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KOMATSU WA200-8E0 WHEEL LOADER SHOP MANUAL VENBM35000 – PDF DOWNLOAD
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KOMATSU WA200-8E0 WHEEL LOADER SHOP MANUAL VENBM35000 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA200-8E0 WHEEL LOADER SHOP MANUAL VENBM35000 – PDF DOWNLOAD
Language : English
Pages : 3108
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA200-8E0 WHEEL LOADER SHOP MANUAL VENBM35000 – PDF DOWNLOAD
00 INDEX AND FOREWORD.................................................................................................................... 3 INDEX................................................................................................................................ 4 FOREWORD, SAFETY, BASIC INFORMATION.................................................................................................. 21 HOW TO READ THE SHOP MANUAL...................................................................................................... 21 SAFETY NOTICE FOR OPERATION...................................................................................................... 23 PRECAUTIONS TO PREVENT FIRE...................................................................................................... 31 ACTIONS IF FIRE OCCURS........................................................................................................... 33 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS..................................................................................... 34 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS.................................................................................... 35 PRECAUTIONS FOR DEF.............................................................................................................. 36 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING............................................................................... 36 PRECAUTIONS FOR ADDING....................................................................................................... 36 PRECAUTIONS FOR STORING...................................................................................................... 36 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...................................................................................... 36 THE OTHER PRECAUTIONS........................................................................................................ 36 STORE AdBlue/DEF................................................................................................................. 37 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT..................................................................................... 38 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS.......................................................................... 41 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT.................................................................................... 48 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT................................................................................... 50 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................. 51 PRACTICAL USE OF KOMTRAX......................................................................................................... 52 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER.................................................................................... 53 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER........................................................ 53 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER........................................................ 54 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER........................................................ 55 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS....................................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR........................................................................ 61 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR................................................................ 62 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.............................................................. 64 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.............................................................. 65 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE......................................................... 67 HOW TO READ ELECTRICAL WIRE CODE................................................................................................. 68 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................................................... 72 STANDARD TIGHTENING TORQUE TABLE................................................................................................. 75 CONVERSION TABLE................................................................................................................. 82 ABBREVIATION LIST................................................................................................................ 87 01 SPECIFICATIONS........................................................................................................................ 91 CONTENTS............................................................................................................................. 92 SPECIFICATIONS....................................................................................................................... 93 SPECIFICATION DRAWING............................................................................................................ 93 SPECIFICATION DRAWING: WA200-8E0............................................................................................. 93 SPECIFICATIONS................................................................................................................... 95 SPECIFICATIONS: WA200-8E0.................................................................................................... 95 WEIGHT TABLE..................................................................................................................... 100 WEIGHT TABLE: WA200-8E0...................................................................................................... 100 FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)................................................................................... 102 10 STRUCTURE AND FUNCTION................................................................................................................ 103 CONTENTS............................................................................................................................. 104 UREA SCR SYSTEM...................................................................................................................... 108 LAYOUT DRAWING OF UREA SCR SYSTEM................................................................................................ 108 UREA SCR SYSTEM DIAGRAM.......................................................................................................... 110 FUNCTION OF UREA SCR SYSTEM...................................................................................................... 111 FUNCTION OF AdBlue/DEF SUPPLY SYSTEM......................................................................................... 111 INDUCEMENT STRATEGY.......................................................................................................... 114 COMPONENT PARTS OF UREA SCR SYSTEM............................................................................................... 120 SCR ASSEMBLY................................................................................................................. 121 AdBlue/DEF TANK.............................................................................................................. 123 AdBlue/DEF PUMP.............................................................................................................. 125 AdBlue/DEF INJECTOR.......................................................................................................... 126 AdBlue/DEF HOSE.............................................................................................................. 127 AdBlue/DEF TANK HEATING VALVE................................................................................................ 128 BOOT-UP SYSTEM....................................................................................................................... 129 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................. 129 SYSTEM OPERATING LAMP SYSTEM..................................................................................................... 