ARTICULATEDDUMPTRUCK
MachinemodelSerialnumber
Compositionofshopmanual1
ThecontentsofthisshopmanualareshowntogetherwithFormNo.inalist.
SectionTitleFormNumber
ShopManual,contentsbinder,binderlabelandtabsSEN03017-13
00IndexandforewordSEN03018-13
IndexSEN03019-13
ForewordandgeneralinformationSEN03020-04
01SpecificationSEN03021-00
SpecificationandtechnicaldataSEN03022-00
10Structure,functionandmaintenancestandardSEN03023-01
EngineandcoolingsystemSEN03024-00
Powertrain,Part1SEN03025-01
Powertrain,Part2SEN03026-01
SteeringsystemSEN03027-00
BrakesystemSEN03028-00
UndercarriageandframeSEN03029-00
HydraulicsystemSEN03030-00
CabanditsattachmentsSEN03031-00
Electricalsystem,Part1SEN03032-00
Electricalsystem,Part2SEN03033-00
Electricalsystem,Part3SEN03034-00
20StandardvaluetableSEN03035-00
StandardservicevaluetableSEN03347-00
30TestingandadjustingSEN03036-05
Testingandadjusting,Part1SEN03348-05 Testingandadjusting,Part2SEN03349-03 Testingandadjusting,Part3SEN03350-01
40TroubleshootingSEN03037-05
FailurecodetableandfuselocationsSEN03351-01
GeneralinformationontroubleshootingSEN03352-03
Troubleshootingbyfailurecode(Displayofcode),Part1SEN03353-02
Troubleshootingbyfailurecode(Displayofcode),Part2SEN03354-02
Troubleshootingbyfailurecode(Displayofcode),Part3SEN03355-02
Troubleshootingbyfailurecode(Displayofcode),Part4SEN03356-03
Troubleshootingbyfailurecode(Displayofcode),Part5SEN03357-03
Troubleshootingbyfailurecode(Displayofcode),Part6SEN03358-01 Troubleshootingbyfailurecode(Displayofcode),Part7SEN03359-01
Troubleshootingbyfailurecode(Displayofcode),Part8SEN03360-02
Troubleshootingofelectricalsystem(E-mode)SEN03361-01
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN03362-00
Troubleshootingofengine(S-mode)SEN03363-01
50DisassemblyandassemblySEN03038-08
GeneralinformationondisassemblyandassemblySEN04135-04
Engineandcoolingsystem(SAA6D140E-5)SEN04136-00
Engine(SAA6D140E-5)SEN04137-02
Powertrain,Part1SEN04138-02
Powertrain,Part2(Differential)SEN04139-01
Powertrain,Part3(Finaldrive,brake,axle)SEN04140-03
UndercarriageandframeSEN04141-03
HydraulicsystemSEN04142-00
CabanditsattachmentsSEN04143-01
ElectricalsystemSEN04144-00
90DiagramsanddrawingsSEN03039-03
HydraulicdiagramsanddrawingsSEN03040-00
ElectricaldiagramsanddrawingsSEN03041-03
Tableofcontents
00Indexandforeword
IndexSEN03019-13
Compositionofshopmanual.......................................................................................................2
Tableofcontents.........................................................................................................................4
ForewordandgeneralinformationSEN03020-04
Safetynotice................................................................................................................................2
Howtoreadtheshopmanual.....................................................................................................8
Explanationoftermsformaintenancestandard..........................................................................10
Handlingofelectricequipmentandhydrauliccomponent...........................................................12
Handlingofconnectorsnewlyusedforengines..........................................................................21
Howtoreadelectricwirecode....................................................................................................24
Precautionswhencarryingoutoperation....................................................................................27
Methodofdisassemblingandconnectingpush-pulltypecoupler...............................................30
Standardtighteningtorquetable.................................................................................................33
Conversiontable.........................................................................................................................37
01Specification
SpecificationandtechnicaldataSEN03022-00
Specificationdrawings.................................................................................................................2
Weighttable................................................................................................................................6
Fuel,coolantandlubricants........................................................................................................7
10Structure,functionandmaintenancestandard
EngineandcoolingsystemSEN03024-00
Radiator,oilcooler,aftercooler....................................................................................................2
Outputshaft.................................................................................................................................3
Powertrain,Part1SEN03025-01
Powertrainskeleton....................................................................................................................2
Powertrain,Part2SEN03026-01 Driveshaft...................................................................................................................................2
Testingengineoilpressure..........................................................................................................18
Handlingoffuelsystemdevices..................................................................................................19
Releasingresidualpressurefromfuelsystem............................................................................19
Testingfuelpressure...................................................................................................................20
Testingfuelreturnandleakageamount......................................................................................21
Bleedingairfromfuelcircuit........................................................................................................24
Testingthefuelcircuitforleakage...............................................................................................26
Testingandadjustingfanbelttension.........................................................................................27
