056
FAILURE CODE [B@C7NS]...1057
FAILURE CODE [B@CENS]...1059
FAILURE CODE [B@JANS]...1060
FAILURE CODE [CA115]...1061
FAILURE CODE [CA122]...1064
FAILURE CODE [CA123]...1066
FAILURE CODE [CA131]...1068
FAILURE CODE [CA132]...1070
FAILURE CODE [CA135]...1072
FAILURE CODE [CA141]...1074
FAILURE CODE [CA144]...1076
FAILURE CODE [CA145]...1078
FAILURE CODE [CA153]...1080
FAILURE CODE [CA154]...1082
FAILURE CODE [CA187]...1084
FAILURE CODE [CA212]...1086
FAILURE CODE [CA213]...1088
FAILURE CODE [CA221]...1090
FAILURE CODE [CA222]...1092
FAILURE CODE [CA227]...1094
FAILURE CODE [CA234]...1096
FAILURE CODE [CA238]...1097
FAILURE CODE [CA239]...1098
FAILURE CODE [CA271]...1099
FAILURE CODE [CA272]...1101
FAILURE CODE [CA273]...1102
FAILURE CODE [CA274]...1104
FAILURE CODE [CA322]...1105
FAILURE CODE [CA323]...1107
FAILURE CODE [CA324]...1109
FAILURE CODE [CA325]...1111
FAILURE CODE [CA331]...1113
FAILURE CODE [CA332]...1115
FAILURE CODE [CA343]...1117
FAILURE CODE [CA351]...1120
FAILURE CODE [CA352]...1123
FAILURE CODE [CA356]...1125
FAILURE CODE [CA357]...1127
FAILURE CODE [CA386]...1129
FAILURE CODE [CA431]...1131
FAILURE CODE [CA432]...1134
FAILURE CODE [CA441]...1137
FAILURE CODE [CA442]...1140
FAILURE CODE [CA449]...1143
FAILURE CODE [CA451]...1144
FAILURE CODE [CA452]...1146
FAILURE CODE [CA515]...1148
FAILURE CODE [CA516]...1150
FAILURE CODE [CA553]...1152
FAILURE CODE [CA555]...1153
FAILURE CODE [CA556]...1155
FAILURE CODE [CA559]...1157
FAILURE CODE [CA595]...1162
FAILURE CODE [CA687]...1164
FAILURE CODE [CA689]...1166
FAILURE CODE [CA691]...1168
FAILURE CODE [CA692]...1170
FAILURE CODE [CA697]...1172
FAILURE CODE [CA698]...1173
FAILURE CODE [CA731]...1174
FAILURE CODE [CA778]...1177
FAILURE CODE [CA1117]...1179
FAILURE CODE [CA1135]...1182
FAILURE CODE [CA1257]...1185
FAILURE CODE [CA1664]...1186
FAILURE CODE [CA1691]...1188
FAILURE CODE [CA1695]...1190
FAILURE CODE [CA1696]...1192
FAILURE CODE [CA1843]...1194
FAILURE CODE [CA1844]...1196
FAILURE CODE [CA1879]...1198
FAILURE CODE [CA1881]...1200
FAILURE CODE [CA1883]...1202
FAILURE CODE [CA1921]...1205
FAILURE CODE [CA1922]...1207
FAILURE CODE [CA1923]...1210
FAILURE CODE [CA1924]...1212
FAILURE CODE [CA1925]...1214
FAILURE CODE [CA1927]...1216
FAILURE CODE [CA1928]...1218
FAILURE CODE [CA1942]...1220
FAILURE CODE [CA1963]...1222
FAILURE CODE [CA1977]...1226
FAILURE CODE [CA1993]...1228
FAILURE CODE [CA2185]...1230
FAILURE CODE [CA2186]...1232
FAILURE CODE [CA2249]...1234
FAILURE CODE [CA2265]...1239
FAILURE CODE [CA2266]...1241
FAILURE CODE [CA2271]...1243
FAILURE CODE [CA2272]...1245
FAILURE CODE [CA2349]...1247
FAILURE CODE [CA2353]...1249
FAILURE CODE [CA2357]...1251
FAILURE CODE [CA2381]...1253
FAILURE CODE [CA2382]...1255
FAILURE CODE [CA2383]...1257
FAILURE CODE [CA2386]...1259
FAILURE CODE [CA2387]...1261
FAILURE CODE [CA2555]...1263
FAILURE CODE [CA2556]...1265
FAILURE CODE [CA2637]...1267
FAILURE CODE [CA2639]...1269
FAILURE CODE [CA2732]...1271
FAILURE CODE [CA2733]...1273
FAILURE CODE [CA2741]...1275
FAILURE CODE [CA2765]...1276
FAILURE CODE [CA2777]...1277
FAILURE CODE [CA2878]...1278
FAILURE CODE [CA2881]...1281
FAILURE CODE [CA3133]...1284
FAILURE CODE [CA3134]...1286
FAILURE CODE [CA3135]...1288
FAILURE CODE [CA3167]...1291
FAILURE CODE [CA3251]...1293
FAILURE CODE [CA3253]...1295
FAILURE CODE [CA3254]...1298
FAILURE CODE [CA3255]...1300
FAILURE CODE [CA3256]...1302
FAILURE CODE [CA3311]...1304
FAILURE CODE [CA3312]...1306
FAILURE CODE [CA3313]...1308
FAILURE CODE [CA3314]...1309
FAILURE CODE [CA3315]...1310
FAILURE CODE [CA3316]...1313
FAILURE CODE [CA3317]...1314
FAILURE CODE [CA3318]...1315
FAILURE CODE [CA3319]...1318
FAILURE CODE [CA3321]...1319
FAILURE CODE [CA3322]...1320
FAILURE CODE [CA3419]...1323
FAILURE CODE [CA3421]...1325
FAILURE CODE [CA4151]...1327
FAILURE CODE [CA4158]...1330
FAILURE CODE [CA4161]...1332
FAILURE CODE [CA4162]...1334
FAILURE CODE [CA4163]...1336
FAILURE CODE [CA4259]...1338
FAILURE CODE [CA4952]...1340
FAILURE CODE [CA5383]...1342
FAILURE CODE [CB115]...1343
FAILURE CODE [CB187]...1347
FAILURE CODE [CB227]...1348
FAILURE CODE [CB238]...1349
FAILURE CODE [CB239]...1351
FAILURE CODE [CB271]...1353
FAILURE CODE [CB272]...1355
FAILURE CODE [CB273]...1356
FAILURE CODE [CB274]...1358
FAILURE CODE [CB343]...1359
FAILURE CODE [CB352]...1362
