Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 PDF
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Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 – PDF DOWNLOAD
SERIAL NUMBERS 120001 and up
Description
Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 – PDF DOWNLOAD
Language : English
Pages :4684
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 – PDF DOWNLOAD
SERIAL NUMBERS 120001 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu Dump Truck WA475-10 WA475-10E0 Shop Manual SEN06773-10 – PDF DOWNLOAD
SERIAL NUMBERS 120001 and up
Cover 1
00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 30
How to Read the Shop Manual 30
Safety Notice for Operation 32
Precautions to Prevent Fire 40
Procedures If Fire Occurs 42
Precautions for Disposing of Waste Materials 43
Procedures for Exhaust Gas Regulations 44
Precautions for DEF 45
General Character and Precautions for Handling 45
Precautions for Adding 45
Precautions for Storage 45
Precautions for Fire Hazard and Leakage 45
Other Precautions 45
Store DEF 46
Precautions When You Handle Hydraulic Equipment 47
Precautions When You Disconnect and Connect Pipings 50
Precautions When You Handle Electrical Equipment 57
Precautions When You Handle Fuel System Equipment 59
Precautions When You Handle Intake System Equipment 60
Practical Use of KOMTRAX 61
Disconnect and Connect Push-Pull Type Coupler 62
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 62
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 63
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 64
Precautions for Disconnection and Connection of Connectors 66
How to Disconnect and Connect Deutsch Connector 70
How to Disconnect and Connect Slide Lock Type Connector 71
How to Disconnect and Connect Connector with Lock to Pull 73
How to Disconnect and Connect Connector with Lock to Push 74
How to Disconnect and Connect Connector with Housing to Rotate 76
How to Read the Codes for Electric Cable 77
Explanation of Terms for Maintenance Standard 81
Standard Tightening Torque Table 84
Conversion Table 91
Abbreviation List 96
01 Specifications 99
Table of Contents 100
Specifications 101
Specification Drawing 101
Specification Drawing: WA475-10 101
Specification Drawing: WA475-10E0 103
Specifications 105
Specifications: WA475-10 105
Specifications: WA475-10E0 110
Weight Table 115
Weight Table: WA475-10 115
Weight Table: WA475-10E0 117
Fuel, Coolant, Lubricants (For North America) 119
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 119
Fuel, Coolant, Lubricants (for European Union and Turkey) 121
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 121
10 Structure and Function 123
Table of Contents 124
Urea SCR System 129
Layout Drawing of Urea SCR System 129
Urea SCR System Diagram 131
Function of Urea SCR System 132
Function of DEF System 132
Inducement Strategy 135
Component Parts of Urea SCR System 149
DEF Mixing Tube 149
SCR Assembly 150
DEF Tank 152
DEF Pump 154
DEF Injector 155
DEF Hose 156
DEF Tank Heating Valve 157
Boot-up System 158
Layout Drawing of Boot-up System 158
System Operating Lamp System 160
System Diagram of System Operating Lamp System 160
Function of Operation Lamp System 160
Battery Disconnect Switch 162
Function of Battery Disconnect Switch 162
Operation of Battery Disconnect Switch 162
Preheating System 163
System Diagram of Preheating System 163
Function of Automatic Preheating System 163
Operation of Automatic Preheating System 163
Function of Manual Preheating System 164
Operation of Manual Preheating System 164
Engine System 165
Layout Drawing of Engine System 165
Function of Engine System 166
Engine Control System 167
System Diagram of Engine Control 167
Function of Engine Control System 168
Operation of Engine Control System 169
Automatic Idle Stop System 171
Function of Automatic Idle Stop System 171
Component Parts of Engine System 172
VGT 172
EGR System 176
EGR Valve 178
EGR Cooler 180
KCCV System 181
KCCV Ventilator 183
KDPF 185
Cooling System 189
Layout Drawing of Cooling System 189
Specifications of Cooling System 190
Cooling Fan Control System 191
System Diagram of Cooling Fan Control System 191
Function of Cooling Fan Control System 192
Component Parts of Cooling System 196
Brake and Cooling Fan Pump 196
Cooling Fan Motor 204
Control System 211
Layout Drawing of Control System 211
Machine Monitor System 213
System Diagram of Machine Monitor System 213
Function of Machine Monitor System 213
Rearview Monitor System 215
System Diagram of Rearview Monitor System 215
Function of Rearview Monitor System 215
KOMTRAX System 216
System Diagram of KOMTRAX System 216
Function of KOMTRAX System 216
Load Meter System 217
System Diagram of Load Meter (Applicable Machine: 120001 to 120801) 217
System Diagram of Load Meter (Applicable Machine: 120802 and Up) 218
Function of Load Meter System 218
Component Parts of Control System 224
Machine Monitor 224
Monitor Switch 247
Keypad 248
Rearview Monitor 249
Rearview Camera 251
Gateway Function Controller 252
Communication Terminal 255
Transmission Controller 256
Work Equipment Controller 260
Monitor Controller 264
CAN Terminating Resistor 269
Engine Controller 270
Accelerator Pedal 277
Speed Control Dial 279
Hydraulic System 280
Layout Drawing of Hydraulic System 280
CLSS 281
Structure of CLSS 281
Function of CLSS 282
Work Equipment Pump and Steering Pump Control System 285
Swash Plate Control Function of Work Equipment Pump and Steering Pump 285
Pickup Assistance Control Function When Engine Speed is Low 285
Overheat Prevention Function of Work Equipment Circuit 285
Component Parts of Hydraulic System 286
Hydraulic Tank 286
Work Equipment Pump 289
Steering Pump 307
Power Train Charge Pump and Power Train Lubrication Pump 320
Control Valve 321
Total Control System 361
System Diagram of Total Control System 361
Independent Work Equipment Control Function 362
Power Mode Selector Function 364
Overheat Prevention Function 365
Output Limitation Function for Low Temperature 366
Work Equipment Speed Level 367
Power Train System 368
Layout Drawing of Power Train System 368
Operation of Power Train System 370
HST Charge System 371
System Diagram of HST Charge System 371
Function of HST Charge System 371
Pump Motor Control System 372
System Diagram of Pump Motor Control System 372
Stepless Gear Shift Adjustment Function 372
Inching Control Function 373
Transmission Gear Shift Control System 374
System Diagram of Transmission Gear Shift Control System 374
Automatic Gear Shift Function 374
Gear Shift Display Function 375
Hunting Prevention Function 375
Transmission Protection Function 376
Travel Speed Limitation Function 376
Neutralizer Function 376
Directional Selector Switch Control Function 377
Traction Control System 379
System Diagram of Traction Control System 379
Function of Traction Control System 379
Component Parts of Power Train System 382
Drive Shaft 382
Transmission 384
Transmission Control Valve 386
ECMV 390
Valve Assembly (Main Relief, Power Train Oil Cooler Relief) 393
Solenoid Valve (Transmission Charge Pump Bypass) 396
HST Pump Motor 398
HST Valve 405
HST Charge Pump 411
Pilot Sequence Valve 412
Manifold Valve 415
Solenoid Valve (HST Charge Pump Bypass) 418
Axle 420
Conventional Differential 422
Limited Slip Differential 425
Final Drive 430
AJSS Knob 432
Combination Switch 433
Work Equipment System 438
Layout Drawing of Work Equipment System 438
Work Equipment Control System 441
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 441
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 441
Work Equipment Lever Operating Function System Diagram 442
Work Equipment Lever Operation Function 443
Boom Stop Modulation Function 443
Work Equipment Shock Reduction Function 444
Work Equipment Neutral Lock System 447
Work Equipment Neutral Lock System Diagram 447
Function of Work Equipment Neutral Lock System 447
Remote Positioner System 449
Remote Bucket Positioner System Diagram 449
Function of Remote Bucket Positioner System 449
Remote Boom Positioner System Diagram 451
Function of Remote Boom Positioner System 451
Automatic Bucket Shake System 454
System Diagram of Automatic Bucket Shake System 454
Function of Automatic Bucket Shake System 454
Bucket Positioner and Boom Positioner 455
Structure of Bucket Positioner and Boom Positioner 455
Auto-Digging System 456
Auto-Digging System Diagram 456
Function of Auto-Digging System 457
ECSS 459
ECSS Diagram 459
Function of ECSS 459
Operation of ECSS 459
Component Parts of Work Equipment System 461
Work Equipment Lock Solenoid Valve 461
Pilot Circuit Accumulator 462
ECSS Circuit Accumulator 463
Work Equipment Electric Lever 465
Bucket Control Switch 468
Multifunction Mono-Lever 469
Steering System 471
Layout Drawing of Steering System 471
Secondary Steering System 474
Secondary Steering System Diagram 474
Function of Secondary Steering System 474
AJSS 476
Layout Drawing of AJSS 476
AJSS System Diagram 477
Function of AJSS 478
Neutralizer Function of AJSS 478
AJSS Neutral Interlock Function 479
AJSS Speed Sensing Steering Function 480
AJSS Turn Signal Pilot Lamp Control Function 481
Steering Column 482
Structure of Steering Column 482
Component Parts of Steering System 483
AJSS EPC Valve 483
Steering Lock Valve 484
Rotary Valve 485
Orbitrol Valve 488
Stop Valve 492
Steering Valve 493
Secondary Steering Pump 505
Secondary Steering Motor 506
Brake System 507
Layout Drawing of Brake System 507
Layout Drawing of Brake Cooling System 509
Parking Brake Control System 511