Testingandadjustingalternatorbelttension...............................................................................28
Testingandadjustingairconditionercompressorbelttension....................................................29
Adjustingtheshimsinthebodymount........................................................................................30
Testingandadjusting,Part2SEN03349-03
Testingtorqueconverterstallspeed............................................................................................3
Testingpowertrainoilpressure...................................................................................................4
Testingandadjustingofdifferentiallockoilpressure(differentiallockspec.).............................12
Adjustingtransmissionspeedsensor..........................................................................................17
Testingandadjustingbrakeoilpressure.....................................................................................19
Testingofaccumulatornitrogengaspressureandprocedureforchargingaccumulatorwith nitrogengas.........................................................................................................................23
Testingbrakeperformance..........................................................................................................31
Releasingremainingpressureinbrakecircuit............................................................................32
Bleedingairfrombrakecircuit.....................................................................................................33
Testingwearofwheelbrakedisc................................................................................................34
Testingtheparkingbrakepadwear............................................................................................35
Emergencyreleaseoftheparkingbrake.....................................................................................36
Testingandadjustingsteeringcircuitoilpressure.......................................................................37
Testingandadjustingsuspensioncylinder..................................................................................39
Methodoftiltingcabup...............................................................................................................43
Testingandadjustingdumpcircuitoilpressure...........................................................................45
Adjustingbodypositionersensor................................................................................................47
Adjustinglengthofspringinbodyheatingsphericaljoint............................................................48
Adjustmentoftiltlockleverofsteeringwheel.............................................................................49
Handlingofvoltagecircuitofenginecontroller............................................................................50
Adjustingtransmissioncontroller.................................................................................................50
Methodforemergencyescapeatelectricalsystemfailure.........................................................51
Testingandadjusting,Part3SEN03350-01
Settingandadjustingvariousequipments...................................................................................2
Specialfunctionofmachinemonitor...........................................................................................11
HowtostartoperationofKOMTRAXterminal.............................................................................55
LampdisplayofKOMTRAXterminal...........................................................................................60
PmClinicchecksheet.................................................................................................................63
40Troubleshooting
FailurecodetableandfuselocationsSEN03351-01
Failurecodestable......................................................................................................................2
Fuselocations.............................................................................................................................9
GeneralinformationontroubleshootingSEN03352-03
Precautionsbeforework..............................................................................................................2
Pointstorememberwhenperformingtroubleshooting................................................................3
Howtoproceedintroubleshooting..............................................................................................5
Checkbeforetroubleshooting.....................................................................................................7
Classificationandproceduresoftroubleshooting........................................................................8
Informationintroubleshootingtable............................................................................................12
Troubleshootingmethodfordisconnectingwiringharnessofpressuresensorsystem..............14
PhenomenalookingliketroublesandtroubleshootingNos........................................................17
Connectiontableforconnectorpinnumbers...............................................................................19
T-branchboxandT-branchadaptertable.................................................................................55
Troubleshootingbyfailurecode(Displayofcode),Part1SEN03353-02
Failurecode[1500L0]Detectingdualengagement....................................................................3
Failurecode[15B0NX]Transmissionoilfilter:Clogging.............................................................4
Failurecode[15F0KM]RoFgearshiftabuse1.......................................................................6
Failurecode[15F0MB]RoFgearshiftabuse2.......................................................................6
Failurecode[15F7KM]Transmissionforwardclutchabuse.......................................................7