131 SYSTEM OPERATING LAMP SYSTEM DIAGRAM......................................................................................... 131 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM..................................................................................... 131 BATTERY DISCONNECT SWITCH........................................................................................................ 132 FUNCTION OF BATTERY DISCONNECT SWITCH........................................................................................ 132 PREHEATING SYSTEM................................................................................................................ 133 PREHEATING SYSTEM DIAGRAM.................................................................................................... 133 FUNCTION OF AUTOMATIC PREHEATING SYSTEM...................................................................................... 133 OPERATION OF AUTOMATIC PREHEATING SYSTEM..................................................................................... 133 FUNCTION OF MANUAL PREHEATING SYSTEM......................................................................................... 134 OPERATION OF MANUAL PREHEATING SYSTEM........................................................................................ 134 ENGINE SYSTEM........................................................................................................................ 135 LAYOUT DRAWING OF ENGINE SYSTEM.................................................................................................. 135 FUNCTION OF ENGINE SYSTEM.................................................................................................... 136 ENGINE CONTROL SYSTEM............................................................................................................ 137 SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM...................................................................................... 137 FUNCTION OF ENGINE CONTROL SYSTEM............................................................................................ 139 OPERATION OF ENGINE CONTROL SYSTEM........................................................................................... 142 AUTOMATIC IDLE STOP SYSTEM....................................................................................................... 144 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM....................................................................................... 144 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................. 145 DAMPER....................................................................................................................... 145 TURBOCHARGER................................................................................................................. 146 CRANKCASE VENTILATION SYSTEM................................................................................................. 149 IMPACTOR (FILTERLESS)........................................................................................................ 150 EXHAUST THROTTLE VALVE....................................................................................................... 151 KDPF......................................................................................................................... 152 COOLING SYSTEM....................................................................................................................... 156 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................. 156 SPECIFICATIONS OF COOLING SYSTEM............................................................................................. 157 COOLING FAN CONTROL SYSTEM....................................................................................................... 158 COOLING FAN CONTROL SYSTEM DIAGRAM........................................................................................... 158 FUNCTION OF COOLING FAN CONTROL SYSTEM....................................................................................... 159 COMPONENT PARTS OF COOLING SYSTEM................................................................................................ 163 COOLING FAN MOTOR............................................................................................................ 163 HYDRAULIC OIL COOLER BYPASS VALVE............................................................................................ 173 CONTROL SYSTEM....................................................................................................................... 174 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................. 174 MACHINE MONITOR SYSTEM........................................................................................................... 176 MACHINE MONITOR SYSTEM DIAGRAM............................................................................................... 176 FUNCTION OF MACHINE MONITOR SYSTEM........................................................................................... 176 REARVIEW MONITOR SYSTEM.......................................................................................................... 178 REARVIEW MONITOR SYSTEM DIAGRAM.............................................................................................. 178 FUNCTION OF REARVIEW MONITOR SYSTEM.......................................................................................... 178 KOMTRAX SYSTEM................................................................................................................... 179 SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER).................................................. 179 FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)........................................................ 179 COMPONENT PARTS OF CONTROL SYSTEM................................................................................................ 180 MACHINE MONITOR.............................................................................................................. 180 SWITCH PANEL................................................................................................................. 198 REARVIEW MONITOR............................................................................................................. 199 REARVIEW CAMERA.............................................................................................................. 201 GATEWAY FUNCTION CONTROLLER.................................................................................................. 202 COMMUNICATION TERMINAL....................................................................................................... 205 MONITOR CONTROLLER........................................................................................................... 207 HST CONTROLLER............................................................................................................... 212 CAN TERMINATING RESISTOR..................................................................................................... 216 ENGINE CONTROLLER............................................................................................................ 217 ACCELERATOR PEDAL............................................................................................................ 224 HYDRAULIC SYSTEM..................................................................................................................... 226 LAYOUT DRAWING OF HYDRAULIC SYSTEM............................................................................................... 226 COMPONENT PARTS OF HYDRAULIC SYSTEM.............................................................................................. 227 HYDRAULIC TANK............................................................................................................... 227 HYDRAULIC OIL FILTER......................................................................................................... 229 STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP............................................... 230 CONTROL VALVE................................................................................................................ 232 POWER TRAIN SYSTEM................................................................................................................... 253 LAYOUT DRAWING OF POWER TRAIN SYSTEM............................................................................................. 253 OPERATION OF POWER TRAIN SYSTEM.................................................................................................. 255 DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION..................................................................................... 256 HST CONTROL SYSTEM............................................................................................................... 