FAILURE CODE [CB386]...1364
FAILURE CODE [CB441]...1366
FAILURE CODE [CB442]...1369
FAILURE CODE [CB689]...1372
FAILURE CODE [CB697]...1374
FAILURE CODE [CB698]...1375
FAILURE CODE [CB731]...1376
FAILURE CODE [CB778]...1379
FAILURE CODE [CB1117]...1381
FAILURE CODE [CB1257]...1384
FAILURE CODE [CB1664]...1385
FAILURE CODE [CB1691]...1387
FAILURE CODE [CB1695]...1389
FAILURE CODE [CB1696]...1391
FAILURE CODE [CB1879]...1393
FAILURE CODE [CB1881]...1395
FAILURE CODE [CB1883]...1397
FAILURE CODE [CB1921]...1400
FAILURE CODE [CB1922]...1402
FAILURE CODE [CB1923]...1405
FAILURE CODE [CB1924]...1407
FAILURE CODE [CB1925]...1409
FAILURE CODE [CB1927]...1411
FAILURE CODE [CB1928]...1413
FAILURE CODE [CB1963]...1415
FAILURE CODE [CB1977]...1419
FAILURE CODE [CB1993]...1422
FAILURE CODE [CB2265]...1424
FAILURE CODE [CB2266]...1426
FAILURE CODE [CB2637]...1428
FAILURE CODE [CB2639]...1430
FAILURE CODE [CB2732]...1432
FAILURE CODE [CB2733]...1434
FAILURE CODE [CB2741]...1436
FAILURE CODE [CB2777]...1437
FAILURE CODE [CB2878]...1438
FAILURE CODE [CB2881]...1440
FAILURE CODE [CB3133]...1443
FAILURE CODE [CB3134]...1445
FAILURE CODE [CB3135]...1447
FAILURE CODE [CB3167]...1450
FAILURE CODE [CB3251]...1452
FAILURE CODE [CB3253]...1454
FAILURE CODE [CB3254]...1457
FAILURE CODE [CB3255]...1459
FAILURE CODE [CB3256]...1461
FAILURE CODE [CB3311]...1463
FAILURE CODE [CB3312]...1465
FAILURE CODE [CB3313]...1467
FAILURE CODE [CB3314]...1468
FAILURE CODE [CB3315]...1469
FAILURE CODE [CB3316]...1472
FAILURE CODE [CB3317]...1473
FAILURE CODE [CB3318]...1474
FAILURE CODE [CB3319]...1477
FAILURE CODE [CB3321]...1478
FAILURE CODE [CB3322]...1479
FAILURE CODE [CB4151]...1482
FAILURE CODE [CB4158]...1485
FAILURE CODE [CB4161]...1486
FAILURE CODE [CB4162]...1488
FAILURE CODE [CB4163]...1490
FAILURE CODE [CB4259]...1492
FAILURE CODE [CB4952]...1494
FAILURE CODE [CB5383]...1496
FAILURE CODE [D150KB]...1497
FAILURE CODE [D150KZ]...1498
FAILURE CODE [D164KY]...1499
FAILURE CODE [D19HKZ]...1500
FAILURE CODE [D19JKZ]...1502
FAILURE CODE [D19QKZ]...1503
FAILURE CODE [D1EHKA]...1505
FAILURE CODE [D1EHKB]...1507
FAILURE CODE [D1EHKY]...1509
FAILURE CODE [D1EMKA]...1510
FAILURE CODE [D1EMKB]...1511
FAILURE CODE [D1EMKY]...1512
FAILURE CODE [D1FBKB]...1513
FAILURE CODE [D5ZHL6]...1515
FAILURE CODE [D5ZKKZ]...1517
FAILURE CODE [D862KA]...1519
FAILURE CODE [DAF0KT]...1520
FAILURE CODE [DAF0MB]...1521
FAILURE CODE [DAF0MC]...1522
FAILURE CODE [DAF3KK]...1523
FAILURE CODE [DAF8KB]...1525
FAILURE CODE [DAFDKB]...1526
FAILURE CODE [DAFGMC]...1528
FAILURE CODE [DAFLKA]...1529
FAILURE CODE [DAFLKB]...1531
FAILURE CODE [DAFQKR]...1533
FAILURE CODE [DAQ0KK]...1534
FAILURE CODE [DAQ0KT]...1537
FAILURE CODE [DAQ0MC]...1538
FAILURE CODE [DAQ1KA]...1539
FAILURE CODE [DAQ2KK]...1541
FAILURE CODE [DAQ9KQ]...1544
FAILURE CODE [DAQLKA]...1545
FAILURE CODE [DAQLKB]...1547
FAILURE CODE [DAQQKR]...1549
FAILURE CODE [DAQRKR]...1550
FAILURE CODE [DAQRMA]...1551
FAILURE CODE [DAQV00]...1552
FAILURE CODE [DAQW00]...1553
FAILURE CODE [DAZ9KQ]...1554
FAILURE CODE [DAZQKR]...1555
FAILURE CODE [DB10KT]...1556
FAILURE CODE [DB10MC]...1557
FAILURE CODE [DB11KA]...1558
FAILURE CODE [DB12KK]...1561
FAILURE CODE [DB13KK]...1564
FAILURE CODE [DB19KQ]...1567
FAILURE CODE [DB1LKA]...1568
FAILURE CODE [DB1LKB]...1570
FAILURE CODE [DB1QKR]...1572
FAILURE CODE [DB1QMA]...1573
FAILURE CODE [DB1RKR]...1574
FAILURE CODE [DB2QKR]...1575
FAILURE CODE [DB2RKR]...1581
FAILURE CODE [DBV0MC]...1586
FAILURE CODE [DBV1KK]...1587
FAILURE CODE [DBV6KB]...1589
FAILURE CODE [DBV7KB]...1591
FAILURE CODE [DBVLKA]...1592
FAILURE CODE [DBVLKB]...1594
FAILURE CODE [DBVQKR]...1596
FAILURE CODE [DBVRKR]...1597
FAILURE CODE [DBVVKR]...1598
FAILURE CODE [DBVWKR]...1599
FAILURE CODE [DDAAL6]...1600
FAILURE CODE [DDD7KX]...1602
FAILURE CODE [DDTHKA]...1604
FAILURE CODE [DDTJKA]...1606
FAILURE CODE [DDTKKA]...1608
FAILURE CODE [DDTLKA]...1610
FAILURE CODE [DDTMKA]...1612
FAILURE CODE [DDTNKA]...1614
FAILURE CODE [DDTPKA]...1616
FAILURE CODE [DF10KA]...1618
FAILURE CODE [DF10KB]...1621
FAILURE CODE [DGE5KX]...1626
FAILURE CODE [DGF1KX]...1628
FAILURE CODE [DGR2KB]...1630
FAILURE CODE [DGR6KB]...1631
FAILURE CODE [DGR6L8]...1632
FAILURE CODE [DGT1KX]...1633
FAILURE CODE [DGT4KA]...1635
FAILURE CODE [DGT4KB]...1637
FAILURE CODE [DHA4KA]...1639
FAILURE CODE [DHAAMA]...1641