Failurecode[15G0MW]Reverseclutchsystemfailure(Slipisdetected)..................................8
Failurecode[15G7KM]Transmissionreverseclutchabuse.......................................................10
Failurecode[15H0MW]Hiclutchsystemfailure(Slipisdetected).............................................12
Failurecode[15J0MW]Loclutchsystemfailure(Slipisdetected).............................................14
Failurecode[15K0MW]1stclutchsystemfailure(Slipisdetected)...........................................16
Failurecode[15L0MW]2ndclutchsystemfailure(Slipisdetected)...........................................18
Failurecode[15M0MW]3rdclutchsystemfailure(Slipisdetected)..........................................20
Failurecode[15SBL1]Reverseclutchpressurecontrolvalvefailure......................................22
Failurecode[15SBMA]Reverseclutchpressurecontrolvalvefailure....................................25
Failurecode[15SCL1]Hiclutchpressurecontrolvalvefailure................................................26
Failurecode[15SCMA]Hiclutchpressurecontrolvalvefailure..............................................29
Failurecode[15SDL1]Loclutchpressurecontrolvalvefailure...............................................30
Failurecode[15SDMA]Loclutchpressurecontrolvalvefailure.............................................33
Troubleshootingbyfailurecode(Displayofcode),Part2SEN03354-02
Failurecode[15SEL1]1stclutchpressurecontrolvalvefailure...............................................4
Failurecode[15SEMA]1stclutchpressurecontrolvalvefailure.............................................7
Failurecode[15SFL1]2ndclutchpressurecontrolvalvefailure..............................................8
Failurecode[15SFMA]2ndclutchpressurecontrolvalvefailure............................................11
Failurecode[15SGL1]3rdclutchpressurecontrolvalvefailure..............................................12
Failurecode[15SGMA]3rdclutchpressurecontrolvalvefailure............................................15
Failurecode[15SJMA]Lockupclutchpressurecontrolvalvefailure......................................16
Failurecode[15SKMA]Interaxledifferentiallockclutchpressurecontrolvalvefailure...........18
Failurecode[2A62L1]Frontwheeldifferentiallockpressurecontrolvalvefailure..................20
Failurecode[2A62LH]Frontwheeldifferentiallockpressurecontrolvalvefailure..................22
Failurecode[2B62L1]Rearwheeldifferentiallockpressurecontrolvalvefailure..................24
Failurecode[2B62LH]Rearwheeldifferentiallockpressurecontrolvalvefailure...................26
Failurecode[2C4MNX]Retardercoolingoilfilterclogging.........................................................28
Failurecode[2F00KM]Draggingofparkingbrake.....................................................................30
Failurecode[2G42ZG]Loweringofaccumulatoroilpressure(front).........................................32
Failurecode[2G43ZG]Loweringofaccumulatoroilpressure(rear)..........................................32
Failurecode[989A00]Engineoverrunpreventionactivated......................................................33
Failurecode[989D00]Rearsectiontippingoveralarm(Raisingoperationonslope)................33
Failurecode[A570NX]Engineoilfilterclogging.........................................................................34
Failurecode[AA10NX]Aircleanerclogging...............................................................................36
Failurecode[AB00MA]Batterychargecircuitfailure..................................................................38
Failurecode[B@BAZG]Loweringofengineoilpressure...........................................................39
Failurecode[B@BAZK]Loweringofengineoillevel..................................................................40
Failurecode[B@BCNS]Engineoverheat..................................................................................41
Failurecode[B@BCZK]Loweringofcoolantlevel.....................................................................42
Failurecode[B@C6NS]Overheatofbrakecoolingoiltemperature(front)................................44
Failurecode[B@C8NS]Overheatofbrakecoolingoiltemperature(center).............................44
Failurecode[B@CENS]Overheatoftorqueconverteroiltemperature.....................................45
Failurecode[B@JANS]Overheatofsteeringoiltemperature....................................................45
Troubleshootingbyfailurecode(Displayofcode),Part3SEN03355-02
Failurecode[CA111]Abnormalityinenginecontroller................................................................4
Failurecode[CA115]EngineNeorBkupspeedsensorerror....................................................6
Failurecode[CA122]Charge(boost)pressuresensorhigherror..............................................8
Failurecode[CA123]Charge(boost)pressuresensorlowerror................................................10
Failurecode[CA131]Throttlesensorhigherror.........................................................................12
Failurecode[CA132]Throttlesensorlowerror..........................................................................14
Failurecode[CA135]Engineoilpressuresensorhigherror......................................................16
Failurecode[CA141]Engineoilpressuresensorlowerror........................................................18
Failurecode[CA144]Coolanttemperaturesensorhigherror.....................................................20
Failurecode[CA145]Coolanttemperaturesensorlowerror......................................................22
Failurecode[CA153]Charge(boost)temperaturesensorhigherror.........................................24
Failurecode[CA154]Charge(boost)temperaturesensorlowerror..........................................26
Failurecode[CA187]Sensorpowersupply2lowerror..............................................................28
Failurecode[CA221]Atmosphericpressuresensorhigherror...................................................30