258 HST CONTROL SYSTEM DIAGRAM................................................................................................... 258 ENGINE OVERRUN PREVENTION FUNCTION........................................................................................... 259 NEUTRALIZER FUNCTION......................................................................................................... 259 HST CHARGE SYSTEM................................................................................................................ 260 SYSTEM DIAGRAM OF HST CHARGE SYSTEM.......................................................................................... 260 FUNCTION OF HST CHARGE SYSTEM................................................................................................ 260 HST PUMP CONTROL SYSTEM.......................................................................................................... 261 SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM.................................................................................... 261 DIRECTIONAL SELECTION FUNCTION............................................................................................... 261 INCHING CONTROL FUNCTION..................................................................................................... 261 TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED).............................................................................. 262 HST CONTROLLER GEAR SHIFT CONTROL FUNCTION....................................................................................... 263 GEAR SHIFT FUNCTION.......................................................................................................... 263 GEAR SHIFT DISPLAY FUNCTION.................................................................................................. 265 TRAVEL SPEED ADJUSTMENT FUNCTION............................................................................................. 265 TRANSFER CLUTCH CONTROL FUNCTION................................................................................................. 266 HST SYSTEM PROTECTION FUNCTION................................................................................................... 267 DIRECTION PROTECTION FUNCTION................................................................................................ 267 HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1.................................................................................... 267 HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2.................................................................................... 268 TRAVEL SPEED LIMITATION FUNCTION............................................................................................. 268 KOMATSU TRACTION CONTROL SYSTEM (KTCS)........................................................................................... 269 KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM............................................................................... 269 FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS)........................................................................... 270 COMPONENT PARTS OF POWER TRAIN SYSTEM............................................................................................ 274 DRIVE SHAFT.................................................................................................................. 274 HST PUMP..................................................................................................................... 276 HST CHARGE PUMP.............................................................................................................. 284 HST MOTOR.................................................................................................................... 286 TRANSFER..................................................................................................................... 295 AXLE......................................................................................................................... 303 TORQUE PROPORTIONING DIFFERENTIAL............................................................................................ 305 LIMITED SLIP DIFFERENTIAL.................................................................................................... 309 FINAL DRIVE.................................................................................................................. 313 COMBINATION SWITCH........................................................................................................... 315 WORK EQUIPMENT SYSTEM................................................................................................................ 319 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.......................................................................................... 319 WORK EQUIPMENT CONTROL SYSTEM.................................................................................................... 321 WORK EQUIPMENT LEVER OPERATION FUNCTION...................................................................................... 321 WORK EQUIPMENT LOCK SYSTEM....................................................................................................... 322 WORK EQUIPMENT LOCK SYSTEM DIAGRAM........................................................................................... 322 FUNCTION OF WORK EQUIPMENT LOCK SYSTEM....................................................................................... 322 BUCKET POSITIONER SYSTEM......................................................................................................... 324 BUCKET POSITIONER SYSTEM DIAGRAM............................................................................................. 324 FUNCTION OF BUCKET POSITIONER SYSTEM......................................................................................... 324 OPERATION OF BUCKET POSITIONER SYSTEM........................................................................................ 325 BOOM KICK-OUT SYSTEM............................................................................................................. 327 SYSTEM DRAWING OF BOOM KICK-OUT SYSTEM....................................................................................... 327 FUNCTION OF BOOM KICK-OUT SYSTEM............................................................................................. 327 OPERATION OF BOOM KICK-OUT SYSTEM............................................................................................ 328 ECSS............................................................................................................................. 330 ECSS DIAGRAM................................................................................................................. 330 FUNCTION OF ECSS............................................................................................................. 330 OPERATION OF ECSS............................................................................................................ 330 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM......................................................................................... 332 WORK EQUIPMENT LOCK SOLENOID VALVE........................................................................................... 332 ATTACHMENT EPC SOLENOID VALVE................................................................................................ 333 PILOT CIRCUIT ACCUMULATOR.................................................................................................... 334 ECSS CIRCUIT ACCUMULATOR..................................................................................................... 335 MULTIFUNCTION MONO-LEVER..................................................................................................... 336 MULTIFUNCTION MONO-LEVER PPC VALVE........................................................................................... 338 QUICK COUPLER SOLENOID VALVE................................................................................................. 343 STEERING SYSTEM...................................................................................................................... 344 LAYOUT DRAWING OF STEERING SYSTEM................................................................................................ 344 STEERING COLUMN.................................................................................................................. 345 STRUCTURE OF STEERING COLUMN................................................................................................. 345 COMPONENT PARTS OF STEERING SYSTEM............................................................................................... 