FAILURE CODE [DHABMA]...1642
FAILURE CODE [DHACMA]...1643
FAILURE CODE [DHADMA]...1644
FAILURE CODE [DHP4KY]...1645
FAILURE CODE [DHP4KZ]...1647
FAILURE CODE [DHP5KY]...1649
FAILURE CODE [DHP5KZ]...1651
FAILURE CODE [DHP6KA]...1653
FAILURE CODE [DHP6KX]...1655
FAILURE CODE [DHP6KY]...1657
FAILURE CODE [DHP6KZ]...1659
FAILURE CODE [DHP7KA]...1661
FAILURE CODE [DHP7KX]...1663
FAILURE CODE [DHP7KY]...1665
FAILURE CODE [DHP7KZ]...1667
FAILURE CODE [DHQ2KX]...1669
FAILURE CODE [DHQ4KX]...1671
FAILURE CODE [DHT5KX]...1673
FAILURE CODE [DHT5L6]...1675
FAILURE CODE [DHT8KX]...1676
FAILURE CODE [DHT8ZG]...1678
FAILURE CODE [DHU2KX]...1679
FAILURE CODE [DHU3KX]...1681
FAILURE CODE [DHUCKX]...1683
FAILURE CODE [DHUDKX]...1686
FAILURE CODE [DHUHKX]...1688
FAILURE CODE [DHULKX]...1690
FAILURE CODE [DHUMKX]...1692
FAILURE CODE [DHUPKX]...1694
FAILURE CODE [DJF1KA]...1696
FAILURE CODE [DK30KX]...1697
FAILURE CODE [DK51L5]...1699
FAILURE CODE [DK52KX]...1702
FAILURE CODE [DK53L8]...1704
FAILURE CODE [DK54KX]...1706
FAILURE CODE [DK60KX]...1708
FAILURE CODE [DKD0L6]...1710
FAILURE CODE [DKH0KX]...1712
FAILURE CODE [DKH1KX]...1714
FAILURE CODE [DLF1KA]...1716
FAILURE CODE [DLF1LC]...1717
FAILURE CODE [DLF2KA]...1719
FAILURE CODE [DLF2LC]...1720
FAILURE CODE [DLF8KA]...1722
FAILURE CODE [DLF8LC]...1723
FAILURE CODE [DLF9KA]...1725
FAILURE CODE [DLF9LC]...1726
FAILURE CODE [DLM3KA]...1728
FAILURE CODE [DLM3LC]...1729
FAILURE CODE [DLM3MB]...1731
FAILURE CODE [DLT3KA]...1732
FAILURE CODE [DLT3LC]...1733
FAILURE CODE [DPQ1KR]...1735
FAILURE CODE [DPQ2KR]...1738
FAILURE CODE [DPQ3KR]...1741
FAILURE CODE [DSJ0KR]...1744
FAILURE CODE [DV00KB]...1745
FAILURE CODE [DW2AKA]...1747
FAILURE CODE [DW2AKB]...1748
FAILURE CODE [DW2AKY]...1749
FAILURE CODE [DW2AL1]...1750
FAILURE CODE [DW2ALH]...1751
FAILURE CODE [DW2BKA]...1752
FAILURE CODE [DW2BKB]...1753
FAILURE CODE [DW2BKY]...1754
FAILURE CODE [DW2BL1]...1755
FAILURE CODE [DW2BLH]...1756
FAILURE CODE [DW35KZ]...1757
FAILURE CODE [DW36KZ]...1759
FAILURE CODE [DW4BK4]...1761
FAILURE CODE [DW4BMA]...1763
FAILURE CODE [DW72KZ]...1765
FAILURE CODE [DW73KA]...1767
FAILURE CODE [DW73KB]...1769
FAILURE CODE [DW73KY]...1771
FAILURE CODE [DW78KZ]...1772
FAILURE CODE [DW7BKB]...1774
FAILURE CODE [DW7BKY]...1775
FAILURE CODE [DW7BKZ]...1776
FAILURE CODE [DW7NKZ]...1777
FAILURE CODE [DWNMKZ]...1779
FAILURE CODE [DX11K4]...1781
FAILURE CODE [DX11KA]...1783
FAILURE CODE [DX11KB]...1785
FAILURE CODE [DX11KY]...1787
FAILURE CODE [DX11MA]...1788
FAILURE CODE [DX13KA]...1790
FAILURE CODE [DX13KB]...1792
FAILURE CODE [DX13KY]...1794
FAILURE CODE [DX16KA]...1795
FAILURE CODE [DX16KB]...1796
FAILURE CODE [DX16KY]...1798
FAILURE CODE [DX37K4]...1799
FAILURE CODE [DX37KA]...1801
FAILURE CODE [DX37KB]...1803
FAILURE CODE [DX37KY]...1805
FAILURE CODE [DX37MA]...1806
FAILURE CODE [DX38K4]...1808
FAILURE CODE [DX38KA]...1810
FAILURE CODE [DX38KB]...1812
FAILURE CODE [DX38KY]...1814
FAILURE CODE [DX38MA]...1815
FAILURE CODE [DXH1KA]...1817
FAILURE CODE [DXH1KB]...1819
FAILURE CODE [DXH1KY]...1821
FAILURE CODE [DXH2KA]...1822
FAILURE CODE [DXH2KB]...1824
FAILURE CODE [DXH2KY]...1826
FAILURE CODE [DXH3KA]...1829
FAILURE CODE [DXH3KB]...1831
FAILURE CODE [DXH3KY]...1833
FAILURE CODE [DXH4KA]...1836
FAILURE CODE [DXH4KB]...1838
FAILURE CODE [DXH4KY]...1840
FAILURE CODE [DXH5KA]...1843
FAILURE CODE [DXH5KB]...1845
FAILURE CODE [DXH5KY]...1847
FAILURE CODE [DXH6KA]...1850
FAILURE CODE [DXH6KB]...1852
FAILURE CODE [DXH6KY]...1854
FAILURE CODE [DXH7KA]...1857
FAILURE CODE [DXH7KB]...1859
FAILURE CODE [DXH7KY]...1861
FAILURE CODE [DXHHKA]...1863
FAILURE CODE [DXHHKB]...1865
FAILURE CODE [DXHHKY]...1867
FAILURE CODE [DY30MA]...1869
FAILURE CODE [DY30MC]...1871
FAILURE CODE [DY30ME]...1874
FAILURE CODE [F@BYNR]...1876
FAILURE CODE [F@BYNS]...1877
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...1878
E-1 ENGINE DOES NOT START (ENGINE DOES NOT TURN)...1878
E-2 MANUAL PREHEAT SYSTEM DOES NOT WORK...1886
E-3 AUTOMATIC PREHEAT SYSTEM DOES NOT WORK...1889
E-4 WHILE PREHEAT IS ON, PREHEAT MONITOR DOES NOT ILLUMINATE...1891
E-5 ALL OF THE LCD UNITS, LED UNITS, AND METER UNITS ON THE MACHINE MONITOR HAVE NO DISPLAY...1893
E-6 LCD UNIT ON MACHINE MONITOR HAS NO DISPLAY...1896
E-7 LIGHT OF LCD UNIT ON MACHINE MONITOR IS INCORRECT, (LIGHT GOES OUT OR IS INTERMITTENT)...1898