Failurecode[CA222]Atmosphericpressuresensorlowerror....................................................32
Failurecode[CA227]Sensorpowersupply2higherror.............................................................34
Failurecode[CA234]Engineoverspeed.....................................................................................35
Failurecode[CA238]Nespeedsensorpowersupplyerror........................................................36
Failurecode[CA263]FuelTemperatureSensorHighError........................................................38
Failurecode[CA265]FuelTemperatureSensorLowError........................................................40
Failurecode[CA271]PCV1Shortcircuit....................................................................................42
Failurecode[CA272]PCV1Disconnection.................................................................................43
Failurecode[CA273]PCV2Shortcircuit....................................................................................44
Failurecode[CA274]PCV2Disconnection.................................................................................45
Failurecode[CA322]Injector#1open/shorterror......................................................................46
Failurecode[CA323]Injector#5open/shorterror......................................................................48
Failurecode[CA324]Injector#3open/shorterror......................................................................50
Failurecode[CA325]Injector#6open/shorterror......................................................................52
Failurecode[CA331]Injector#2open/shorterror......................................................................54
Failurecode[CA332]Injector#4open/shorterror......................................................................56
Failurecode[CA342]Calibrationcodeinconsistency.................................................................58
Failurecode[CA351]Injectorsdrivecircuiterror........................................................................59
Failurecode[CA352]Sensorpowersupply1lowerror..............................................................60
Failurecode[CA386]Sensorpowersupply1higherror.............................................................62
Troubleshootingbyfailurecode(Displayofcode),Part4SEN03356-03
Failurecode[CA431]Idlevalidationswitcherror........................................................................3
Failurecode[CA432]Idlevalidationactionerror........................................................................6
Failurecode[CA441]Batteryvoltagelowerror...........................................................................9
Failurecode[CA442]Batteryvoltagehigherror.........................................................................10
Failurecode[CA449]Commonrailpressurehigherror2...........................................................11
Failurecode[CA451]Commonrailpressuresensorhigherror..................................................12
Failurecode[CA452]Commonrailpressuresensorlowerror...................................................14
Failurecode[CA553]Commonrailpressurehigherror1...........................................................16
Failurecode[CA554]Commonrailpressuresensorinrangeerror............................................17
Failurecode[CA559]Supplypumppressureverylowerror1....................................................18
Failurecode[CA689]EngineNespeedsensorerror..................................................................22
Failurecode[CA731]EngineBkupspeedsensorphaseerror...................................................24
Failurecode[CA757]Allcontinuousdatalosterror....................................................................25
Failurecode[CA778]EngineBkupspeedsensorerror..............................................................26
Failurecode[CA1633]KOMNETdatalinktimeouterror.............................................................28
Failurecode[CA2185]Throttlesensorpowersupplyvoltagehigherror....................................30
Failurecode[CA2186]Throttlesensorpowersupplyvoltagelowerror......................................32
Failurecode[CA2249]Supplypumppressureverylowerror2..................................................34
Failurecode[CA2555]Intakeairheaterrelayopencircuiterror.................................................36
Failurecode[CA2556]Intakeairheaterrelayshortcircuiterror.................................................38
Troubleshootingbyfailurecode(Displayofcode),Part5SEN03357-03
Failurecode[DAF9KM]Wrongconnectionofconnector............................................................4
Failurecode[DAFRKR]AbnormalCANcommunication(machinemonitor): Abnormalcommunication.....................................................................................................5
Failurecode[DAQ0KK]Loweringofsourcevoltage...................................................................6
Failurecode[DAQ0KT]Troubleinnon-volatilememory.............................................................8
Failurecode[DAQ2KK]Troubleinsolenoidpowersupplysystem.............................................10
Failurecode[DAQ9KQ]Disagreementofmodelselection(Transmissioncontroller).................12
Failurecode[DAQRKR]AbnormalCANcommunication(Transmission): Abnormalcommunication.....................................................................................................14
Failurecode[DAQRMA]Disagreementofoptionsetting(Transmissioncontroller)...................19
Failurecode[DB10KT]Troubleinnon-volatilememory..............................................................19
Failurecode[DB12KK]Troubleinsolenoidpowersupplysystem..............................................20
Failurecode[DB13KK]Loweringofbatterydirectvoltage..........................................................22
Failurecode[DB19KQ]Disagreementofmodelselection(Retardercontroller).........................24