346 PRIORITY VALVE............................................................................................................... 346 ORBITROL VALVE............................................................................................................... 349 CUSHION VALVE................................................................................................................ 356 2-WAY RESTRICTOR VALVE....................................................................................................... 358 SECONDARY STEERING VALVE..................................................................................................... 359 BRAKE SYSTEM......................................................................................................................... 362 LAYOUT DRAWING OF BRAKE SYSTEM................................................................................................... 362 PARKING BRAKE CONTROL SYSTEM..................................................................................................... 364 PARKING BRAKE CONTROL SYSTEM DIAGRAM......................................................................................... 364 OPERATION OF PARKING BRAKE CONTROL SYSTEM.................................................................................... 364 COMPONENT PARTS OF BRAKE SYSTEM.................................................................................................. 367 BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE....................................................................................... 367 PARKING BRAKE SOLENOID VALVE................................................................................................. 371 BRAKE CIRCUIT ACCUMULATOR.................................................................................................... 373 BRAKE VALVE.................................................................................................................. 375 SLACK ADJUSTER............................................................................................................... 379 BRAKE........................................................................................................................ 381 PARKING BRAKE................................................................................................................ 384 PARKING BRAKE CYLINDER....................................................................................................... 386 AUTO-GREASING SYSTEM................................................................................................................. 387 LAYOUT DRAWING OF AUTOMATIC GREASE SYSTEM........................................................................................ 387 SPECIFICATIONS OF AUTOMATIC GREASE SYSTEM........................................................................................ 389 FUNCTION OF AUTO-GREASING SYSTEM................................................................................................. 391 COMPONENT PARTS OF AUTO-GREASING SYSTEM.......................................................................................... 392 AUTO-GREASING PUMP........................................................................................................... 392 UNDERCARRIAGE AND FRAME.............................................................................................................. 393 FRAME, AXLE MOUNT AND CENTER HINGE PIN........................................................................................... 393 STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN.......................................................................... 393 FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN........................................................................... 394 TIRE............................................................................................................................. 396 FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE......................................................................... 396 STRUCTURE OF RADIAL TIRE..................................................................................................... 396 FUNCTION OF RADIAL TIRE...................................................................................................... 397 STRUCTURE OF BIAS TIRE....................................................................................................... 397 FUNCTION OF BIAS TIRE........................................................................................................ 397 WORK EQUIPMENT....................................................................................................................... 398 STRUCTURE OF WORK EQUIPMENT...................................................................................................... 398 STRUCTURE OF BUCKET.............................................................................................................. 399 CAB AND ITS ATTACHMENTS.............................................................................................................. 400 ROPS CAB......................................................................................................................... 400 STRUCTURE OF ROPS CAB........................................................................................................ 400 FUNCTION OF ROPS CAB......................................................................................................... 400 CAB MOUNT........................................................................................................................ 401 STRUCTURE OF CAB MOUNT....................................................................................................... 401 FUNCTION OF CAB MOUNT........................................................................................................ 401 20 STANDARD VALUE TABLE.................................................................................................................. 403 CONTENTS............................................................................................................................. 404 STANDARD VALUE TABLE FOR ENGINE...................................................................................................... 405 STANDARD VALUE TABLE FOR ENGINE:WA200-8E0........................................................................................ 405 STANDARD VALUE TABLE FOR MACHINE..................................................................................................... 410 STANDARD VALUE TABLE FOR MACHINE:WA200-8E0....................................................................................... 410 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE.......................................................................... 422 30 TESTING AND ADJUSTING................................................................................................................. 425 CONTENTS............................................................................................................................. 426 RELATED INFORMATION ON TESTING AND ADJUSTING......................................................................................... 430 TOOLS FOR TESTING AND ADJUSTING.................................................................................................. 430 ENGINE AND COOLING SYSTEM............................................................................................................ 439 TEST ENGINE SPEED................................................................................................................ 439 METHOD FOR TESTING ENGINE SPEED.............................................................................................. 439 TEST BOOST PRESSURE.............................................................................................................. 443 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR......................................................................... 443 METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL............................................................................ 444 TESTING EXHAUST GAS TEMPERATURE.................................................................................................. 446 METHOD FOR TESTING EXHAUST GAS TEMPERATURE................................................................................... 446 TEST EXHAUST GAS COLOR........................................................................................................... 448 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER.................................................................. 448 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER.......................................................................... 450 TEST AND ADJUST VALVE CLEARANCE.................................................................................................. 