System Diagram of Parking Brake Control System 511
Operation of Parking Brake Control System 511
Brake Cooling Control System 513
Brake Cooling Control System Diagram 513
Function of Brake Cooling Control System 513
Component Parts of Brake System 514
Charge Valve 514
Parking Brake Solenoid Valve 519
Parking Brake Emergency Release Valve 521
Brake Circuit Accumulator 522
Brake Valve 524
Slack Adjuster 528
Brake 530
Parking Brake 533
Brake Cooling Pump 535
Brake Cooling Oil Cooler 536
Auto-Greasing System 537
Layout Drawing of Auto-Greasing System 537
Specifications of Auto-Greasing System 538
Function of Auto-Greasing System 540
Auto-Greasing System 541
Auto-Greasing Pump 541
Undercarriage and Frame 542
Frame, Axle Mount and Center Hinge Pin 542
Structure of Frame, Axle Mount and Center Hinge Pin 542
Function of Frame, Axle Mount and Center Hinge Pin 542
Tires 544
Features of Radial Tire When Compared with Bias Tire 544
Structure of Radial Tire 544
Function of Radial Tire 545
Structure of Bias Tire 545
Function of Bias Tire 545
Work Equipment 546
Structure of Work Equipment 546
Structure of Bucket 547
CAB Related Parts 548
ROPS CAB 548
Structure of ROPS CAB 548
Function of ROPS CAB 548
20 Standard Value Table 549
Table of Contents 550
Standard Value Table for Engine 551
Standard Value Table for Engine: WA475-10 551
Standard Value Table for Engine: WA475-10E0 555
Standard Value Table for Machine 559
Standard Value Table for Machine: WA475-10 559
Standard Value Table for Machine: WA475-10E0 582
Machine Posture and Procedures to Measure Performance 605
30 Testing and Adjusting 609
Table of Contents 610
Precautions Before Work 614
Related Information on Testing and Adjusting 615
Differences In Machine Monitor Symbols 615
Tools for Testing and Adjusting 616
Sketch of Tools for Testing and Adjusting 627
Engine and Cooling System 629
Examine Engine Speed 629
How to Examine Engine Speed 629
Examine Boost Pressure 631
How to Examine Boost Pressure on Machine Monitor 631
How to Examine Boost Pressure by Testing Tool 632
Examine Exhaust Gas Temperature 635
How to Examine Exhaust Gas Temperature 636
Examine Exhaust Gas Color 638
How to Examine Exhaust Gas Color with the Handy Smoke Checker 638
How to Examine Exhaust Gas Color with Smoke Meter 640
Examine and Adjust Valve Clearance 642
How to Examine Valve Clearance 642
How to Adjust Valve Clearance 644
Examine Compression Pressure 645
How to Examine Compression Pressure 645
Examine Blowby Pressure 648
How to Examine Blowby Pressure 648
Examine Engine Oil Pressure 651
How to Examine Engine Oil Pressure on Machine Monitor 651
How to Examine Engine Oil Pressure by Testing Tool 651
Examine EGR Valve and VGT Oil Pressure 654
How to Examine EGR Valve and VGT Oil Pressure 654
Examine Fuel Pressure 656
How to Examine Fuel Pressure 656
Examine Fuel Return Rate and Leakage 659
How to Examine Fuel Return Rate and Leakage 660
Bleed Air from Fuel System 664
How to Bleed Air from Fuel System 665
Examine Fuel Circuit for Leakage 667
How to Examine Fuel System for Leakage 667
Handle Cylinder Cut-out Mode Operation 670
Handle No-Injection Cranking Operation 671
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 672
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 672
Examine Installed Condition of Cylinder Heads and Manifolds 673
How to Examine Installed Condition of Cylinder Heads and Manifolds 673
Examine Engine Piping for Damage and Looseness 674
How to Examine Engine Piping for Damage and Looseness 674
Examine and Adjust Air Conditioner Compressor Belt Tension 675
How to Examine Air Conditioner Compressor Belt Tension 675
How to Adjust Air Conditioner Compressor Belt Tension 675
Examine Alternator Belt 678
How to Examine Alternator Belt 678
Examine Automatic Tensioner 680
How to Examine Automatic Tensioner 680
Clean Fuel Doser 683
How to Clean Fuel Doser 683
Write Injector Compensation Value to Engine Controller 685
How to Write Injector Compensation Value 685
Write Correction for Ash in Soot Accumulation to Engine Controller 692
How to Write Correction for Ash in Soot Accumulation to Engine Controller 692
Examine SCR Related Function 693
Examine DEF Pump Raised Pressure 697
Examine Injection Volume from DEF Injector 701
Examine DEF Line Heater Relay 1 707
Examine DEF Line Heater Relay 2 711
Examine DEF Pump Heater Relay 715
Examine DEF Tank Heater Valve 720
Examine SCR Denitration Efficiency 725
Clean DEF Tank 730
How to Clean DEF Tank 730
Clean DEF Pump 735
How to Clean DEF Pump 735
Power Train 741
Examine and Adjust Power Train Oil Pressure 741
How to Examine Power Train Oil Pressure 744
Examine and Adjust HST Oil Pressure 764
How to Examine HST Oil Pressure 764
How to Adjust HST Oil Pressure 768
Adjust Transmission Input Shaft Speed Sensor 769
How to Adjust Transmission Input Shaft Speed Sensor 769
Adjust Transmission M2 Speed Sensor 771
How to Adjust Transmission M2 Speed Sensor 771
Flush Transmission Hydraulic Circuit 773
How to Flush Transmission Hydraulic Circuit 773
Examine Drive Shaft for Looseness, Backlash, and Damage 775
How to Examine Drive Shaft for Looseness, Backlash, and Damage 775
How to Move When Electric System Failure Occurs 776
Steering System 778
Examine Steering Wheel 778
How to Examine Steering Wheel 778
Examine and Adjust Steering Circuit Oil Pressure 781
How to Examine Steering Circuit Oil Pressure 781
How to Adjust Steering Circuit Oil Pressure 788
Bleed Air from Steering Cylinder Circuit 789
How to Bleed Air from Steering Cylinder Circuit 789
Examine and Adjust Steering Stop Valve 790
How to Examine Steering Stop Valve 790
How to Adjust Steering Stop Valve 790
Brake System 792
Release Remained Pressure in Brake Accumulator Circuit 792
How to Release Remained Pressure in Brake Accumulator Circuit 792
Examine Wheel Brake Oil Pressure 793
How to Examine Wheel Brake Oil Pressure 793
Examine and Adjust Accumulator Charge Pressure 796
How to Examine Accumulator Charge Pressure 796
How to Adjust Accumulator Charge Pressure 797
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 799
How to Examine Accumulator Nitrogen Gas Pressure for Brake 799
How to Charge Accumulator Nitrogen Gas for Brake 802
How to Release Nitrogen Gas When You Discard Accumulator 806
Bleed Air from Brake Circuit 808
How to Bleed Air from Brake Circuit 808
Examine Brake Performance 811
How to Examine Brake Performance 811
Examine Brake Pedal 812
How to Examine Brake Pedal 812
Examine Pressure Decrease of Wheel Brake 814
How to Examine Pressure Decrease of Wheel Brake by Brake Tester 815
How to Examine Pressure Decrease of Wheel Brake When Engine Runs 817
Examine Wear of Wheel Brake Disc 818
How to Examine Wear of Wheel Brake Disc 818
Examine Parking Brake Oil Pressure 820
How to Examine Parking Brake Oil Pressure 820
Examine Parking Brake Performance 822
How to Examine Parking Brake Performance 822
Release Parking Brake Manually 823
How to Release Parking Brake Manually 823
Examine Wear Volume of Parking Brake Disc 826
How to Examine Wear Quantity of Parking Brake Disc 826
Hydraulic System 827
Release Remained Pressure from Work Equipment Circuit 827
How to Release Remained Pressure from Work Equipment Circuit 827
Examine and Adjust Work Equipment Oil Pressure 829
How to Examine Work Equipment Oil Pressure 829
How to Adjust Work Equipment Oil Pressure 835
Examine and Adjust Work Equipment EPC Oil Pressure 837
How to Examine Work Equipment EPC Oil Pressure 837
How to Adjust Work Equipment EPC Oil Pressure 841
Bleed Air from Work Equipment Circuit 843
Bleed Air from Work Equipment Pump 843
How to Bleed Air from Work Equipment Cylinder 844
Examine Cooling Fan Speed 845
How to Examine Cooling Fan Speed 845
Examine Cooling Fan Circuit Oil Pressure 847
How to Examine Cooling Fan Circuit Oil Pressure 847
Bleed Air from Cooling Fan Circuit 851
How to Bleed Air from Cooling Fan Circuit 851
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 853
How to Examine ECSS Accumulator Nitrogen Gas Pressure 853
How to Charge ECSS Accumulator with Nitrogen Gas 855
Work Equipment 859
Examine and Adjust Bucket Potentiometer Lever 859
How to Examine Bucket Potentiometer Lever 859
How to Adjust Bucket Potentiometer Lever 860
Examine and Adjust Boom Potentiometer Lever 861
How to Examine Boom Potentiometer Lever 861
How to Adjust Boom Potentiometer Lever 862
CAB Related Parts 863
Examine Directional Lever 863
How to Examine Directional Lever 863
Examine Work Equipment Control Lever 864
How to Examine Work Equipment Control Lever 864
Examine AJSS Lever (AJSS Specifications) 868
How to Examine AJSS Lever 868
Examine Steering Lock Lever (AJSS Specification) 871
How to Examine Steering Lock Lever 871
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications) 872
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 872
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 872
Examine and Adjust Steering Stopper Bolt (AJSS Specifications) 876
How to Examine Steering Stopper Bolt 876
How to Adjust Steering Stopper Bolt 876
Adjust Play of Operator Seat 877
How to Adjust Play of Operator Seat 877
Adjust Mirrors 878
How to Adjust Mirrors 878
Electrical System 880
Set and Adjust Each Equipment 880
Set and Operate Machine Monitor 884
Operator Mode 888
Function to Show Technician Identification Status Screen 888
Function to Show Operator Identification Input Screen 888
Examine Function by LCD (Liquid Crystal Display) 889
Examine Function of Service Meter and Odometer 890
How to Set Usage Limitation and Change Maintenance Password 890
Service Mode 895