Failurecode[DB1QMA]Disagreementofoptionsetting(Retardercontroller)...........................25
Failurecode[DB1RKR]CANcommunication(retardercontroller):Communicationdisabled....26
Failurecode[DB2RKR]CANcommunication(enginecontroller):Communicationdisabled......30
Failurecode[DD1ML4]Disagreementofaccelerator-linkedretarderswitchsignal...................36
Failurecode[DDTHKA]TroubleinHiclutchflowsensorvalve..................................................38
Failurecode[DDTJKA]TroubleinLoclutchflowsensorvalve...................................................39
Failurecode[DDTKKA]Troublein1stclutchflowsensorvalve.................................................40
Failurecode[DDTLKA]Troublein2ndclutchflowsensorvalve................................................41
Failurecode[DDTMKA]Troublein3rdclutchflowsensorvalve................................................42
Failurecode[DDTNKA]Troubleinreverseclutchflowsensorvalve..........................................43
Failurecode[DF10KA]Inputofnoleversignals.........................................................................44
Failurecode[DF10KB]Inputofmultipleleversignals................................................................48
Failurecode[DGF1KX]Transmissionoiltemperatureoutofrange............................................52
Failurecode[DGR3KZ]Groundfaultinbrakeoiltemperaturesensor(center)..........................54
Failurecode[DGR3L8]Disconnectioninbrakeoiltemperaturesensor(center)........................56
Failurecode[DGR4KZ]Groundfaultinbrakeoiltemperaturesensor(front).............................58
Failurecode[DGR4L8]Disconnectioninbrakeoiltemperaturesensor(front)...........................60
Failurecode[DGR6KX]Steeringoiltemperatureoutofrange...................................................62
Troubleshootingbyfailurecode(Displayofcode),Part6SEN03358-01
Failurecode[DGT1KX]Shortcircuitintorqueconverteroiltemperaturesensorsystem...........4
Failurecode[DHT5KX]Disconnection,groundfault,orshortcircuitintorqueconverteroil pressuresensorsystem.......................................................................................................6
Failurecode[DHT5L6]Torqueconverteroilpressuresensorfailure..........................................8
Failurecode[DHU2KX]Accumulatoroilpressuresensor(front)systemfailure.........................10
Failurecode[DHU3KX]Accumulatoroilpressuresensor(rear)systemfailure..........................12
Failurecode[DJF1KA]Disconnectioninfuellevelsensorsystem.............................................14
Failurecode[DK51L5]ManualretarderpotentiometerandRVSfailure.....................................16
Failurecode[DK52KX]Dumpleverpotentiometer1failure.......................................................18
Failurecode[DK53L8]Dumpleverpotentiometer2failure........................................................20
Failurecode[DK54KX]Bodypositionersensorfailure...............................................................22
Failurecode[DKH0KX]Pitchanglesensorsignaloutofrange..................................................24
Failurecode[DLF1KA]Disconnectionintransmissioninputshaftspeedsensorsystem...........26
Failurecode[DLF1LC]Transmissioninputshaftspeedsensorfailure.......................................27
Failurecode[DLF2KA]Disconnectionintransmissionintermediateshaftspeed sensorsystem......................................................................................................................28
Failurecode[DLF2LC]Transmissionintermediateshaftspeedsensorfailure...........................29
Failurecode[DLF4KA]Disconnectionintransmissiondifferentialspeedsensorsystem...........30
Failurecode[DLT3KA]Disconnectionintransmissionoutputshaftspeedsensorsystem.........31
Failurecode[DV00KB]Shortcircuitinbuzzeroutputcircuit.......................................................32
Failurecode[DW72KZ]Kick-outsolenoidoutputsystemfailure (disconnectionorgroundfault)............................................................................................34
Failurecode[DW73KZ]Dumpselectorvalveoutputsystemfailure...........................................36
Failurecode[DW78KZ]RearwheelBCVcommandoutputsystemfailure................................38
Failurecode[DW79KZ]FrontwheelBCVcommandoutputsystemfailure................................40
Failurecode[DX11K4]Rearwheelproportionalsolenoidpressurereducingvalvefailure1......42
Failurecode[DX11KA]Disconnectioninoutputcircuitofrearwheelproportionalsolenoid pressurereducingvalve.......................................................................................................44
Failurecode[DX11KB]Groundfaultinoutputcircuitofrearwheelproportionalsolenoid pressurereducingvalve.......................................................................................................46
Failurecode[DX11KY]Hotshortinoutputcircuitofrearwheelproportionalsolenoid pressurereducingvalve.......................................................................................................48
Failurecode[DX11MA]Rearwheelproportionalsolenoidpressurereducingvalvefailure2.....50
Failurecode[DX12K4]Frontwheelproportionalsolenoidpressurereducingvalvefailure1.....52
Failurecode[DX12KA]Disconnectioninoutputcircuitoffrontwheelproportionalsolenoid pressurereducingvalve.......................................................................................................54
Failurecode[DX12KB]Groundfaultinoutputcircuitoffrontwheelproportionalsolenoid pressurereducingvalve.......................................................................................................56
Failurecode[DX12KY]Hotshortinoutputcircuitoffrontwheelproportionalsolenoid pressurereducingvalve.......................................................................................................58
Failurecode[DX12MA]Frontwheelproportionalsolenoidpressurereducingvalvefailure2....60
Troubleshootingbyfailurecode(Displayofcode),Part7SEN03359-01
Failurecode[DX13KA]DisconnectioninoutputcircuitofdumpEPCvalve...............................4