453 METHOD FOR TESTING VALVE CLEARANCE........................................................................................... 453 METHOD FOR ADJUSTING VALVE CLEARANCE......................................................................................... 454 TEST COMPRESSION PRESSURE........................................................................................................ 456 METHOD FOR TESTING COMPRESSION PRESSURE...................................................................................... 456 TEST BLOWBY PRESSURE............................................................................................................. 461 TEST BLOWBY PRESSURE......................................................................................................... 461 TEST ENGINE OIL PRESSURE......................................................................................................... 463 METHOD FOR TESTING ENGINE OIL PRESSURE....................................................................................... 463 TEST FUEL PRESSURE............................................................................................................... 464 METHOD FOR TESTING FUEL PRESSURE............................................................................................. 465 TEST FUEL DISCHARGE, RETURN AND LEAKAGE.......................................................................................... 469 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE........................................................................ 470 BLEED AIR FROM FUEL SYSTEM....................................................................................................... 475 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM..................................................................................... 475 TEST FUEL CIRCUIT FOR LEAKAGE.................................................................................................... 477 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE.................................................................................. 477 HANDLE CYLINDER CUT-OUT MODE OPERATION........................................................................................... 479 HANDLE NO-INJECTION CRANKING OPERATION........................................................................................... 480 TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE........................................................................ 481 METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE...................................................... 481 TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS......................................................................... 482 METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS....................................................... 482 TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS...................................................................................... 483 METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS.................................................................... 483 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION.......................................................................... 484 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT.......................................................................... 484 ADJUST AIR CONDITIONER COMPRESSOR BELT....................................................................................... 484 TEST ALTERNATOR BELT............................................................................................................. 486 METHOD FOR TESTING ALTERNATOR BELT........................................................................................... 486 TEST AUTOMATIC TENSIONER......................................................................................................... 488 METHOD FOR TESTING AUTOMATIC TENSIONER....................................................................................... 488 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................................... 491 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................. 491 TEST SCR RELATED FUNCTIONS....................................................................................................... 492 TEST AdBlue/DEF PUMP RAISED PRESSURE......................................................................................... 496 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR............................................................................... 499 TEST AdBlue/DEF LINE HEATER RELAY 1.......................................................................................... 505 TEST AdBlue/DEF LINE HEATER RELAY 2.......................................................................................... 509 TEST AdBlue/DEF PUMP HEATER RELAY............................................................................................ 513 TEST AdBlue/DEF TANK HEATER VALVE............................................................................................ 517 TEST SCR NOx REMOVAL EFFICIENCY.............................................................................................. 521 CLEAN AdBlue/DEF TANK............................................................................................................ 524 METHOD FOR CLEANING AdBlue/DEF TANK.......................................................................................... 524 CLEAN AdBlue/DEF PUMP............................................................................................................ 529 CLEAN AdBlue/DEF PUMP........................................................................................................ 529 POWER TRAIN.......................................................................................................................... 535 TEST AND ADJUST HST OIL PRESSURE................................................................................................. 535 METHOD FOR TESTING HST OIL PRESSURE.......................................................................................... 535 METHOD FOR ADJUSTING HST OIL PRESSURE........................................................................................ 538 TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH..................................................................................... 540 METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH................................................................... 540 TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE............................................................................. 542 METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE........................................................... 542 STEERING SYSTEM...................................................................................................................... 543 TEST STEERING WHEEL.............................................................................................................. 543 METHOD FOR TESTING STEERING WHEEL............................................................................................ 543 TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE.................................................................................... 545 METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE............................................................................. 545 METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE........................................................................... 546 BLEED AIR FROM STEERING CYLINDER CIRCUIT......................................................................................... 548 METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT....................................................................... 548 BRAKE SYSTEM......................................................................................................................... 549 RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT.......................................................................... 549 METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT......................................................... 549 TEST WHEEL BRAKE OIL PRESSURE.................................................................................................... 550 METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE.................................................................................. 550 TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE................................................................................ 552 METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE......................................................................... 552 METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE....................................................................... 553 BLEED AIR FROM BRAKE CIRCUIT..................................................................................................... 