E-8 LCD DISPLAY ON THE MACHINE MONITOR IS NOT CORRECT...1900
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS INCORRECT...1902
E-10 NIGHT LIGHT LAMP OF METER UNIT ON THE MACHINE MONITOR IS INCORRECT...1905
E-11 LED UNIT LAMP ON MACHINE MONITOR IS NOT NORMAL...1909
E-12 NIGHT LIGHT LAMP OF SWITCH PANEL ON MACHINE MONITOR IS NOT NORMAL OR SWITCH DOES NOT OPERATE CORRECTLY...1911
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION...1913
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...1915
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY...1917
E-16 REAR VIEW MONITOR DOES NOT ILLUMINATE OR THE LIGHT IS INTERMITTENT...1918
E-17 IMAGE DISPLAY OF THE REAR VIEW MONITOR IS NOT CLEAR...1920
E-18 REAR VIEW MONITOR INTENSITY CANNOT BE ADJUSTED...1923
E-19 NIGHT LIGHT LAMP OF REAR VIEW MONITOR IS ABNORMAL...1926
E-20 REAR VIEW MONITOR DOES NOT SHOW WHILE THE REVERSE DISPLAY IS ACTIVATED...1928
E-21 GUIDE LINE DOES NOT SHOW ON THE REAR VIEW MONITOR WHEN THE GUIDE LINE IS SET...1931
E-22 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL...1933
E-23 SEAT BELT CAUTION LAMP INDICATION IS INCORRECT...1935
E-24 MACHINE MONITOR DOES NOT OPERATE WHEN THE START SWITCH IS IN THE OFF POSITION...1937
E-25 ALARM BUZZER DOES NOT SOUND...1938
E-26 ALARM BUZZER DOES NOT STOP...1940
E-27 AISS FUNCTION DOES NOT OPERATE CORRECTLY...1942
E-28 HOIST LEVER DOES NOT OPERATE CORRECTLY...1944
E-29 ELECTRICAL PRIMING PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY...1946
E-30 TURN SIGNAL LAMP AND HAZARD LAMP DO NOT OPERATE CORRECTLY...1949
E-31 NONE OF THE HEAD LAMPS, CLEARANCE LAMPS, OR REAR LAMPS ILLUMINATE...1953
E-32 SMALL LAMP (CLEARANCE LAMP) DOES NOT ILLUMINATE...1956
E-33 TAIL LAMP DOES NOT ILLUMINATE...1959
E-34 (LOW BEAM) HEAD LAMP DOES NOT LIGHT UP...1962
E-35 (HIGH BEAM) HEAD LAMP DOES NOT ILLUMINATE...1964
E-36 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEAD LAMPS ILLUMINATE...1966
E-37 HIGH BEAMS DO NOT ILLUMINATE WHILE THE PASSING SWITCH IS OPERATED...1968
E-38 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...1970
E-39 CANNOT PERFORM DATA DOWNLOAD WIRELESS LAN...1972
TROUBLESHOOT THE HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...1973
INFORMATION MENTIONED IN THE TROUBLESHOOT TABLE (H MODE)...1973
FAILURE MODE AND CAUSE TABLE...1974
H-1 MACHINE DOES NOT START...1982
H-2 MACHINE DOES NOT TRAVEL SMOOTHLY (IRREGULAR ENGINE RPM)...1985
H-3 LOCKUP IS NOT DISENGAGED...1986
H-4 THERE IS SUDDEN MOVEMENT WHEN YOU START THE MACHINE OR SHIFT GEAR...1987
H-5 GEAR DOES NOT SHIFT UP...1989
H-6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN YOU TRAVEL IN LOCKUP DRIVE MODE AT ALL GEAR SPEEDS...1992
H-7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN YOU TRAVEL IN TORQUE CONVERTER MODE...1993
H-8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN YOU TRAVEL AT SOME GEAR SPEED...1994
H-9 LARGE TIME DIFFERENCE IS OBSERVED FROM WHEN THE MACHINE STARTS TO WHEN IT SHIFTS INTO GEAR...1996
H-10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH...1999
H-11 OIL PRESSURE OF THE TORQUE CONVERTER IS LOW...2000
H-12 STEERING WHEEL IS HARD TO OPERATE...2001
H-13 STEERING WHEEL DOES NOT OPERATE...2002
H-14 STEERING WHEEL HAS EXCESS PLAY...2003
H-15 FRONT BRAKE IS NOT SUFFICIENT...2004
H-16 REAR BRAKE IS NOT SUFFICIENT...2005
H-17 DUMP BODY LIFT SPEED IS LOW...2006
H-18 EXCESS HYDRAULIC DRIFT OF DUMP BODY...2008
H-19 DUMP BODY DOES NOT MOVE...2009
H-20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR STOPS)...2011
H-21 UNUSUAL NOISE IS HEARD FROM AROUND FAN...2012
TROUBLESHOOT OF ENGINE (S-MODE)...2013
INFORMATION MENTIONED IN THE TABLE TO TROUBLESHOOT TABLE (S MODE)...2013
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...2014
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...2015
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...2016
S-4 ENGINE STARTABILITY IS POOR...2017
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...2019
S-6 ENGINE STOPS DURING OPERATION...2021
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...2022
S-8 ENGINE LACKS POWER...2023
S-9 IN A SHORT PERIOD OF TIME THE KDPF IS CLOGGED...2025
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...2027
S-11 OIL BECOMES CONTAMINATED QUICKLY...2028
S-12 FUEL CONSUMPTION IS EXCESSIVE...2029