Failurecode[DX13KB]GroundfaultinoutputcircuitofdumpEPCvalve..................................6
Failurecode[DX13KY]HotshortinoutputcircuitofdumpEPCvalve.......................................8
Failurecode[DX14KZ]Rearwheeldifferentiallockcommandoutputsystemfailure.................10
Failurecode[DX15KZ]Frontwheeldifferentiallockcommandoutputsystemfailure................12
Failurecode[DXH0KA]Disconnectioninoutputcircuitofinteraxledifferentiallock clutchsolenoid.....................................................................................................................14
Failurecode[DXH0KB]Groundfaultinoutputcircuitofinteraxledifferentiallock clutchsolenoid.....................................................................................................................16
Failurecode[DXH0KY]Hotshortinoutputcircuitofinteraxledifferentiallockclutchsolenoid..18
Failurecode[DXH1KA]Disconnectioninoutputcircuitoflockupclutchsolenoid......................20
Failurecode[DXH1KB]Groundfaultinoutputcircuitoflockupclutchsolenoid.........................22
Failurecode[DXH1KY]Hotshortinoutputcircuitoflockupclutchsolenoid..............................24
Failurecode[DXH2KA]DisconnectioninoutputcircuitofHiclutchECMVsolenoid..................26
Failurecode[DXH2KB]GroundfaultinoutputcircuitofHiclutchECMVsolenoid.....................28
Failurecode[DXH2KY]HotshortinoutputcircuitofHiclutchECMVsolenoid..........................30
Failurecode[DXH3KA]DisconnectioninoutputcircuitofLoclutchECMVsolenoid.................32
Failurecode[DXH3KB]GroundfaultinoutputcircuitofLoclutchECMVsolenoid....................34
Failurecode[DXH3KY]HotshortinoutputcircuitofLoclutchECMVsolenoid.........................36
Failurecode[DXH4KA]Disconnectioninoutputcircuitof1stclutchECMVsolenoid................38
Failurecode[DXH4KB]Groundfaultinoutputcircuitof1stclutchECMVsolenoid...................40
Failurecode[DXH4KY]Hotshortinoutputcircuitof1stclutchECMVsolenoid........................42
Troubleshootingbyfailurecode(Displayofcode),Part8SEN03360-02
Failurecode[DXH5KA]Disconnectioninoutputcircuitof2ndclutchECMVsolenoid...............2
Failurecode[DXH5KB]Groundfaultinoutputcircuitof2ndclutchECMVsolenoid..................4
Failurecode[DXH5KY]Hotshortinoutputcircuitof2ndclutchECMVsolenoid.......................6
Failurecode[DXH6KA]Disconnectioninoutputcircuitof3rdclutchECMVsolenoid................8
Failurecode[DXH6KB]Groundfaultinoutputcircuitof3rdclutchECMVsolenoid...................10
Failurecode[DXH6KY]Hotshortinoutputcircuitof3rdclutchECMVsolenoid........................12 Failurecode[DXH7KA]DisconnectioninoutputcircuitofReverseclutchECMVsolenoid........14 Failurecode[DXH7KB]GroundfaultinoutputcircuitofReverseclutchECMVsolenoid...........16
Failurecode[DXH7KY]HotshortinoutputcircuitofReverseclutchECMVsolenoid................18
Troubleshootingofelectricalsystem(E-mode)SEN03361-01 Beforetroubleshootingforelectricalsystem...............................................................................3 Informationintroubleshootingtable............................................................................................9
E-1Enginedoesnotstart............................................................................................................10
E-2Autopreheaterdoesnotoperate..........................................................................................15
E-3WhenstartingswitchisturnedON,machinemonitordisplaysnothing................................18
E-4WhenstartingswitchisturnedOFF,machinemonitorcannotbeoperated.........................20
E-5Alarmbuzzerdoesnotsound...............................................................................................22
E-6Machinemonitordoesnotnormallydisplaygauges,cautionlamps, andcharacterdisplaysection...............................................................................................24
E-7Displayofcharacterdisplaysectioncannotbechanged......................................................25
E-8Powermodeselectionfunctiondoesnotoperatenormally..................................................28
E-9AISSfunctiondoesnotoperatenormally..............................................................................30
E-10Rightandleftdifferentiallockfunctiondoesnotoperatenormally (Differentiallock-upspecification)........................................................................................32
E-11Interaxledifferentiallock-upfunctiondoesnotoperatenormally........................................36
E-12Displayofseatbeltcautionlampisabnormal....................................................................38
E-13Bothturnsignallampsandhazardlampsdonotoperatenormally....................................40
E-14Nightlightingisabnormal...................................................................................................45
E-15Backuplampandbackupbuzzeroperateabnormally........................................................52
E-16Emergencysteeringsystemdoesnotoperate...................................................................56
E-17Indicationofthefuelgaugeisabnormal.............................................................................60
E-18Dumpleverdoesnotoperatenormally...............................................................................62
E-19KOMTRAXsystemdoesnotoperatenormally...................................................................64
E-20Electricprimingpumpdoesnotoperateordoesnotstopautomatically............................68
E-21Airconditionerdoesnotoperatenarmally..........................................................................70
Troubleshootingofhydraulicandmechanicalsystem(H-mode)SEN03362-00 Informationintroubleshootingtable............................................................................................3
H-1Machinedoesnotstart.........................................................................................................4