554 BLEED AIR FROM BRAKE CIRCUIT................................................................................................. 554 TEST BRAKING PERFORMANCE......................................................................................................... 556 METHOD FOR TESTING BRAKING PERFORMANCE....................................................................................... 556 TEST BRAKE PEDAL................................................................................................................. 557 METHOD FOR TESTING BRAKE PEDAL............................................................................................... 557 TEST AND ADJUST BRAKE PEDAL AND LINKAGE.......................................................................................... 558 METHOD FOR TESTING BRAKE PEDAL AND LINKAGE................................................................................... 558 METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE................................................................................. 558 TEST LOWERING OF WHEEL BRAKE PRESSURE............................................................................................ 559 METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE.......................................................................... 560 TEST WEAR OF WHEEL BRAKE DISC.................................................................................................... 562 METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC.................................................................................. 562 TEST PARKING BRAKE OIL PRESSURE.................................................................................................. 564 METHOD FOR TESTING PARKING BRAKE OIL PRESSURE................................................................................ 564 TEST PARKING BRAKE PERFORMANCE................................................................................................... 566 METHOD FOR TESTING PARKING BRAKE PERFORMANCE................................................................................. 566 RELEASE PARKING BRAKE MANUALLY................................................................................................... 567 METHOD FOR RELEASING PARKING BRAKE MANUALLY.................................................................................. 567 HYDRAULIC SYSTEM..................................................................................................................... 568 RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT........................................................................... 568 METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT.......................................................... 568 TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE...................................................................................... 570 METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE............................................................................... 570 METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE............................................................................. 571 TEST WORK EQUIPMENT PPC OIL PRESSURE............................................................................................. 573 METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE........................................................................... 573 BLEED AIR FROM WORK EQUIPMENT PPC CIRCUIT........................................................................................ 575 METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT PPC CIRCUIT....................................................... 575 TEST COOLING FAN SPEED........................................................................................................... 576 METHOD FOR TESTING COOLING FAN SPEED......................................................................................... 576 TEST COOLING FAN CIRCUIT OIL PRESSURE............................................................................................ 577 METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE.......................................................................... 577 BLEED AIR FROM COOLING FAN CIRCUIT............................................................................................... 579 METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT............................................................................. 579 TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS............................................. 581 METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE.................................................................... 581 METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS....................................................................... 583 WORK EQUIPMENT....................................................................................................................... 586 TEST AND ADJUST BUCKET POSITIONER................................................................................................ 586 METHOD FOR TESTING BUCKET POSITIONER......................................................................................... 586 ADJUST BUCKET POSITIONER..................................................................................................... 586 CAB AND ITS ATTACHMENTS.............................................................................................................. 588 TEST DIRECTIONAL LEVER........................................................................................................... 588 METHOD FOR TESTING DIRECTIONAL LEVER......................................................................................... 588 TEST MULTIFUNCTION MONO-LEVER.................................................................................................... 589 METHOD FOR TESTING MULTIFUNCTION MONO-LEVER.................................................................................. 589 TEST ACCELERATOR PEDAL........................................................................................................... 591 METHOD FOR TESTING ACCELERATOR PEDAL......................................................................................... 591 ADJUST RATTLING OPERATOR'S SEAT.................................................................................................. 593 METHOD FOR ADJUSTING RATTLING OPERATOR'S SEAT................................................................................ 593 ELECTRICAL SYSTEM.................................................................................................................... 594 SET AND ADJUST EACH EQUIPMENT.................................................................................................... 594 SET AND OPERATE MACHINE MONITOR.................................................................................................. 596 OPERATOR MODE................................................................................................................ 600 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN.................................................................. 600 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN..................................................................... 600 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)............................................................................ 601 CHECKING FUNCTION OF SERVICE METER AND ODOMETER.............................................................................. 602 METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD........................................................ 602 SERVICE MODE................................................................................................................. 606 METHOD FOR OPERATING SERVICE MODE............................................................................................ 606 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION....................................................................... 608 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION....................................................................... 614 ABNORMALITY RECORD MENU...................................................................................................... 626 METHOD FOR CONFIRMING MAINTENANCE RECORD..................................................................................... 