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...2030
S-14 OIL PRESSURE DROPS...2031
S-15 FUEL MIXES INTO ENGINE OIL...2032
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...2033
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...2034
S-18 UNUSUAL NOISE IS HEARD...2035
S-19 VIBRATION IS EXCESSIVE...2036
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...2037
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...2038
S-22 ACTIVE REGENERATION TAKES TIME...2039
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...2040
50 DISASSEMBLY AND ASSEMBLY...2041
CONTENTS...2042
ABBREVIATIONS...2046
DISASSEMBLE AND ASSEMBLE-RELATED INFORMATION...2051
HOW TO READ THIS MANUAL...2051
COATING MATERIALS LIST...2053
SPECIAL TOOL LIST...2056
DIAGRAMS OF SPECIAL TOOLS...2067
ENGINE AND COOLING SYSTEM...2070
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...2070
PROCEDURE TO REMOVE SUPPLY PUMP ASSEMBLY...2070
PROCEDURE TO INSTALL SUPPLY PUMP ASSEMBLY...2081
REMOVE AND INSTALL INJECTOR ASSEMBLY...2094
PROCEDURE TO REMOVE INJECTOR ASSEMBLY...2095
PROCEDURE TO INSTALL INJECTOR ASSEMBLY...2116
REMOVE AND INSTALL FUEL DOSER ASSEMBLY...2143
PROCEDURE TO REMOVE FUEL DOSER ASSEMBLY...2143
PROCEDURE TO INSTALL FUEL DOSER ASSEMBLY...2144
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...2147
PROCEDURE TO REMOVE CYLINDER HEAD ASSEMBLY...2149
PROCEDURE TO INSTALL CYLINDER HEAD ASSEMBLY...2192
REMOVE AND INSTALL EGR VALVE ASSEMBLY...2246
PROCEDURE TO REMOVE EGR VALVE ASSEMBLY...2246
PROCEDURE TO INSTALL EGR VALVE ASSEMBLY...2249
REMOVE AND INSTALL EGR COOLER ASSEMBLY...2252
PROCEDURE TO REMOVE EGR COOLER ASSEMBLY...2252
PROCEDURE TO INSTALL EGR COOLER ASSEMBLY...2261
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...2268
PROCEDURE TO REMOVE STARTING MOTOR ASSEMBLY...2268
PROCEDURE TO INSTALL STARTING MOTOR ASSEMBLY...2269
REMOVE AND INSTALL ALTERNATOR BELT...2270
PROCEDURE TO REMOVE ALTERNATOR BELT...2270
PROCEDURE TO INSTALL ALTERNATOR BELT...2271
REMOVE AND INSTALL COOLER ASSEMBLY...2273
PROCEDURE TO REMOVE COOLER ASSEMBLY...2274
PROCEDURE TO INSTALL COOLER ASSEMBLY...2289
REMOVE AND INSTALL RADIATOR...2302
PROCEDURE TO REMOVE RADIATOR...2302
PROCEDURE TO INSTALL RADIATOR...2308
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...2315
PROCEDURE TO REMOVE COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...2315
PROCEDURE TO INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY...2317
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...2320
PROCEDURE TO REMOVE AFTERCOOLER ASSEMBLY...2320
PROCEDURE TO INSTALL AFTERCOOLER ASSEMBLY...2327
REMOVE AND INSTALL ENGINE ASSEMBLY...2333
PROCEDURE TO REMOVE ENGINE ASSEMBLY...2334
PROCEDURE TO INSTALL ENGINE ASSEMBLY...2347
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...2361
PROCEDURE TO REMOVE ENGINE FRONT OIL SEAL...2361
PROCEDURE TO INSTALL ENGINE FRONT OIL SEAL...2362
REMOVE AND INSTALL ENGINE REAR OIL SEAL...2365
PROCEDURE TO REMOVE ENGINE REAR OIL SEAL...2365
PROCEDURE TO INSTALL ENGINE REAR OIL SEAL...2366
REMOVE AND INSTALL OUTPUT SHAFT ASSEMBLY...2371
PROCEDURE TO REMOVE OUTPUT SHAFT ASSEMBLY...2371
PROCEDURE TO INSTALL OUTPUT SHAFT ASSEMBLY...2373
DISASSEMBLE AND ASSEMBLE OF OUTPUT SHAFT ASSEMBLY...2376
PROCEDURE TO DISASSEMBLE OUTPUT SHAFT ASSEMBLY...2376
PROCEDURE TO ASSEMBLE OUTPUT SHAFT ASSEMBLY...2377
REMOVE AND INSTALL KDPF ASSEMBLY (WITH BRACKET)...2379
PROCEDURE TO REMOVE KDPF ASSEMBLY...2379
PROCEDURE TO INSTALL KDPF ASSEMBLY...2383
REMOVE AND INSTALL KDPF ASSEMBLY (WITHOUT BRACKET)...2388
PROCEDURE TO REMOVE KDPF ASSEMBLY...2388
PROCEDURE TO INSTALL KDPF ASSEMBLY...2395
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...2402
PROCEDURE TO DISASSEMBLE KDPF ASSEMBLY...2403
PROCEDURE TO ASSEMBLE KDPF ASSEMBLY...2408
REMOVE AND INSTALL KCCV ASSEMBLY...2416
PROCEDURE TO REMOVE KCCV ASSEMBLY...2416
PROCEDURE TO INSTALL KCCV ASSEMBLY...2418
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...2420
PROCEDURE TO REMOVE AIR CLEANER ASSEMBLY...2420
PROCEDURE TO INSTALL AIR CLEANER ASSEMBLY...2422
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...2424
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...2424
PROCEDURE TO INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...2425
POWER TRAIN...2427
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2427