How to Operate Service Mode 895
How to See Pre-defined Monitoring Information 899
How to Examine Monitoring Information 916
Abnormality Record Menu 936
How to See Maintenance Record 942
Maintenance Mode Setting 944
How to Set Phone Number Entry 950
Default Setting Menu 952
Testing Menu 969
Adjustment Menu 983
No-Injection Cranking Operation1060
KOMTRAX Settings Menu1063
How to Show Service Message1067
How to Start Up KOMTRAX System (Machine with Gateway Function Controller)1069
How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)1075
Adjust Rearview Camera Angle1077
How to Adjust Rearview Camera Angle1077
Set Region of Bluetooth(R) Compatible Radio1080
How to Set Region of Bluetooth(R) Compatible Radio1080
Handle Voltage Circuit of Engine Controller1082
Handle Battery Disconnect Switch1083
Examine Diodes1084
How to Examine Diodes by Digital Tester1084
How to Examine Diodes by Analog Tester1084
Auto-Greasing Device1085
Bleed the Air in Auto-Greasing System1085
How to Bleed the Air in Auto-Greasing System1085
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1088
Correspondence in Case of Grease Leakage from over Pressure Protection Valve1088
Change Lubrication Time and Lubrication Interval1089
How to Change Lubrication Time and Lubrication Interval1090
Examine and Fill Auto-Greasing1092
How to Examine Auto-Greasing1092
How to Fill Auto-Greasing1093
Pm Clinic1094
Pm Clinic Service1094
Pm Clinic Check Sheet: WA475-101096
Pm Clinic Check Sheet: WA475-10E01108
40 Troubleshooting1121
Table of Contents1122
Precautions Before Work1139
Related Information to Troubleshooting1140
Precautions for Troubleshooting1140
Sequence of Events in Troubleshooting1141
General Troubleshooting Points1143
Troubleshooting Points for Urea SCR System1144
Checks Before Troubleshooting1158
Inspection Procedure Before Troubleshooting1160
Walk-Around Check1160
Test in Accordance with Testing Procedure1162
Examine Fuel Level and Type1162
Examine for Impure Ingredient in Fuel1162
Examine DEF Level and Type1163
Examine Fuel Prefilter1163
Examine Fuel Main Filter1165
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1166
Examine Coolant Level (Expansion Tank)1167
Examine Air Cleaner Clogging1168
Clean Outer Element1169
Replace Element1170
Examine Hydraulic Oil Level1171
Examine Hydraulic Oil Strainer1172
Examine Hydraulic Oil Filter1174
Examine Oil Level in Transmission Case1176
Examine Oil Level in Front Axle Case1177
Examine Oil Level in Rear Axle Case1178
Bleed Air from Fuel System1179
Bleed Air from Hydraulic System1179
How to Examine Electric Equipment1179
Preparation for Troubleshooting of Electrical System1186
Procedure for Troubleshooting1196
Adjustment After Troubleshooting1199
Symptom and Troubleshooting Numbers1201
Information Shown in Troubleshooting Table1206
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness1208
Connector and Wiring Harness Identification Table1211
Connector Layout1224
Connector Contact Connection Table1235
T-Branch Box and T-Branch Adapter Table1282
Fuse Location Table1288
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1292
Prepare Troubleshoot Machine Monitor1296
Procedure to Make Harness Checker on Machine Monitor LCD Unit1298
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])1304
Failure Code Table1306
Troubleshooting by Failure Code (Display of Code)1334
Failure Code [1500L0]1334
Failure Code [1500MA]1335
Failure Code [1500MC]1336
Failure Code [1AR0MA]1337
Failure Code [2F00MA]1338
Failure Code [2F00MB]1342
Failure Code [2G42ZG]1345
Failure Code [2G43ZG]1347
Failure Code [6071NX]1349
Failure Code [879AKA]1351
Failure Code [879AKB]1353
Failure Code [879BKA]1355
Failure Code [879BKB]1357
Failure Code [879CKA]1359
Failure Code [879CKB]1361
Failure Code [879DKZ]1363
Failure Code [879EMC]1365
Failure Code [879FMC]1368
Failure Code [989A00]1371
Failure Code [989L00]1372
Failure Code [989M00]1373
Failure Code [989N00]1374
Failure Code [A1U0N3]1375
Failure Code [A1U0N4]1377
Failure Code [AA10NX]1379
Failure Code [AB00KE]1381
Failure Code [AB00KY]1383
Failure Code [AQ10N3]1385
Failure Code [AS00N3]1387
Failure Code [AS00R2]1389
Failure Code [AS00R3]1390
Failure Code [AS00R4]1391
Failure Code [AS00R5]1392
Failure Code [AS00R6]1393
Failure Code [AS00ZK]1394
Failure Code [AS10KM]1395
Failure Code [AS10NR]1396
Failure Code [AS10NT]1397
Failure Code [B@BAZG]1398
Failure Code [B@BAZK]1399
Failure Code [B@BCNS]1401
Failure Code [B@BCQA]1402
Failure Code [B@BCZK]1404
Failure Code [B@C6NS]1406
Failure Code [B@CFNS]1408
Failure Code [B@HANS]1410
Failure Code [CA115]1411
Failure Code [CA122]1412
Failure Code [CA123]1414
Failure Code [CA131]1416
Failure Code [CA132]1418
Failure Code [CA135]1421
Failure Code [CA141]1423
Failure Code [CA144]1425
Failure Code [CA145]1427
Failure Code [CA153]1429
Failure Code [CA154]1432
Failure Code [CA187]1435
Failure Code [CA221]1437
Failure Code [CA222]1439
Failure Code [CA227]1441
Failure Code [CA234]1442
Failure Code [CA238]1443
Failure Code [CA239]1445
Failure Code [CA249]1447
Failure Code [CA256]1449
Failure Code [CA271]1451
Failure Code [CA272]1453
Failure Code [CA273]1454
Failure Code [CA274]1456
Failure Code [CA322]1457
Failure Code [CA323]1459
Failure Code [CA324]1461
Failure Code [CA325]1463
Failure Code [CA331]1465
Failure Code [CA332]1467
Failure Code [CA343]1469
Failure Code [CA351]1470
Failure Code [CA352]1471
Failure Code [CA356]1474
Failure Code [CA357]1476
Failure Code [CA386]1478
Failure Code [CA431]1479
Failure Code [CA432]1482
Failure Code [CA441]1486
Failure Code [CA442]1488
Failure Code [CA449]1489
Failure Code [CA451]1490
Failure Code [CA452]1492
Failure Code [CA515]1494
Failure Code [CA516]1496
Failure Code [CA553]1498
Failure Code [CA555]1499
Failure Code [CA556]1500
Failure Code [CA559]1501
Failure Code [CA595]1506
Failure Code [CA687]1507
Failure Code [CA689]1509
Failure Code [CA691]1511
Failure Code [CA692]1513
Failure Code [CA697]1515
Failure Code [CA698]1516
Failure Code [CA731]1517
Failure Code [CA778]1518
Failure Code [CA1117]1521
Failure Code [CA1664]1522
Failure Code [CA1669]1525
Failure Code [CA1673]1526
Failure Code [CA1677]1527
Failure Code [CA1678]1528
Failure Code [CA1682]1529
Failure Code [CA1683]1533
Failure Code [CA1684]1535
Failure Code [CA1686]1537
Failure Code [CA1691]1538
Failure Code [CA1694]1541
Failure Code [CA1695]1543
Failure Code [CA1696]1544
Failure Code [CA1712]1546
Failure Code [CA1713]1549
Failure Code [CA1714]1551
Failure Code [CA1715]1552
Failure Code [CA1776]1553
Failure Code [CA1777]1556
Failure Code [CA1843]1559
Failure Code [CA1844]1561
Failure Code [CA1879]1564
Failure Code [CA1881]1567
Failure Code [CA1883]1569
Failure Code [CA1885]1573
Failure Code [CA1887]1575
Failure Code [CA1921]1577
Failure Code [CA1922]1580
Failure Code [CA1923]1585
Failure Code [CA1924]1587
Failure Code [CA1925]1589
Failure Code [CA1927]1591
Failure Code [CA1928]1593
Failure Code [CA1942]1595
Failure Code [CA1963]1596
Failure Code [CA1977]1603
Failure Code [CA1993]1606
Failure Code [CA2185]1609
Failure Code [CA2186]1611
Failure Code [CA2249]1613
Failure Code [CA2265]1614
Failure Code [CA2266]1617
Failure Code [CA2271]1620
Failure Code [CA2272]1622
Failure Code [CA2349]1624
Failure Code [CA2353]1626
Failure Code [CA2357]1628
Failure Code [CA2381]1629
Failure Code [CA2382]1631
Failure Code [CA2383]1633
Failure Code [CA2386]1635
Failure Code [CA2387]1637
Failure Code [CA2555]1638
Failure Code [CA2556]1640
Failure Code [CA2637]1642
Failure Code [CA2639]1644
Failure Code [CA2732]1647
Failure Code [CA2733]1649
Failure Code [CA2741]1651
Failure Code [CA2765]1652
Failure Code [CA2771]1653
Failure Code [CA2777]1659
Failure Code [CA2878]1662
Failure Code [CA2881]1665
Failure Code [CA2976]1670
Failure Code [CA3133]1672
Failure Code [CA3134]1674
Failure Code [CA3135]1676
Failure Code [CA3142]1679
Failure Code [CA3143]1680
Failure Code [CA3144]1681
Failure Code [CA3146]1684
Failure Code [CA3147]1685
Failure Code [CA3148]1686
Failure Code [CA3151]1689
Failure Code [CA3165]1695
Failure Code [CA3167]1697
Failure Code [CA3229]1700
Failure Code [CA3231]1702
Failure Code [CA3232]1704
Failure Code [CA3235]1708
Failure Code [CA3239]1710
Failure Code [CA3241]1713
Failure Code [CA3242]1716
Failure Code [CA3251]1719
Failure Code [CA3253]1721
Failure Code [CA3254]1724
Failure Code [CA3255]1727
Failure Code [CA3256]1731
Failure Code [CA3311]1733
Failure Code [CA3312]1735
Failure Code [CA3313]1738
Failure Code [CA3314]1739
Failure Code [CA3315]1740
Failure Code [CA3316]1743
Failure Code [CA3317]1744
Failure Code [CA3318]1745
Failure Code [CA3319]1748
Failure Code [CA3321]1749
Failure Code [CA3322]1751
Failure Code [CA3419]1754
Failure Code [CA3421]1756
Failure Code [CA3497]1758
Failure Code [CA3498]1759
Failure Code [CA3543]1760
Failure Code [CA3545]1767
Failure Code [CA3547]1769
Failure Code [CA3558]1770
Failure Code [CA3559]1772
Failure Code [CA3562]1774
Failure Code [CA3563]1776
Failure Code [CA3567]1779
Failure Code [CA3568]1782
Failure Code [CA3571]1788
Failure Code [CA3572]1790
Failure Code [CA3574]1792
Failure Code [CA3575]1795
Failure Code [CA3577]1797
Failure Code [CA3578]1799
Failure Code [CA3582]1801
Failure Code [CA3583]1809
Failure Code [CA3596]1811
Failure Code [CA3649]1814
Failure Code [CA3681]1816
Failure Code [CA3682]1821
Failure Code [CA3713]1827
Failure Code [CA3717]1830
Failure Code [CA3718]1831
Failure Code [CA3725]1832
Failure Code [CA3748]1835
Failure Code [CA3751]1838
Failure Code [CA3755]1840
Failure Code [CA3866]1842
Failure Code [CA3867]1846