631 METHOD FOR OPERATING MAINTENANCE MODE SETTING................................................................................ 633 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING.............................................................................. 638 DEFAULT MENU................................................................................................................. 640 DIAGNOSTIC TESTS MENU........................................................................................................ 654 ADJUSTMENT MENU.............................................................................................................. 666 METHOD FOR PERFORMING NO-INJECTION CRANKING.................................................................................. 686 KOMTRAX SETTINGS MENU........................................................................................................ 688 METHOD FOR DISPLAYING SERVICE MESSAGE........................................................................................ 690 START UP KOMTRAX SYSTEM.......................................................................................................... 692 STOP USING OF KOMTRAX SYSTEM..................................................................................................... 698 ADJUST REARVIEW CAMERA ANGLE..................................................................................................... 700 ADJUST REARVIEW CAMERA ANGLE................................................................................................. 700 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...................................................................................... 702 HANDLE BATTERY DISCONNECT SWITCH................................................................................................. 703 TEST DIODES...................................................................................................................... 704 METHOD FOR TESTING DIODE USING DIGITAL TESTER................................................................................ 704 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................. 704 Pm CLINIC............................................................................................................................ 705 Pm CLINIC SERVICE................................................................................................................ 705 Pm CLINIC CHECK SHEET:WA200-8E0.............................................................................................. 707 40 TROUBLESHOOTING....................................................................................................................... 715 CONTENTS............................................................................................................................. 716 RELATED INFORMATION TO TROUBLESHOOT.................................................................................................. 727 PRECAUTIONS FOR TROUBLESHOOTING.................................................................................................. 727 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................ 728 GENERAL TROUBLESHOOTING POINTS................................................................................................... 730 CHECKS BEFORE TROUBLESHOOTING.................................................................................................... 731 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...................................................................................... 733 WALK-AROUND CHECK............................................................................................................ 733 TESTING IN ACCORDANCE WITH TESTING PROCEDURE..................................................................................... 735 CHECK FUEL LEVEL AND TYPE.................................................................................................... 735 FUEL - CHECK FOR FOREIGN MATERIAL............................................................................................ 735 CHECK AdBule/DEF LEVEL AND TYPE.............................................................................................. 736 CHECK FUEL PREFILTER......................................................................................................... 736 CHECK MAIN FILTER............................................................................................................ 738 OIL PAN - CHECK ENGINE OIL LEVEL AND TYPE.................................................................................... 740 CHECK COOLANT LEVEL (RESERVOIR TANK)......................................................................................... 741 CHECK CLOGGING OF AIR CLEANER................................................................................................ 742 OUTER ELEMENT - CLEAN........................................................................................................ 743 REPLACE ELEMENT.............................................................................................................. 745 CHECK HYDRAULIC OIL LEVEL.................................................................................................... 747 CHECK HYDRAULIC FILTER....................................................................................................... 749 CHECK THE OIL LEVEL IN THE TRANSFER CASE..................................................................................... 750 CHECK OIL LEVEL IN FRONT AXLE CASE........................................................................................... 751 CHECK OIL LEVEL IN REAR AXLE CASE............................................................................................ 752 BLEED AIR FROM FUEL SYSTEM................................................................................................... 753 BLEED AIR FROM HYDRAULIC SYSTEM.............................................................................................. 753 METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod................................................................................. 753 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION.................................................................................. 760 PROCEDURE FOR TESTING AND TROUBLESHOOTING........................................................................................ 768 SYMPTOM AND TROUBLESHOOTING NUMBERS.............................................................................................. 770 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE................................................................................... 774 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM.............................................. 776 CONNECTORS LIST.................................................................................................................. 779 CONNECTOR LAYOUT................................................................................................................. 789 CONNECTOR CONTACT IDENTIFICATION................................................................................................. 799 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.......................................................................................... 841 FUSE LOCATION TABLE.............................................................................................................. 847 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...................................................................... 851 PREPARATION TO TROUBLESHOOT MACHINE MONITOR...................................................................................... 855 PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT.............................................................. 857 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...................................... 863 FAILURE CODES TABLE.............................................................................................................. 865 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE).................................................................................... 883 FAILURE CODE [2F00MA]............................................................................................................ 883 FAILURE CODE [2F00MB]............................................................................................................ 886 FAILURE CODE [2G42ZG]............................................................................................................ 888 FAILURE CODE [2G43ZG]............................................................................................................ 890 FAILURE CODE [6091NX]............................................................................................................ 