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2427
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2431
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2435
PROCEDURE TO DISCONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2435
PROCEDURE TO CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...2441
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER ASSEMBLY...2456
PROCEDURE TO DISASSEMBLE TORQUE CONVERTER ASSEMBLY...2457
PROCEDURE TO ASSEMBLE TORQUE CONVERTER ASSEMBLY...2463
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY...2474
PROCEDURE TO DISASSEMBLE TRANSMISSION ASSEMBLY...2475
PROCEDURE TO ASSEMBLE TRANSMISSION ASSEMBLY...2495
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY...2523
PROCEDURE TO REMOVE DIFFERENTIAL ASSEMBLY...2523
PROCEDURE TO INSTALL DIFFERENTIAL ASSEMBLY...2525
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY...2527
PROCEDURE TO DISASSEMBLE DIFFERENTIAL ASSEMBLY...2527
PROCEDURE TO ASSEMBLE DIFFERENTIAL ASSEMBLY...2533
REMOVE AND INSTALL FRONT BRAKE CALIPER PAD...2544
PROCEDURE TO REMOVE FRONT BRAKE CALIPER PAD...2544
PROCEDURE TO INSTALL FRONT BRAKE CALIPER PAD...2544
REMOVE AND INSTALL FRONT BRAKE CALIPER ASSEMBLY...2545
PROCEDURE TO REMOVE FRONT BRAKE CALIPER ASSEMBLY...2545
PROCEDURE TO INSTALL FRONT BRAKE CALIPER ASSEMBLY...2545
DISASSEMBLE AND ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY...2547
DISASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY...2547
ASSEMBLE OF FRONT BRAKE CALIPER ASSEMBLY...2547
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY...2549
PROCEDURE TO REMOVE FINAL DRIVE AND REAR BRAKE ASSEMBLY...2549
PROCEDURE TO INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY...2553
REMOVE AND INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2557
PROCEDURE TO REMOVE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2557
PROCEDURE TO INSTALL FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2560
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2564
PROCEDURE TO DISASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2564
PROCEDURE TO ASSEMBLE FINAL DRIVE, REAR BRAKE AND PARKING BRAKE ASSEMBLY...2571
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY...2580
PROCEDURE TO REMOVE FINAL DRIVE CARRIER ASSEMBLY...2580
PROCEDURE TO INSTALL FINAL DRIVE CARRIER ASSEMBLY...2581
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY...2583
PROCEDURE TO DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY...2583
PROCEDURE TO ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY...2583
STEERING SYSTEM...2584
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY...2584
PROCEDURE TO DISASSEMBLE STEERING CYLINDER ASSEMBLY...2584
PROCEDURE TO ASSEMBLE STEERING CYLINDER ASSEMBLY...2586
UNDERCARRIAGE AND FRAME...2589
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY...2589
PROCEDURE TO REMOVE FRONT WHEEL ASSEMBLY...2589
PROCEDURE TO INSTALL FRONT WHEEL ASSEMBLY...2590
REMOVE AND INSTALL REAR WHEEL ASSEMBLY...2592
PROCEDURE TO REMOVE REAR WHEEL ASSEMBLY...2592
PROCEDURE TO INSTALL REAR WHEEL ASSEMBLY...2594
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY...2596
PROCEDURE TO REMOVE FRONT SUSPENSION CYLINDER ASSEMBLY...2596
PROCEDURE TO INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY...2598
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)...2599
PROCEDURE TO DISASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY...2599
PROCEDURE TO ASSEMBLE FRONT SUSPENSION CYLINDER ASSEMBLY...2601
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY...2603
PROCEDURE TO REMOVE REAR SUSPENSION CYLINDER ASSEMBLY...2603
PROCEDURE TO INSTALL REAR SUSPENSION CYLINDER ASSEMBLY...2603
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER RING)...2604
PROCEDURE TO DISASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY...2604
PROCEDURE TO ASSEMBLE REAR SUSPENSION CYLINDER ASSEMBLY...2605
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB ASSEMBLY...2608
PROCEDURE TO DISASSEMBLE FRONT WHEEL HUB ASSEMBLY...2608
PROCEDURE TO ASSEMBLE FRONT WHEEL HUB ASSEMBLY...2609
HYDRAULIC SYSTEM...2613
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY...2613
PROCEDURE TO DISASSEMBLE HOIST CYLINDER ASSEMBLY...2614
PROCEDURE TO ASSEMBLE HOIST CYLINDER ASSEMBLY...2617
WORK EQUIPMENT...2624
REMOVE AND INSTALL DUMP BODY ASSEMBLY...2624