H-2Travelisnotsmooth(Machinehunts)..................................................................................6
H-3Lockupisnotreset...............................................................................................................6
H-4Startshockandgearshiftshockareabnormallylarge........................................................7
H-5Gearisnotshiftedup...........................................................................................................8
H-6Travelspeedorpowerislow................................................................................................10
H-7Startandgearshifttimelagislarge......................................................................................14
H-8Torqueconverteroiltemperatureishigh..............................................................................16
H-9Torqueconverteroiltemperatureislow...............................................................................17
H-10Frontbrakedoesnotworkfully..........................................................................................18
H-17Dumpbodydoesnotmove................................................................................................25
H-18Hydraulicdriftofdumpbodyislarge..................................................................................26
Troubleshootingofengine(S-mode)SEN03363-01 Methodofusingtroubleshootingchart........................................................................................3
S-1Startingperformanceofengineispoor................................................................................6
S-2Enginedoesnotstart............................................................................................................7
S-3Enginedoesnotpickupsmoothly........................................................................................10
S-4Enginestopsduringoperation..............................................................................................11
S-5Enginedoesnotrotatesmoothly..........................................................................................12
S-6Enginelackoutput(orlackspower).....................................................................................13
S-7Exhaustgasisblack(incompletecombustion).....................................................................14
S-8Oilconsumptionisexcessive(orexhaustgasisblue).........................................................15
S-9Oilbecomesdirtyquickly......................................................................................................16
S-10Fuelconsumptionisexcessive...........................................................................................17
S-11Oilisincoolant(orcoolantspurtsbackorcoolantlevelgoesdown).................................18
S-12Oilpressuredrops..............................................................................................................19
S-13Oillevelrises(Entryofcoolantorfuel)...............................................................................20
S-14Coolanttemperaturebecomestoohigh(Overheating)......................................................21
S-15Abnormalnoiseismade.....................................................................................................22
S-16Vibrationisexcessive.........................................................................................................23
S-17Aircannotbebledfromfuelcircuit.....................................................................................24
50Disassemblyandassembly GeneralinformationondisassemblyandassemblySEN04135-04
Precautionsbeforework.............................................................................................................2 Howtoreadthismanual.............................................................................................................3 Coatingmaterialslist...................................................................................................................5 Specialtoollist............................................................................................................................8 Sketchesofspecialtools.............................................................................................................13
Engineandcoolingsystem(SAA6D140E-5)SEN04136-00
Removalandinstallationofengineassembly.............................................................................2
Removalandinstallationofradiatorassembly............................................................................11
Removalandinstallationofcoolingassembly.............................................................................15
Removalandinstallationofaftercoolerassembly.......................................................................19
Removalandinstallationofoutputshaftassembly.....................................................................22
Disassemblyandassemblyofoutputshaftassembly.................................................................27
Engine(SAA6D140E-5)SEN04137-02
Removalandinstallationoffuelsupplypumpassembly.............................................................2
Removalandinstallationofcylinderheadassembly...................................................................7
Removalandinstallationoffuelinjectorassembly......................................................................23
Removalandinstallationofenginefrontseal..............................................................................27
Removalandinstallationofenginerearseal..............................................................................29
Replacementprocedureofexhaustpipefirepreventioncover...................................................33
Powertrain,Part1SEN04138-02
Removalandinstallationoftransmissionandfrontdifferentialassembly...................................2
Disconnectionandcouplingoffrontdifferentialandtransmission..............................................9