Failure Code [CA3868]1849
Failure Code [CA3899]1853
Failure Code [CA3911]1855
Failure Code [CA3912]1859
Failure Code [CA3932]1861
Failure Code [CA3933]1863
Failure Code [CA3934]1865
Failure Code [CA3935]1868
Failure Code [CA3936]1870
Failure Code [CA4151]1872
Failure Code [CA4152]1876
Failure Code [CA4155]1880
Failure Code [CA4156]1882
Failure Code [CA4157]1885
Failure Code [CA4158]1887
Failure Code [CA4159]1888
Failure Code [CA4161]1889
Failure Code [CA4162]1892
Failure Code [CA4163]1895
Failure Code [CA4164]1897
Failure Code [CA4165]1899
Failure Code [CA4166]1901
Failure Code [CA4168]1903
Failure Code [CA4169]1906
Failure Code [CA4171]1908
Failure Code [CA4249]1911
Failure Code [CA4251]1913
Failure Code [CA4259]1915
Failure Code [CA4261]1918
Failure Code [CA4277]1921
Failure Code [CA4281]1925
Failure Code [CA4459]1928
Failure Code [CA4461]1930
Failure Code [CA4731]1933
Failure Code [CA4732]1934
Failure Code [CA4739]1935
Failure Code [CA4768]1936
Failure Code [CA4769]1938
Failure Code [CA4842]1941
Failure Code [CA4952]1945
Failure Code [CA5115]1947
Failure Code [CA5179]1950
Failure Code [CA5181]1952
Failure Code [CA5383]1954
Failure Code [D110KB]1956
Failure Code [D150KA]1958
Failure Code [D150KB]1960
Failure Code [D150KY]1962
Failure Code [D160KA]1964
Failure Code [D160KB]1966
Failure Code [D160KY]1968
Failure Code [D191KA]1970
Failure Code [D191KB]1973
Failure Code [D191KY]1976
Failure Code [D192KA]1978
Failure Code [D192KB]1980
Failure Code [D192KY]1982
Failure Code [D19JKZ]1984
Failure Code [D1E6KA]1986
Failure Code [D1E6KB]1988
Failure Code [D1E6KY]1990
Failure Code [D1Q1KA] (Applicable Machine: 120001 to 120801)1992
Failure Code [D1Q1KA] (Applicable Machine: 120802 and Up)1994
Failure Code [D1Q1KB] (Applicable Machine: 120001 to 120801)1996
Failure Code [D1Q1KB] (Applicable Machine: 120802 and Up)1998
Failure Code [D1Q1KY]2000
Failure Code [D1Q1MC]2001
Failure Code [D5ZHKA]2003
Failure Code [D5ZHKB]2005
Failure Code [D5ZHKZ]2007
Failure Code [D5ZHL6]2010
Failure Code [D811MC]2012
Failure Code [D862KA]2013
Failure Code [D8ALKA]2014
Failure Code [D8ALKB]2016
Failure Code [D8AQK4]2018
Failure Code [D8AQKR]2019
Failure Code [D8ARKR]2021
Failure Code [D8G1KT]2023
Failure Code [D8G6KT]2024
Failure Code [DAF0KT]2025
Failure Code [DAF0MB]2026
Failure Code [DAF0MC]2027
Failure Code [DAF3KK]2028
Failure Code [DAF8KB]2030
Failure Code [DAFDKB]2031
Failure Code [DAFGMC]2033
Failure Code [DAFLKA]2034
Failure Code [DAFLKB]2036
Failure Code [DAFQKR]2038
Failure Code [DAQ0KK]2039
Failure Code [DAQ0KT]2042
Failure Code [DAQ0MC]2043
Failure Code [DAQ1KA]2044
Failure Code [DAQ2KK]2046
Failure Code [DAQ2KT]2049
Failure Code [DAQ4KB]2052
Failure Code [DAQ9KQ]2054
Failure Code [DAQLKA]2055
Failure Code [DAQLKB]2057
Failure Code [DAQQKR]2059
Failure Code [DAQRKR]2060
Failure Code [DAQRMA]2061
Failure Code [DAZ9KQ]2062
Failure Code [DAZQKR]2063
Failure Code [DB2QKR]2064
Failure Code [DB2RKR]2072
Failure Code [DB90KK]2079
Failure Code [DB90KT]2082
Failure Code [DB90MC]2083
Failure Code [DB91KA]2084
Failure Code [DB92KK]2086
Failure Code [DB92KT]2089
Failure Code [DB95KX] (Applicable Machine: 120001 to 120801)2092
Failure Code [DB95KX] (Applicable Machine: 120802 and Up)2095
Failure Code [DB96KX] (Applicable Machine: 120001 to 120801)2098
Failure Code [DB96KX] (Applicable Machine: 120802 and Up)2100
Failure Code [DB99KQ]2102
Failure Code [DB9LKA]2103
Failure Code [DB9LKB]2105
Failure Code [DB9QKR]2107
Failure Code [DB9RKR]2108
Failure Code [DB9RMA]2109
Failure Code [DBE5KX] (Applicable Machine: 120001 to 120801)2110
Failure Code [DBE5KX] (Applicable Machine: 120802 and Up)2112
Failure Code [DBE6KX]2114
Failure Code [DBE7KX] (Applicable Machine: 120001 to 120801)2116
Failure Code [DBE7KX] (Applicable Machine: 120802 and Up)2118
Failure Code [DD1LKA]2120
Failure Code [DD1LKB]2123
Failure Code [DD1LLD]2126
Failure Code [DD61KA]2128
Failure Code [DD61KB]2130
Failure Code [DD61LD]2132
Failure Code [DDAAL6]2134
Failure Code [DDB6L4]2136
Failure Code [DDK3KA]2139
Failure Code [DDK3KB]2142
Failure Code [DDK4KA]2145
Failure Code [DDK4KB]2148
Failure Code [DDK6KA]2150
Failure Code [DDK6KB]2153
Failure Code [DDKLKA]2156
Failure Code [DDKLKB]2158
Failure Code [DDNRKA]2160
Failure Code [DDNRKY]2163
Failure Code [DDP5KA]2165
Failure Code [DDUAKR]2167
Failure Code [DDUBKR]2171
Failure Code [DDUCKR]2175
Failure Code [DF50KA]2179
Failure Code [DF50KY]2181
Failure Code [DGF1KA]2183
Failure Code [DGF1KB]2185
Failure Code [DGH2KA]2187
Failure Code [DGH2KX]2189
Failure Code [DGH4KA]2191
Failure Code [DGH4KX]2193
Failure Code [DGR4KB]2195
Failure Code [DGR4KZ]2197
Failure Code [DH21KA]2199
Failure Code [DH21KB]2202
Failure Code [DHA4KA]2205
Failure Code [DHHBKA]2207
Failure Code [DHHBKY]2209
Failure Code [DHHCKA]2211
Failure Code [DHHCKY]2213
Failure Code [DHPCKA]2215
Failure Code [DHPCKY]2217
Failure Code [DHPDKA]2219
Failure Code [DHPDKY]2221
Failure Code [DHT1KX]2223
Failure Code [DHT8KA]2225
Failure Code [DHT8KB]2228
Failure Code [DHT8ZG]2230
Failure Code [DHTCL6]2231
Failure Code [DHUDKA]2233
Failure Code [DHUDKB]2236
Failure Code [DJF1KA]2238
Failure Code [DK30KA]2240
Failure Code [DK30KY]2242
Failure Code [DK55KA]2244
Failure Code [DK55KY]2247
Failure Code [DK55L5]2249
Failure Code [DK59KA] (Applicable Machine: 120001 to 120801)2250
Failure Code [DK59KA] (Applicable Machine: 120802 and Up)2254
Failure Code [DK59KY] (Applicable Machine: 120001 to 120801)2258
Failure Code [DK59KY] (Applicable Machine: 120802 and Up)2262
Failure Code [DK59L8] (Applicable Machine: 120001 to 120801)2266
Failure Code [DK59L8] (Applicable Machine: 120802 and Up)2271
Failure Code [DK5AKA] (Applicable Machine: 120001 to 120801)2276
Failure Code [DK5AKA] (Applicable Machine: 120802 and Up)2280
Failure Code [DK5AKY] (Applicable Machine: 120001 to 120801)2284
Failure Code [DK5AKY] (Applicable Machine: 120802 and Up)2288
Failure Code [DK5BKA] (Applicable Machine: 120001 to 120801)2292
Failure Code [DK5BKA] (Applicable Machine: 120802 and Up)2296
Failure Code [DK5BKY] (Applicable Machine: 120001 to 120801)2300
Failure Code [DK5BKY] (Applicable Machine: 120802 and Up)2304
Failure Code [DK5BL8] (Applicable Machine: 120001 to 120801)2308
Failure Code [DK5BL8] (Applicable Machine: 120802 and Up)2313
Failure Code [DK5CKA] (Applicable Machine: 120001 to 120801)2318
Failure Code [DK5CKA] (Applicable Machine: 120802 and Up)2322
Failure Code [DK5CKY] (Applicable Machine: 120001 to 120801)2326
Failure Code [DK5CKY] (Applicable Machine: 120802 and Up)2330
Failure Code [DK5DKA] (Applicable Machine: 120001 to 120801)2334
Failure Code [DK5DKA] (Applicable Machine: 120802 and Up)2338
Failure Code [DK5DKY] (Applicable Machine: 120001 to 120801)2342
Failure Code [DK5DKY] (Applicable Machine: 120802 and Up)2346
Failure Code [DK5DL8] (Applicable Machine: 120001 to 120801)2350
Failure Code [DK5DL8] (Applicable Machine: 120802 and Up)2355
Failure Code [DK5EKA] (Applicable Machine: 120001 to 120801)2360
Failure Code [DK5EKA] (Applicable Machine: 120802 and Up)2364
Failure Code [DK5EKY] (Applicable Machine: 120001 to 120801)2368
Failure Code [DK5EKY] (Applicable Machine: 120802 and Up)2372
Failure Code [DK60KB]2376
Failure Code [DK60KR]2377
Failure Code [DK70KA]2380
Failure Code [DK70KY]2383
Failure Code [DK71KA]2386
Failure Code [DK71KY]2389
Failure Code [DK72KA]2392
Failure Code [DK72L8]2393
Failure Code [DKA0KA]2397
Failure Code [DKA0KY]2400
Failure Code [DKA0L0]2403
Failure Code [DKA1KA]2406
Failure Code [DKA1KY]2409
Failure Code [DKD0KA]2412
Failure Code [DKD0KY]2414
Failure Code [DKD0L8]2416
Failure Code [DKR0KA]2417
Failure Code [DKR0KB]2420
Failure Code [DKR1KA]2422
Failure Code [DKR1KB]2425
Failure Code [DKR2KX]2427
Failure Code [DKR2NX]2428
Failure Code [DKR5KA]2430
Failure Code [DKR5KB]2433
Failure Code [DLF1KA]2435
Failure Code [DLF1LC]2437
Failure Code [DLM0KA]2439
Failure Code [DLM0LC]2441
Failure Code [DLM3KA]2443
Failure Code [DLM3LC]2445
Failure Code [DLT3KX]2447
Failure Code [DLT4KX]2449
Failure Code [DLT4L0]2451
Failure Code [DPQ2KR]2452
Failure Code [DPQ3KR]2455
Failure Code [DSJ0KR]2458
Failure Code [DV00KB]2461
Failure Code [DV20KB]2463
Failure Code [DV20KY]2465
Failure Code [DW4PKA]2466
Failure Code [DW4PKB]2468
Failure Code [DW4PKY]2470
Failure Code [DW4QKA]2472
Failure Code [DW4QKB]2474
Failure Code [DW4QKY]2476
Failure Code [DW4RKA]2478
Failure Code [DW4RKB]2480
Failure Code [DW4RKY]2482
Failure Code [DW4SKA]2484
Failure Code [DW4SKB]2486
Failure Code [DW4SKY]2488
Failure Code [DW7BKA]2490
Failure Code [DW7BKB]2492
Failure Code [DW7BKY]2494
Failure Code [DWM1KA]2496
Failure Code [DWM1KB]2498
Failure Code [DWM1KY]2500
Failure Code [DWR1KA] (Applicable Machine: 120001 to 120801)2502
Failure Code [DWR1KA] (Applicable Machine: 120802 and Up)2504
Failure Code [DWR1KB] (Applicable Machine: 120001 to 120801)2506
Failure Code [DWR1KB] (Applicable Machine: 120802 and Up)2508
Failure Code [DWR1KY]2510
Failure Code [DWR2KA]2512
Failure Code [DWR2KB]2513
Failure Code [DWR2KY]2514
Failure Code [DWRAKA]2515
Failure Code [DWRAKB]2516
Failure Code [DWRAKY]2517
Failure Code [DWRBKA]2518
Failure Code [DWRBKB]2520
Failure Code [DWRBKY]2522
Failure Code [DWRCKA]2523
Failure Code [DWRCKB]2525
Failure Code [DWRCKY]2527
Failure Code [DWRDKA]2528
Failure Code [DWRDKB]2530
Failure Code [DWRDKY]2532
Failure Code [DWREKA]2534
Failure Code [DWREKB]2536
Failure Code [DWREKY]2538
Failure Code [DWRFKA]2540
Failure Code [DWRFKB]2542
Failure Code [DWRFKY]2544
Failure Code [DWRGKA]2546
Failure Code [DWRGKB]2548
Failure Code [DWRGKY]2550