PROCEDURE TO REMOVE DUMP BODY ASSEMBLY...2624
PROCEDURE TO INSTALL DUMP BODY ASSEMBLY...2625
CAB AND ITS ATTACHMENTS...2628
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY...2628
PROCEDURE TO REMOVE AIR CONDITIONER ASSEMBLY...2629
PROCEDURE TO INSTALL AIR CONDITIONER ASSEMBLY...2635
REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY...2642
PROCEDURE TO REMOVE OPERATOR'S SEAT ASSEMBLY...2642
PROCEDURE TO INSTALL OPERATOR'S SEAT ASSEMBLY...2644
REMOVE AND INSTALL SEAT BELT...2647
PROCEDURE TO REMOVE SEAT BELT...2647
PROCEDURE TO INSTALL SEAT BELT...2648
ELECTRICAL SYSTEM...2649
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...2649
PROCEDURE TO REMOVE ENGINE CONTROLLER ASSEMBLY...2649
PROCEDURE TO INSTALL ENGINE CONTROLLER ASSEMBLY...2651
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY...2654
PROCEDURE TO REMOVE RETARDER AND HOIST CONTROLLER ASSEMBLY...2654
PROCEDURE TO INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY...2655
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY...2656
PROCEDURE TO REMOVE TRANSMISSION CONTROLLER ASSEMBLY...2656
PROCEDURE TO INSTALL TRANSMISSION CONTROLLER ASSEMBLY...2657
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...2658
PROCEDURE TO REMOVE MACHINE MONITOR ASSEMBLY...2658
PROCEDURE TO INSTALL MACHINE MONITOR ASSEMBLY...2660
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...2663
PROCEDURE TO REMOVE MONITOR CONTROLLER ASSEMBLY...2663
PROCEDURE TO INSTALL MONITOR CONTROLLER ASSEMBLY...2664
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...2665
PROCEDURE TO REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR...2665
PROCEDURE TO INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...2666
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...2668
PROCEDURE TO REMOVE KCCV CRANKCASE PRESSURE SENSOR...2668
PROCEDURE TO INSTALL KCCV CRANKCASE PRESSURE SENSOR...2669
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY...2671
PROCEDURE TO REMOVE KOMTRAX PLUS CONTROLLER ASSEMBLY...2671
PROCEDURE TO INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY...2672
REMOVE AND INSTALL KOMTRAX CONTROLLER ASSEMBLY...2674
PROCEDURE TO REMOVE KOMTRAX CONTROLLER ASSEMBLY...2674
PROCEDURE TO INSTALL KOMTRAX CONTROLLER ASSEMBLY...2675
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY...2676
PROCEDURE TO REMOVE WIRELESS LAN UNIT ASSEMBLY...2676
PROCEDURE TO INSTALL WIRELESS LAN UNIT ASSEMBLY...2677
60 MAINTENANCE STANDARD...2681
CONTENTS...2682
ABBREVIATIONS...2683
ENGINE AND COOLING SYSTEM...2688
MAINTENANCE STANDARD FOR ENGINE MOUNT...2688
MAINTENANCE STANDARD FOR OUTPUT SHAFT...2689
MAINTENANCE STANDARD FOR COOLING FAN PUMP...2691
MAINTENANCE STANDARD FOR SERVO VALVE FOR COOLING FAN PUMP...2693
MAINTENANCE STANDARD FOR COOLING FAN MOTOR...2694
POWER TRAIN...2696
MAINTENANCE STANDARD FOR DRIVE SHAFT...2696
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND TRANSMISSION MOUNT...2697
MAINTENANCE STANDARD FOR TORQUE CONVERTER AND PTO...2698
MAINTENANCE STANDARD FOR TORQUE CONVERTER VALVE...2702
MAINTENANCE STANDARD FOR TRANSMISSION...2704
MAINTENANCE STANDARD FOR TRANSMISSION CONTROL VALVE...2710
MAINTENANCE STANDARD FOR H, L, 4TH, 3RD, R, 2ND, and 1ST ECMV...2711
MAINTENANCE STANDARD FOR LOCKUP CLUTCH ECMV...2712
MAINTENANCE STANDARD FOR FRONT AXLE...2713
MAINTENANCE STANDARD FOR REAR AXLE...2714
MAINTENANCE STANDARD FOR DIFFERENTIAL...2715
MAINTENANCE STANDARD FOR FINAL DRIVE...2716
STEERING SYSTEM...2717
MAINTENANCE STANDARD FOR STEERING COLUMN...2717
MAINTENANCE STANDARD FOR STEERING LINKAGE...2718
MAINTENANCE STANDARD FOR DEMAND VALVE...2721
MAINTENANCE STANDARD FOR STEERING CYLINDER...2724
BRAKE SYSTEM...2725
MAINTENANCE STANDARD FOR SLACK ADJUSTER...2725
MAINTENANCE STANDARD FOR FRONT BRAKE...2726
MAINTENANCE STANDARD FOR REAR BRAKE...2727
UNDERCARRIAGE AND FRAME...2729
MAINTENANCE STANDARD FOR FRONT SUSPENSION CYLINDER...2729
MAINTENANCE STANDARD FOR REAR SUSPENSION CYLINDER...2731
HYDRAULIC SYSTEM...2733
MAINTENANCE STANDARD FOR STEERING AND HOIST PUMP...2733
MAINTENANCE STANDARD FOR SERVO VALVE FOR STEERING AND HOIST PUMP...2734
MAINTENANCE STANDARD FOR POWER TRAIN AND BRAKE COOLING DUPLEX PUMP...2736
MAINTENANCE STANDARD FOR BRAKE COOLING, CONTROL TRIPLE PUMP...2737
MAINTENANCE STANDARD FOR HOIST VALVE...2739
WORK EQUIPMENT...2741
MAINTENANCE STANDARD FOR HOIST CYLINDER...2741