Disassemblyandassemblyoftorqueconverterassembly.........................................................10
Disassemblyandassemblyoftransmissionassembly...............................................................18
Powertrain,Part2(Differential)SEN04139-01
Disassemblyandassemblyoffrontdifferentialassembly...........................................................2
Removalandinstallationofcenterdifferentialassembly............................................................19
Disassemblyandassemblyofcenterdifferentialassembly........................................................22
Removalandinstallationofreardifferentialassembly................................................................37
Disassemblyandassemblyofreardifferentialassembly............................................................39
Powertrain,Part3(Finaldrive,brake,axle)SEN04140-03
Removalandinstallationoffrontfinaldriveandbrakeassembly...............................................2
Disassemblyandassemblyoffrontfinaldriveandbrakeassembly...........................................5
Removalandinstallationofcenterfinaldriveandbrakeassembly.............................................21
Disassemblyandassemblyofcenterfinaldriveandplateassembly.........................................23
Removalandinstallationofrearfinaldriveassembly.................................................................35
Disassemblyandassemblyofrearfinaldriveassembly.............................................................37
Removalandinstallationofcenteraxleassembly......................................................................44
Removalandinstallationofrearaxleassembly..........................................................................47
UndercarriageandframeSEN04141-03
Removalandinstallationoffrontsuspensioncylinderassembly................................................2
Removalandinstallationofrearsuspensioncylinderassembly.................................................4
Removalandinstallationofequalizerbarassembly...................................................................6
Removalandinstallationoffrontwheelassembly......................................................................8
Removalandinstallationofrearfrontwheelassembly...............................................................9
Removalandinstallationofrearrearwheelassembly................................................................9
Removalandinstallationofhitchframeassembly......................................................................10
Disassemblyandassemblyofhitchframe..................................................................................18
Removalandinstallationofbodyassembly................................................................................23
HydraulicsystemSEN04142-00
Disassemblyandassemblyofsteeringvalve..............................................................................2
Removalandinstallationofflowamplifiervalveassembly..........................................................12
Removalandinstallationofhoistvalveassembly.......................................................................14
Disassemblyandassemblyofhoistvalveassembly...................................................................16
Disassemblyandassemblyofsteeringcylinderassembly.........................................................18
Disassemblyandassemblyofhoistcylinderassembly...............................................................24
CabanditsattachmentsSEN04143-01
Removalandinstallationofoperator'scab.................................................................................2
Removalandinstallationofoperator'scabglass(Stuckglass)..................................................7
Disassemblyandassemblyofoperator'sseatassembly(Ifequipped).......................................14
ElectricalsystemSEN04144-00
Removalandinstallationofairconditionerunitassembly..........................................................2
Removalandinstallationofenginecontroller.............................................................................7
Removalandinstallationofretardercontroller............................................................................10
Removalandinstallationoftransmissioncontrollerassembly....................................................12
90Diagramsanddrawings
HydraulicdiagramsanddrawingsSEN03040-00
Powertrainhydrauliccircuitdiagram..........................................................................................3
Steeringandhoisthydrauliccircuitdiagram...............................................................................5
Brakehydrauliccircuitdiagram...................................................................................................6
Brakecoolinghydrauliccircuitdiagram.......................................................................................7
Differentiallockhydrauliccircuitdiagram....................................................................................8
ElectricaldiagramsanddrawingsSEN03041-03
Electricalcircuitdiagramforinsidecab(1/4)..............................................................................3
Electricalcircuitdiagramforinsidecab(2/4)..............................................................................5
Electricalcircuitdiagramforinsidecab(3/4)..............................................................................7
Electricalcircuitdiagramforinsidecab(4/4)..............................................................................9
Electricalcircuitdiagramforoutsidecab(1/3)............................................................................11
Electricalcircuitdiagramforoutsidecab(2/3)............................................................................13
Electricalcircuitdiagramforoutsidecab(3/3)............................................................................15
Connectorstableandarrangementdrawing...............................................................................17