Failure Code [DWRHKA]2552
Failure Code [DWRHKB]2554
Failure Code [DWRHKY]2556
Failure Code [DWRJKA]2558
Failure Code [DWRJKB]2560
Failure Code [DWRJKY]2562
Failure Code [DWRKKA]2564
Failure Code [DWRKKB]2566
Failure Code [DWRKKY]2568
Failure Code [DWRLKA]2570
Failure Code [DWRLKB]2572
Failure Code [DWRLKY]2574
Failure Code [DX16KA]2576
Failure Code [DX16KB]2578
Failure Code [DX16KY]2580
Failure Code [DX35KA]2582
Failure Code [DX35KB]2584
Failure Code [DX35KY]2586
Failure Code [DX4PKA]2588
Failure Code [DX4PKB]2590
Failure Code [DX4PKY]2592
Failure Code [DXA1KA]2594
Failure Code [DXA1KB]2596
Failure Code [DXA1KY]2598
Failure Code [DXANKA]2599
Failure Code [DXANKB]2601
Failure Code [DXANKY]2603
Failure Code [DXE2KA]2605
Failure Code [DXE2KB]2607
Failure Code [DXE2KY]2609
Failure Code [DXF0KA]2610
Failure Code [DXF0KB]2612
Failure Code [DXF0KY]2614
Failure Code [DXHJKA]2616
Failure Code [DXHJKB]2618
Failure Code [DXHJKY]2620
Failure Code [DXHKKA]2622
Failure Code [DXHKKB]2624
Failure Code [DXHKKY]2626
Failure Code [DY30MA]2628
Failure Code [DY30MC]2632
Failure Code [DY30ME]2637
Failure Code [F313KA]2639
Failure Code [F313KB]2641
Failure Code [F314KA]2642
Failure Code [F314KB]2644
Failure Code [F315KB]2646
Failure Code [F315KY]2648
Failure Code [F316KB]2650
Failure Code [F316KY]2652
Failure Code [F318KB]2654
Failure Code [F318KY]2656
Failure Code [F31AKB]2657
Failure Code [F31AKY]2659
Failure Code [F31BKB]2661
Failure Code [F31BKY]2663
Failure Code [F31CKB]2665
Failure Code [F31CKY]2667
Failure Code [F31DKB]2669
Failure Code [F31DKY]2671
Failure Code [F31EKB]2673
Failure Code [F31EKY]2675
Failure Code [F7FQKR]2677
Failure Code [F7G0MC]2685
Failure Code [FG11KA]2686
Failure Code [FG11KY]2689
Failure Code [FG12KA]2692
Failure Code [FG12KY]2695
Failure Code [FG13L0]2698
Failure Code [FG14MC]2699
Failure Code [FH11N1]2700
Failure Code [FH12N1]2701
Failure Code [FH3100]2702
Failure Code [FL01KR]2703
Failure Code [FL02KR]2704
Failure Code [FL03KR]2705
Failure Code [FL04KR]2706
Failure Code [FL05KR]2707
Failure Code [FL06KR]2708
Failure Code [FL07KR]2709
Failure Code [FL08KR]2710
Failure Code [FL09KR]2711
Failure Code [FL0AKB]2712
Failure Code [FL0ALD]2714
Failure Code [FL0BKB]2715
Failure Code [FL0BLD]2717
Failure Code [FL0CKB]2718
Failure Code [FL0CLD]2720
Failure Code [FL0DKB]2721
Failure Code [FL0DLD]2723
Failure Code [FL0GLD]2724
Failure Code [FL0HLD]2725
Failure Code [FL0JLD]2726
Failure Code [FL0KLD]2727
Failure Code [FL0LLD]2728
Failure Code [FL0MLD]2729
Failure Code [FM10MA]2730
Failure Code [FM11MA]2731
Failure Code [FM12MA]2732
Failure Code [FM13MA]2733
Failure Code [FM14MA]2734
Failure Code [FS10ZE]2735
Failure Code [LA00L3]2736
Failure Code [M000NS]2737
Failure Code [M000ZG]2738
Troubleshooting of Electrical System (E-Mode)2739
Engine Does Not Start (Engine Does Not Crank)2739
Manual Preheating System Does Not Operate2746
Automatic Preheating System Does Not Operate2749
While Preheating is in Operation, Preheating Pilot Lamp Does Not Come On2752
The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing2754
LCD Unit on Machine Monitor Shows Nothing2757
Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)2760
LCD Screen on Machine Monitor Does Not Show Correctly2763
Meter Unit Display on Machine Monitor is Abnormal2766
Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal2769
LED Unit Lamp on Machine Monitor is Abnormal2773
Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally2776
DEF Level is Not Shown Correctly2777
Rearview Monitor Does Not Come On or Backlight Flickers2780
Rearview Monitor Images are Not Shown Clearly2783
Rearview Monitor Brightness Cannot be Adjusted2786
Night Mode Lamp of Rearview Monitor is Abnormal2790
Air Cleaner Clogging Indicator Lamp Does Not Come On2794
Radiator Coolant Level Caution Lamp Does Not Come On2796
Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position2798
Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low2802
Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low2803
Fuel Gauge Does Not Show Normally2804
Hydraulic Oil Temperature Gauge Does Not Rise or Hydraulic Oil Temperature Caution Lamp Does Not Come On2806
Seatbelt Caution Lamp Does Not Show Normally2808
Alarm Buzzer Does Not Operate2809
Alarm Buzzer Does Not Stop2811
Traction Control is Not Released When One-Push Traction Control Switch is Pushed2812
Bucket Positioner Does Not Work When Bucket Control Switch is Pushed (Applicable Machine: 120001 to 120801)2814
Bucket Positioner Does Not Work When Bucket Control Switch is Pushed (Applicable Machine: 120802 and Up)2816
Load Meter Auto Measurement Function and Empty Bucket Calibration Function Do Not Operate When Load Meter Auto Measurement Switch is Pushed (Applicable Machine: 120001 to 120801)2817
Load Meter Auto Measurement Function and Empty Bucket Calibration Function Do Not Operate When Load Meter Auto Measurement Switch is Pushed (Applicable Machine: 120802 and Up)2819
Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in FORWARD or REVERSE Travel When Parking Brake is Released2820
Flow of Loader Pump Does Not Increase from the Minimum Rate2824
Directional Selector (FNR) Switch Mode is Not Selected or Not Released2825
Traction Control Setting Can Not Switch When Traction Control Switch is Pushed2826
ECSS Function Cannot be Selected or Cannot be Released2827
Function of Auto-Digging is Not Enabled or Disabled When Auto-Digging Switch is Pushed2828
Remote Boom Positioner Cannot be Set When Boom Positioner Switch is Pushed2829
Setting of Remote Bucket Positioner Can Not Change When Bucket Positioner Switch is Pushed2830
Horn Does Not Operate (Steering Wheel Specification)2831
Horn Does Not Operate (AJSS Specification)2834
Horn Does Not Stop (Steering Wheel Specification)2837
Horn Does Not Stop (AJSS Specification)2839
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On (Steering Wheel Specification)2841
Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On (AJSS Specification)2843
Clearance Lamp and Tail Lamp Do Not Come On or Go Out (Steering Wheel Specification)2845
Clearance Lamp and Tail Lamp Do Not Come on or Go Out (AJSS Specification)2849
Low Beam and High Beam of Headlamp Do Not Come On or Go Out (Steering Wheel Specification)2853
Low Beam and High Beam of Headlamp Do Not Come On or Go Out (AJSS Specification)2857
Low Beam of Headlamp Does Not Come On or Go Out (Steering Wheel Specification)2861
Low Beam of Headlamp Does Not Come On or Go Out (AJSS Specification)2863
High Beam of Headlamp Does Not Come On or Go Out (Steering Wheel Specification)2865
High Beam of Headlamp Does Not Come On or Go Out (AJSS Specification)2867
Front Working Lamp Does Not Come On or Go Out2869
Front Working Lamp Does Not Come On or Go Off (for European Union and Turkey Specifications)2873
Rear Working Lamp Does Not Come On or Go Out2877
Turn Signal Lamps and Hazard Lamp Do Not Come On or Go Out (Steering Wheel Specification)2881
None of Turn Signal Lamps or Hazard Lamp Comes on or Goes off (Steering Wheel Specification for EU and Turkey)2884
Turn Signal Lamps and Hazard Lamp Do Not Come On or Go Out (AJSS Specification)2887
Turn Signal Lamps Do Not Come On or Go Out (Steering Wheel Specification)2890
Turn Signal Lamps Do Not Come on or Go off (Steering Wheel Specification for EU and Turkey)2893
Turn Signal Lamps Do Not Come On or Go Out (AJSS Specification)2896
Hazard Lamp Does Not Come On or Go Out (Steering Wheel Specification)2899
Hazard Lamp Does Not Come On or Go Off (Steering Wheel Specification for EU and Turkey)2903
Hazard Lamp Does Not Come On or Go Out (AJSS Specification)2907
Brake Lamp Does Not Come On or Stays Lit2910
Backup Lamp Does Not Come On or Stays Lit2914
Backup Buzzer Does Not Sound or Continues to Sound2917
Front Wiper Does Not Operate (Steering Wheel Specification)2919
Front Wiper Does Not Operate (AJSS Specification)2923
Rear Wiper Does Not Operate (Steering Wheel Specification)2927
Rear Wiper Does Not Operate (AJSS Specification)2931
Fuel Feed Pump Does Not Operate or Stop Automatically2935
Fan Does Not Rotate in Reverse2939
Fan Remains Rotated in Reverse2940
Window Washer Does Not Operate2941
KOMTRAX System Does Not Operate Correctly2944
Auto-Greasing Pump Display Shows [FCS]2945
Auto-Greasing Pump Display Shows [FLL]2947
Auto-Greasing System Does Not Operate or Stop2948
Angle of Rear View Mirror Can Not be Adjusted When Electric Mirror Angle Adjustment Switch is Operated2950
Heater Mirror Does Not Work or Turn OFF2957
Rear Heated Wire Glass Does Not Work or Turn OFF2961
Energized Tiltable Engine Hood Does Not Open/Close2965
Command Selector Operation Does Not Work2970
Air Conditioner Panel Operation Does Not Work2973
Travel Speed Control Dial and Travel Speed Control Dial Gauge on Machine Monitor Do Not Agree2976
Keypad Back Light and Pilot Lamp Do Not Dim When Monitor Brightness Selector Switch is at the Night Mode2978
Back Light of Air Conditioner Panel Does Not Dim When Monitor Brightness Selector Switch is at the Night Mode2980
Command Selector Back Light and Pilot Lamp Do Not Dim When Monitor Brightness Selector Switch is at the Night Mode2982
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)2984
Information Shown in Troubleshooting Table (H-Mode)2984
Failure Mode and Cause Table2985
Machine Does Not Move, or Travel Speed is Slow3031
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 0 to 1 km/h (Does Not Move))3032
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 1 to 9km/h)3036
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 9 to 26km/h)3038