CAB AND ITS ATTACHMENTS...2742
MAINTENANCE STANDARD FOR CAB MOUNT...2742
80 THE OTHER INFORMATION...2743
CONTENTS...2744
ABBREVIATIONS...2746
AIR CONDITIONER SYSTEM...2751
PRECAUTIONS FOR REFRIGERANT...2751
AIR CONDITIONER COMPONENT...2752
SPECIFICATIONS OF AIR CONDITIONER...2754
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...2755
OUTLINE OF REFRIGERATION CYCLE...2756
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...2758
AIR CONDITIONER UNIT...2758
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...2758
FUNCTION OF AIR CONDITIONER UNIT...2759
COMPONENT PARTS OF AIR CONDITIONER UNIT...2761
FUNCTION OF EVAPORATOR...2761
FUNCTION OF HEATER CORE...2762
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR...2762
FUNCTION OF SERVO MOTOR...2762
STRUCTURE OF EXPANSION VALVE...2763
FUNCTION OF EXPANSION VALVE...2763
EXPANSION VALVE OPERATION...2763
FUNCTION OF DUAL PRESSURE SWITCH...2764
AIR CONDITIONER CONTROLLER...2765
STRUCTURE OF AIR CONDITIONER CONTROLLER...2765
COMPRESSOR...2766
STRUCTURE OF COMPRESSOR...2766
SPECIFICATIONS OF COMPRESSOR...2766
FUNCTION OF COMPRESSOR...2766
CONDENSER...2767
STRUCTURE OF CONDENSER...2767
SPECIFICATIONS OF CONDENSER...2767
FUNCTION OF CONDENSER...2767
SENSORS FOR AIR CONDITIONER SYSTEM...2769
STRUCTURE OF AMBIENT TEMPERATURE SENSOR...2769
FUNCTION OF AMBIENT TEMPERATURE SENSOR...2769
PROCEDURE TO TEST AND TROUBLESHOOT THE AIR CONDITIONER...2770
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...2772
AIR CONDITIONER SYSTEM DIAGRAM...2774
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...2775
FUNCTION OF AIR CONDITIONER CONTROLLER...2776
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND CONFIGURATION OF CONNECTORS...2777
AIR (DUCT) LEAK TEST...2780
AIR (DUCT) LEAK TEST PROCEDURE...2780
AIR CONDITIONER TEST USING SELF-DIAGNOSIS FUNCTION...2783
PROCEDURE TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD IN THE MACHINE MONITOR...2785
VENT (MODE) CHANGE TEST...2787
VENT (MODE) CHANGE TEST PROCEDURE...2787
FRESH/RECIRC AIR CHANGE TEST...2788
FRESH/RECIRC AIR CHANGE TEST PROCEDURE...2788
TEST REFRIGERANT (DUAL) PRESSURE SWITCH...2789
TEST REFRIGERANT (DUAL) PRESSURE SWITCH PROCEDURE...2789
RELAY TEST...2790
TEST RELAY PROCEDURE...2790
AIR CONDITIONER TROUBLESHOOTING CHART 1...2791
AIR CONDITIONER TROUBLESHOOTING CHART 2...2792
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...2795
FAILURE CODE [879AKA]...2796
FAILURE CODE [879AKB]...2797
FAILURE CODE [879BKA]...2798
FAILURE CODE [879BKB]...2799
FAILURE CODE [879CKA]...2801
FAILURE CODE [879CKB]...2802
FAILURE CODE [879EMC]...2803
FAILURE CODE [879FMC]...2804
FAILURE CODE [879GKX]...2805
A-1 TROUBLESHOOT POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...2806
A-2 TROUBLESHOOT COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...2808
A-3 TROUBLESHOOT BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...2811
A-4 TROUBLESHOOT FOR FRESH/RECIRC AIR CHANGE...2813
TROUBLESHOOT USING GAUGE PRESSURE...2815
CONNECTION OF SERVICE TOOL...2817
PROCEDURE TO CONNECT SERVICE TOOL...2817
PRECAUTIONS TO DISCONNECT AND CONNECT HOSES AND TUBES IN AIR CONDITIONER PIPING...2818
COMPRESSOR OIL PROCEDURES...2820
PROCEDURE TO REPLACE DESICCANT...2822
90 CIRCUIT DIAGRAMS...2825
CONTENTS...2826
ABBREVIATIONS...2827
HYDRAULIC CIRCUIT DIAGRAM...2832
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...2832
HYDRAULIC CIRCUIT DIAGRAM...2837
POWER TRAIN HYDRAULIC DIAGRAM...2838
ELECTRICAL CIRCUIT DIAGRAM...2839
ELECTRICAL DIAGRAMS SYMBOLS...2839
INTERNAL CAB ELECTRICAL DIAGRAM (1/10)...2843
INTERNAL CAB ELECTRICAL DIAGRAM (2/10)...2844
INTERNAL CAB ELECTRICAL DIAGRAM (3/10)...2845
INTERNAL CAB ELECTRICAL DIAGRAM (4/10)...2846
INTERNAL CAB ELECTRICAL DIAGRAM (5/10)...2847
INTERNAL CAB ELECTRICAL DIAGRAM (6/10)...2848
INTERNAL CAB ELECTRICAL DIAGRAM (7/10)...2849
INTERNAL CAB ELECTRICAL DIAGRAM (8/10)...2850
INTERNAL CAB ELECTRICAL DIAGRAM (9/10)...2851
INTERNAL CAB ELECTRICAL DIAGRAM (10/10)...2852
EXTERNAL CAB ELECTRICAL DIAGRAM (1/7)...2854
EXTERNAL CAB ELECTRICAL DIAGRAM (2/7)...2855
EXTERNAL CAB ELECTRICAL DIAGRAM (3/7)...2856
EXTERNAL CAB ELECTRICAL DIAGRAM (4/7)...2857
EXTERNAL CAB ELECTRICAL DIAGRAM (5/7)...2858
EXTERNAL CAB ELECTRICAL DIAGRAM (6/7)...2859
EXTERNAL CAB ELECTRICAL DIAGRAM (7/7)...2860
INDEX...2862