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 0 to 1 km/h (Does Not Move), Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))3039
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))3040
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 1 to 9km/h)3041
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 9 to 26 km/h)3044
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 1 to 7 km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))3045
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))3046
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14km/h, Reverse Travel Speed 1 to 9km/h)3047
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14km/h, Reverse Travel Speed 9 to 26 km/h)3049
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 7 to 14km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))3051
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36km/h, Reverse Travel Speed 0 to 1 km/h (Does Not Move))3052
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36km/h, Reverse Travel Speed 1 to 9km/h)3053
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36km/h, Reverse Travel Speed 9 to 26 km/h)3054
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 14 to 36km/h, Reverse Travel Speed 26 km/h or More (Reverse Travel is Correct))3055
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 0 to 1 km/h (Does Not Move))3056
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 1 to 9 km/h)3057
Machine Does Not Move, or Travel Speed is Slow (Forward Travel Speed 36 km/h or More (Forward Travel is Correct), Reverse Travel Speed 9 to 26km/h)3058
Not Sufficient Drawbar Pull3059
Rim Pull is Weak (Only Immediately After the Machine Goes Into the Objective Material)3060
Not Sufficient Drawbar Pull (Only When Work Equipment is in Operation)3061
Not Sufficient Drawbar Pull (Only When You Increase Travel Speed, Travel Uphill at 0 to 7 km/h, or When You Dig)3062
Not Sufficient Drawbar Pull (Only When You Increase Travel Speed, Travel Uphill at 7 to 14 km/h (0 to 7 km/h is Correct)3064
Strong Shocks are Made When You Start Machine or Shift Gears3065
Strong Shocks are Made When Machine Moves Off and Do the Gear Shift (Only When Machine Moves Off)3066
Strong Shocks are Made at Move Off and Gear Shift (at All Gear Shift)3068
Strong Shocks are Made at Move Off and Gear Shift (Specified Gear Shift)3070
No Shock is Made at Move Off and Gear Shift, but Time Lag is Large3072
Engine Speed Drops Largely3075
Engine Speed Decreases Largely (Only Immediately After Machine Goes in Objective Material)3076
Engine Speed Drops Largely (Only When Work Equipment is in Operation)3077
Engine Speed Decreases Largely (Other Than When Immediately After You Thrust Into Object or When Work Equipment is in Operation)3078
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation)3080
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation) (Only When the Travel Speed is Between 0 and 7 km/h or Between 14 and 38 km/h)3081
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or a Time Lag Occurs at Directional Selection Operation) (Only When the Travel Speed is Between 7 and 14 km/h)3082
The Braking Force of the Engine Brake is Not Sufficient (Braking Force is Weak at Downhill Travel, or Time Lag Occurs at Directional Selection Operation) (Regardless of Travel Speed)3083
Machine Does Not Turn (For Steering Wheel Spec)3086
Machine Does Not Turn (AJSS Specification)3088
Turning Response is Unsatisfactory (For Steering Wheel Specification)3090
Turning Response is Unsatisfactory (AJSS Specification)3092
Steering Wheel is Heavy to Operate3094
Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Specification)3095
Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification)3097
Turning Radius is Different on the Left and Right3099
Wheel Brakes Do Not Operate or are Weak3100
Wheel Brakes are Not Released or Drag3102
Parking Brake Does Not Operate or is Weak3103
Parking Brake is Not Released or Drags3104
Boom Does Not Rise3106
Boom Moves Slow or Lacks Lifting Force3109
Rising Boom Slows Down at Specified Height3112
Lift Cylinders Can Not Hold Bucket on Ground3113
Hydraulic Drift of Boom is Large3115
Boom Moves Up and Down During Operation3116
Bucket Does Not Tilt Back3117
Bucket Moves Slow or Lacks Tilt-Back Force3120
Bucket Slows Down During Tilt Back or Dump Operation3123
Bucket Cylinder Does Not Hold Bucket on Ground3124
Hydraulic Drift of Bucket is Large3126
Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)3127
Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move3128
Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment3129
Large Shocks are Made When Work Equipment Starts to Move and Stops3131
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves3134
ECSS Does Not Operate and Machine Pitches and Bounces3135
Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)3136
Unusual Noise is Heard from Around Fan3138
Troubleshooting of Engine (S-Mode)3139
Information Shown in Troubleshooting Table (S-Mode)3139
Engine Does Not Crank When Starting Switch is Turned to Start Position3140
Engine Cranks but No Exhaust Smoke Comes Out3141
Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)3142
Engine Startability is Unsatisfactory3143
Engine Does Not Pick Up Smoothly3145
Engine Stops During Operation3147
Engine Does Not Rotate Smoothly3149
Engine Lacks Output (or Lacks Power)3150
KDPF Becomes Clogged in a Short Time3152
Engine Oil Consumption is Excessive3154
Engine Oil Becomes Dirty Quickly3155
Fuel Consumption is Excessive3156
Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)3157
Engine Oil Pressure Drops3158
Fuel Mixes Into Engine Oil3160
Water Mixes Into Engine Oil (Milky)3161
Coolant Temperature Increases Too High (Overheat)3162
Unusual Noise is Heard3163
Vibration is Excessive3164
Air Cannot be Bled from Fuel Circuit3165
Active Regeneration is Done Frequently3166
Active Regeneration Continues Long3168
White Smoke is Exhausted During Active Regeneration3169
DEF Consumption is Excessive3170
There is an Unusual Smell (Irritating Odor)3172
Foreign Materials Enter DEF (DEF Increases)3173
Troubleshooting for Auto-Greasing System3174
Outline of Failure Display3174
Troubleshooting When Error Message [FPS] is Shown3175
Troubleshooting for Auto-Greasing Pump3176
Replace Pump Element3178
Troubleshooting for Grease Supply System3179
Replace Auto-Greasing Controller3181
Assembly procedure when disassembled in troubleshooting3182
50 Disassembly and Assembly3183
Table of Contents3184
Precautions Before Work3189
Related Information on Disassembly and Assembly3190
How to Read This Manual3190
Coating Materials List3192
Special Tool List3197
Sketches of Special Tools3221
Prepare3245
Drain and Add Coolant3245
How to Drain Coolant3246
How to Add Coolant3248
Drain and Add Hydraulic Oil3250
How to Drain Hydraulic Oil3251
How to Add Hydraulic Oil3252
Drain and Add Fuel3254
How to Drain Fuel3255
How to Add Fuel3255
Collect and Refill Refrigerant3256
How to Collect Refrigerant3257
How to Refill Refrigerant3258
Engine and Cooling System3259
Remove and Install Supply Pump Assembly3259
How to Remove Supply Pump Assembly3260
How to Install Supply Pump Assembly3268
Remove and Install Injector Assembly3278
How to Remove Injector Assembly3279
How to Install Injector Assembly3292
Remove and Install Fuel Doser Assembly3306
How to Remove Fuel Doser Assembly3307
How to Install Fuel Doser Assembly3310
Remove and Install Cylinder Head Assembly3313
How to Remove Cylinder Head Assembly3313
How to Install Cylinder Head Assembly3335
Remove and Install EGR Valve Assembly3360
How to Remove EGR Valve Assembly3360
How to Install EGR Valve Assembly3363
Remove and Install EGR Cooler Assembly3365
How to Remove EGR Cooler Assembly3365
How to Install EGR Cooler Assembly3371
Remove and Install Starter Assembly3378
How to Remove Starting Motor Assembly3379
How to Install Starting Motor Assembly3382
Remove and Install Air Conditioner Compressor Belt3387
How to Remove Air Conditioner Compressor Belt3388
How to Install Air Conditioner Compressor Belt3390
Remove and Install Alternator Belt3393
How to Remove Alternator Belt3394
How to Install Alternator Belt3397
Remove and Install Automatic Tensioner3400
How to Remove Automatic Tensioner3400
How to Install Automatic Tensioner3401
Remove and Install Radiator Assembly3402
How to Remove Radiator Assembly3403
How to Install Radiator Assembly3408
Remove and Install Cooling Fan and Fan Motor Assembly3414
How to Remove Cooling Fan and Fan Motor Assembly3415
How to Install Cooling Fan and Fan Motor Assembly3418
Remove and Install Hydraulic Oil Cooler Assembly3422
How to Remove Hydraulic Oil Cooler Assembly3423
How to Install Hydraulic Oil Cooler Assembly3427
Remove and Install Aftercooler Assembly3431
How to Remove Aftercooler Assembly3432
How to Install Aftercooler Assembly3436
Remove and Install Power Train Oil Cooler Assembly3440
How to Remove Power Train Oil Cooler Assembly3441
How to Install Power Train Oil Cooler Assembly3449
Remove and Install Engine and Transmission Assembly3460
How to Remove Engine and Transmission Assembly3462
How to Install Engine and Transmission Assembly3495
Disconnect and Connect Engine and Transmission Assembly3528
How to Disconnect Engine and Transmission Assembly3529
How to Connect Engine and Transmission Assembly3532
Remove and Install Engine Front Oil Seal3535
How to Remove Engine Front Oil Seal3536
How to Install Engine Front Oil Seal3542
Remove and Install Engine Rear Oil Seal3549
How to Remove Engine Rear Oil Seal3550
How to Install Engine Rear Oil Seal3551
Remove and Install Engine Hood Assembly3557
How to Remove Engine Hood Assembly3558
How to Install Engine Hood Assembly3568
Remove and Install Fuel Tank Assembly3578
How to Remove Fuel Tank Assembly3579
How to Install Fuel Tank Assembly3584
Remove and Install DEF Tank Assembly3590
How to Remove DEF Tank Assembly3591
How to Install DEF Tank Assembly3597
Remove and Install DEF Tank Sensor Flange Assembly3601
How to Remove DEF Tank Sensor Flange Assembly3602
How to Install DEF Tank Sensor Flange Assembly3603
Remove and Install DEF Tank Sensor3606
How to Remove DEF Tank Sensor3607
How to Install DEF Tank Sensor3608
Remove and Install DEF Tank Strainer3615
How to Remove DEF Tank Strainer3616
How to Install DEF Tank Strainer3616
Remove and Install KDPF Assembly3617
How to Remove KDPF Assembly3618
How to Install KDPF Assembly3625
Disassemble and Assemble KDPF Assembly3632
How to Disassemble KDPF Assembly3633
How to Assemble KDPF Assembly3638
Remove and Install SCR Assembly3645
How to Remove SCR Assembly3646
How to Install SCR Assembly3648
Remove and Install KDPF and SCR Assembly3651
How to Remove KDPF and SCR Assembly3652
How to Install KDPF and SCR Assembly3662
Remove and Install Bellows Pipe Assembly3672
How to Remove Bellows Pipe Assembly3673
How to Install Bellows Pipe Assembly3678
Remove and Install KCCV Assembly3685
How to Remove KCCV Assembly3686
How to Install KCCV Assembly3689
Remove and Install VGT Assembly3693
How to Remove VGT Assembly3693
How to Install VGT Assembly3701
Remove and Install DEF Mixing Tube3709
How to Remove DEF Mixing Tube3710
How to Install DEF Mixing Tube3715
Remove and Install DEF Injector3721
How to Remove DEF Injector3722
How to Install DEF Injector3726
Remove and Install DEF Pump3730
How to Remove DEF Pump3731
How to Install DEF Pump3735
Remove and Install DEF Hose3738
How to Remove DEF Hose3739
How to Install DEF Hose3749
Remove and Install Air Cleaner Assembly3757
How to Remove Air Cleaner Assembly3758
How to Install Air Cleaner Assembly3760
Remove and Install Air Conditioner Compressor Assembly3763
How to Remove Air Conditioner Compressor Assembly3764
How to Install Air Conditioner Compressor Assembly3765
Remove and Install Air Conditioner Condenser Assembly3767
How to Remove Air Conditioner Condenser Assembly3768
How to Install Air Conditioner Condenser Assembly3771
Power Train3774
Remove and Install HST Motor Assembly3774
How to Remove HST Motor Assembly3775
How to Install HST Motor Assembly3780
Disassemble and Assemble Transmission Assembly3786
How to Disassemble Transmission Assembly3788
How to Assemble Transmission Assembly3821
Disassemble and Assemble Transmission Clutch Pack Assembly3858
How to Disassemble Transmission Clutch Pack Assembly3859
How to Assemble Transmission Clutch Pack Assembly3877
Remove and Install Front Axle Assembly3904
How to Remove Front Axle Assembly3905
How to Install Front Axle Assembly3907
Remove and Install Rear Axle Assembly3910
How to Remove Rear Axle Assembly3911
How to Install Rear Axle Assembly3920
Disassemble and Assemble Axle Housing Assembly3928
How to Disassemble Axle Housing Assembly3930
How to Assemble Axle Housing Assembly3936
Disassemble and Assemble Differential Assembly3946
How to Disassemble Differential Assembly3948
How to Assemble Differential Assembly3958
Steering System3978
Remove and Install Steering Valve Assembly3978
How to Remove Steering Valve Assembly3979
How to Install Steering Valve Assembly3985
Remove and Install Orbitrol Valve Assembly3991
How to Remove Orbitrol Valve Assembly3992
How to Install Orbitrol Valve Assembly3994
Remove and Install Rotary Valve Assembly3996
How to Remove Rotary Valve Assembly3997
How to Install Rotary Valve Assembly4002
Brake System4007
Remove and Install Parking Brake Disc and Plate4007
How to Remove Parking Brake Disc and Plate4008
How to Install Parking Brake Disc and Plate4012
Undercarriage and Frame4016
Remove and Install Center Hinge Pin4016
How to Remove Center Hinge Pin4018
How to Install Center Hinge Pin4025
Remove and Install Counterweight Assembly4034
How to Remove Counterweight Assembly4035
How to Install Counterweight Assembly4042
Remove and Install Full-Length Fender Assembly4048
How to Remove Full-Length Fender Assembly4049
How to Install Full-Length Fender Assembly4051
Hydraulic System4053
Remove and Install Hydraulic Tank Assembly4053
How to Remove Hydraulic Tank Assembly4055
How to Install Hydraulic Tank Assembly4066
Remove and Install Work Equipment Pump and Power Train Pump Assembly4077
How to Remove Work Equipment Pump and Power Train Pump Assembly4078
How to Install Work Equipment Pump and Power Train Pump Assembly4082
Remove and Install Steering Pump, Cooling Fan Pump, and HST Charge Pump Assembly4087
How to Remove Steering Pump, Cooling Fan Pump, and HST Charge Pump Assembly4088
How to Install Steering Pump, Cooling Fan Pump, and HST Charge Pump Assembly4093
Remove and Install Control Valve Assembly4098
How to Remove Control Valve Assembly4100
How to Install Control Valve Assembly4106
Work Equipment4112
Remove and Install Work Equipment Assembly4112
How to Remove Work Equipment Assembly4113
How to Install Work Equipment Assembly4121
Disassemble and Assemble Steering Cylinder Assembly4129
How to Disassemble Steering Cylinder Assembly4130
How to Assemble Steering Cylinder Assembly4131
Disassemble and Assemble Lift Cylinder Assembly4134
How to Disassemble Lift Cylinder Assembly4135
How to Assemble Lift Cylinder Assembly4137
Disassemble and Assemble Bucket Cylinder Assembly4140
How to Disassemble Bucket Cylinder Assembly4141
How to Assemble Bucket Cylinder Assembly4143
CAB Related Parts4146
Remove and Install Operator Cab Assembly4146
How to Remove Operator Cab Assembly4147
How to Install Operator Cab Assembly4163
Remove and Install Operator Cab Glass (Adhered Glass)4180
How to Remove Operator Cab Glass (Adhered Glass)4181
How to Install Operator Cab Glass (Adhered Glass)4182
Remove and Install Air Conditioner Unit Assembly4190
How to Remove Air Conditioner Unit Assembly4192
How to Install Air Conditioner Unit Assembly4205
Remove and Install Operator Seat Assembly4219
How to Remove Operator Seat Assembly4220
How to Install Operator Seat Assembly4222
How to Remove and Install Seat Belt4224
How to Remove Seat Belt4225
How to Install Seatbelt4225
Remove and Install AJSS Lever Switch Assembly4227
How to Remove AJSS Lever Switch Assembly4228
How to Install AJSS Lever Switch Assembly4231
Electrical System4235
Remove and Install Engine Controller Assembly4235
How to Remove Engine Controller Assembly4236
How to Install Engine Controller Assembly4240
Remove and Install Work Equipment Controller Assembly4244
How to Remove Work Equipment Controller Assembly4245
How to Install Work Equipment Controller Assembly4248
Remove and Install Transmission Controller Assembly4251
How to Remove Transmission Controller Assembly4252
How to Install Transmission Controller Assembly4254
Remove and Install Monitor Controller Assembly4256
How to Remove Monitor Controller Assembly4257
How to Install Monitor Controller Assembly4258
Remove and Install Machine Monitor Assembly4260
How to Remove Machine Monitor Assembly4261
How to Install Machine Monitor Assembly4267
Remove and Install Mass Air Flow and Temperature Sensor4274
How to Remove Mass Air Flow and Temperature Sensor4275
How to Install Mass Air Flow and Temperature Sensor4276
Remove and Install KCCV Crankcase Pressure Sensor4278
How to Remove KCCV Crankcase Pressure Sensor4279
How to Install KCCV Crankcase Pressure Sensor4280
Remove and Install KDPF Temperature Sensor4282
How to Remove KDPF Temperature Sensor4283
How to Install KDPF Temperature Sensor4286
Remove and Install KDPF Differential Pressure Sensor4289
How to Remove KDPF Differential Pressure Sensor4290
How to Install KDPF Differential Pressure Sensor4293
Remove and Install SCR Temperature Sensor4296
How to Remove SCR Temperature Sensor4297
How to Install SCR Temperature Sensor4300
Remove and Install Ammonia Sensor4303
How to Remove Ammonia Sensor4304
How to Install Ammonia Sensor4306
Remove and Install SCR Outlet NOx Sensor4309
How to Remove SCR Outlet NOx Sensor4310
How to Install SCR Outlet NOx Sensor4312
Remove and Install Gateway Controller Assembly4314
How to Remove Gateway Controller Assembly4315
How to Install Gateway Controller Assembly4316
60 Maintenance Standard4319
Table of Contents4320
Engine and Cooling System4321
Maintenance Standard for Engine Mount4321
Maintenance Standard for Brake and Cooling Fan Pump4322
Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump4323
Maintenance Standard for Cooling Fan Motor4324
Power Train4326
Maintenance Standard for Drive Shaft4326
Maintenance Standard for Transmission4327
Maintenance Standard for Transmission Control Valve4329
Maintenance Standard for ECMV4333
Maintenance Standard for Valve Assembly (Main Relief, Power Train Oil Cooler Relief)4335
Maintenance Standard for Front Axle4336
Maintenance Standard for Rear Axle4337
Maintenance Standard for Front Conventional Differential4338
Maintenance Standard for Rear Conventional Differential4341
Maintenance Standard for Front Limited Slip Differential4344
Maintenance Standard for Rear Limited Slip Differential4346
Maintenance Standard for Final Drive4348
Steering System4351
Maintenance Standard for Steering Column4351
Maintenance Standard for Steering Pump4352
Maintenance Standard for Servo Valve of Steering Pump4355
Maintenance Standard for Steering Valve4356
Maintenance Standard for Steering Cylinder4358
Maintenance Standard for Secondary Steering Pump4361
Brake System4362
Maintenance Standard for Charge Valve4362
Maintenance Standard for Brake Circuit Accumulator4364
Maintenance Standard for Slack Adjuster4365
Maintenance Standard for Front Brake4366
Maintenance Standard for Rear Brake4368
Maintenance Standard for Parking Brake4370
Maintenance Standard for Parking Brake Solenoid Valve4371
Maintenance Standard for Brake Cooling Strainer4372
Undercarriage and Frame4373
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin4373
Hydraulic System4379
Maintenance Standard for Hydraulic Tank4379
Maintenance Standard for Work Equipment Pump4380
Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump4381
Maintenance Standard for HST Charge Pump4383
Maintenance Standard for HST Charge Pump and Brake Cooling Pump4385
Maintenance Standard for Control Valve4387
Maintenance Standard for Work Equipment Lock Solenoid Valve4396
Work Equipment4397
Maintenance Standard for Work Equipment Linkage4397
Maintenance Standard for Bucket4401
Maintenance Standard for Lift Cylinder4402
Maintenance Standard for Bucket Cylinder4403
80 Appendix4405
Table of Contents4406
Precautions Before Work4408
Air Conditioner System4409
Precautions for Refrigerant4409
Air Conditioner Component4410
Specifications of Air Conditioner4412
Structure and Function of Refrigeration Cycle4413
Outline of Refrigeration Cycle4414
Component Parts of Air Conditioner System4416
Air Conditioner Unit4416
Configuration Diagram of Air Conditioner Unit4416
Function of Air Conditioner Unit4417
Component Parts of Air Conditioner Unit4418
Function of Evaporator as Air Conditioner Unit Component4418
Function of Inside Air Temperature Sensor as Air Conditioner Unit Component4418
Function of Blower Amplifier as Air Conditioner Unit Component4419
Function of Blower OFF Relay as Air Conditioner Unit Component4419
Function of Compressor Clutch Relay as Air Conditioner Unit Component4419
Function of Heater Core as Air Conditioner Unit Component4419
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component4419
Function of Servo Motor as Air Conditioner Unit Component4419
Function of Expansion Valve as Air Conditioner Unit Component4420
Function of Dual Pressure Switch4420
Air Conditioner Controller4421
Structure of Air Conditioner Controller4421
Compressor4422
Structure of Compressor4422
Specifications of Compressor4422
Function of Compressor4422
Condenser4423
Structure of Condenser4423
Specifications of Condenser4423
Function of Condenser4423
Receiver Drier4424
Structure of Receiver Dryer4424
Specifications of Receiver Dryer4424
Function of Receiver Dryer4424
Air Conditioner Related Sensors4425
Function of Sunlight Sensor4425
Function of Outside Air Temperature Sensor4425
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4426
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4428
System Diagram of Air Conditioner4431
Input and Output Signals of Air Conditioner Controller4432
Function of Air Conditioner Controller4433
Locations of Air Conditioner Parts and Layout of Connectors4434
Examine Air Conditioner with Self-Diagnosis Function4439
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor4440
Examine Temperature Control Function4442
How to Examine Temperature Control Function4442
Examine Vent (Mode) Changeover4444
How to Examine Vent (Mode) Changeover4444
Examine Fresh/Recirc Air Changeover4446
How to Examine Fresh/Recirc Air Changeover4446
Examine Evaporator Temperature Sensor4447
Examine Relay4449
How to Examine Relay4449
Air Conditioner Troubleshooting Chart 14451
Air Conditioner Troubleshooting Chart 24452
Information Shown in Troubleshooting Table4455
Failure Code [879AKA]4456
Failure Code [879AKB]4458
Failure Code [879BKA]4460
Failure Code [879BKB]4462
Failure Code [879CKA]4464
Failure Code [879CKB]4466
Failure Code [879DKZ]4468
Failure Code [879EMC]4470
Failure Code [879FMC]4473
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4476
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4480
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4484
Troubleshooting for Fresh/Recirc Air Changeover4488
Troubleshooting by Gauge Pressure4490
Connect Service Tool4493
How to Connect Service Tool4494
Precautions for Disconnection and Connection of Air Conditioner Piping4495
Handle Compressor Oil4497
90 Circuit Diagrams4499
Table of Contents4500
How to Read the Codes for Electric Cable4502
Hydraulic Circuit Diagram4506
Symbols Used in Hydraulic Circuit Diagram4506
Hydraulic Circuit Diagram for Work Equipment (1/4) (Steering Wheel Specification)4511
Hydraulic Circuit Diagram for Work Equipment (2/4) (Steering Wheel Specification)4513
Hydraulic Circuit Diagram for Work Equipment (3/4) (AJSS Specification)4515
Hydraulic Circuit Diagram for Work Equipment (4/4) (AJSS Specification)4517
Hydraulic Circuit Diagram for Work Equipment (Combination of Boom RAISE, Steer Left, and Brake Operation 1/2) (Steering Wheel Specification)4519
Hydraulic Circuit Diagram for Work Equipment (Combination of Boom RAISE, Steer Left, and Brake Operation 2/2) (Steering Wheel Specification)4521
Power Train Hydraulic Circuit Diagram4523
Hydraulic Auto-Greasing Diagram4525
Electrical Circuit Diagram4527
Symbols Used in Electric Circuit Diagram4527
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (1/11)4531
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (2/11)4533
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (3/11)4535
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (4/11)4537
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (5/11)4539
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (6/11)4541
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (7/11)4543
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (8/11)4545
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (9/11)4547
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (10/11)4549
Electrical Circuit Diagram of Machine (Applicable Machine: 120001 to 120801) (11/11)4551
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (1/11)4553
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (2/11)4555
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (3/11)4557
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (4/11)4559
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (5/11)4561
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (6/11)4563
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (7/11)4565
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (8/11)4567
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (9/11)4569
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (10/11)4571
Electrical Circuit Diagram of Machine (Applicable Machine: 120802 and Up) (11/11)4573
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (1/9)4575
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (2/9)4577
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (3/9)4579
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (4/9)4581
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (5/9)4583
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (6/9)4585
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (7/9)4587
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (8/9)4589
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120001 to 120801) (9/9)4591
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (1/10)4593
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (2/10)4595
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (3/10)4597
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (4/10)4599
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (5/10)4601
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (6/10)4603
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (7/10)4605
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (8/10)4607
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (9/10)4609
Electrical Circuit Diagram of Floor (AJSS Specification) (Applicable Machine: 120802 and Up) (10/10)4611
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (1/10)4613
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (2/10)4615
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (3/10)4617
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (4/10)4619
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (5/10)4621
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (6/10)4623
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (7/10)4625
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (8/10)4627
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (9/10)4629
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120001 to 120801) (10/10)4631
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (1/11)4633
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (2/11)4635
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (3/11)4637
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (4/11)4639
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (5/11)4641
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (6/11)4643
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (7/11)4645
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (8/11)4647
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (9/11)4649
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (10/11)4651
Electrical Circuit Diagram of Floor (Steering Wheel Specification)(Applicable Machine: 120802 and Up) (11/11)4653
Index4655
S.M 30/12/24