892 FAILURE CODE [7RHYKA]............................................................................................................ 894 FAILURE CODE [7RHYKB]............................................................................................................ 896 FAILURE CODE [7RHYKY]............................................................................................................ 898 FAILURE CODE [879AKA]............................................................................................................ 900 FAILURE CODE [879AKB]............................................................................................................ 902 FAILURE CODE [879BKA]............................................................................................................ 904 FAILURE CODE [879BKB]............................................................................................................ 906 FAILURE CODE [879CKA]............................................................................................................ 908 FAILURE CODE [879CKB]............................................................................................................ 910 FAILURE CODE [879DKZ]............................................................................................................ 912 FAILURE CODE [879EMC]............................................................................................................ 914 FAILURE CODE [879FMC]............................................................................................................ 915 FAILURE CODE [989FN1]............................................................................................................ 916 FAILURE CODE [989L00]............................................................................................................ 917 FAILURE CODE [989M00]............................................................................................................ 918 FAILURE CODE [989N00]............................................................................................................ 919 FAILURE CODE [A1U0N3]............................................................................................................ 920 FAILURE CODE [A1U0N4]............................................................................................................ 922 FAILURE CODE [AB00KE]............................................................................................................ 924 FAILURE CODE [AB00KY]............................................................................................................ 926 FAILURE CODE [AQ10MB]............................................................................................................ 928 FAILURE CODE [AS00R2]............................................................................................................ 930 FAILURE CODE [AS00R3]............................................................................................................ 931 FAILURE CODE [AS00R4]............................................................................................................ 932 FAILURE CODE [AS00R5]............................................................................................................ 933 FAILURE CODE [AS00R6]............................................................................................................ 934 FAILURE CODE [AS00ZK]............................................................................................................ 935 FAILURE CODE [AS10KM]............................................................................................................ 936 FAILURE CODE [AS10NR]............................................................................................................ 937 FAILURE CODE [AS10NT]............................................................................................................ 938 FAILURE CODE [B@BAZG]............................................................................................................ 939 FAILURE CODE [B@BCNS]............................................................................................................ 940 FAILURE CODE [B@BCQA]............................................................................................................ 941 FAILURE CODE [B@BCZK]............................................................................................................ 943 FAILURE CODE [B@C6NS]............................................................................................................ 945 FAILURE CODE [B@CRNS]............................................................................................................ 947 FAILURE CODE [CA115]............................................................................................................. 948 FAILURE CODE [CA122]............................................................................................................. 949 FAILURE CODE [CA123]............................................................................................................. 951 FAILURE CODE [CA131]............................................................................................................. 953 FAILURE CODE [CA132]............................................................................................................. 955 FAILURE CODE [CA144]............................................................................................................. 958 FAILURE CODE [CA145]............................................................................................................. 960 FAILURE CODE [CA153]............................................................................................................. 962 FAILURE CODE [CA154]............................................................................................................. 964 FAILURE CODE [CA187]............................................................................................................. 966 FAILURE CODE [CA227]............................................................................................................. 968 FAILURE CODE [CA234]............................................................................................................. 970 FAILURE CODE [CA238]............................................................................................................. 971 FAILURE CODE [CA239]............................................................................................................. 972 FAILURE CODE [CA249]............................................................................................................. 973 FAILURE CODE [CA256]............................................................................................................. 975 FAILURE CODE [CA271]............................................................................................................. 977 FAILURE CODE [CA272]............................................................................................................. 979 FAILURE CODE [CA322]............................................................................................................. 980 FAILURE CODE [CA324]............................................................................................................. 982 FAILURE CODE [CA331]............................................................................................................. 984 FAILURE CODE [CA332]............................................................................................................. 986 FAILURE CODE [CA343]............................................................................................................. 988 FAILURE CODE [CA351]............................................................................................................. 989 FAILURE CODE [CA352]............................................................................................................. 990 FAILURE CODE [CA386]............................................................................................................. 992 FAILURE CODE [CA428]............................................................................................................. 993 FAILURE CODE [CA429]............................................................................................................. 995 FAILURE CODE [CA431]............................................................................................................. 997 FAILURE CODE [CA432].............................................................................................................1000 FAILURE CODE [CA435].............................................................................................................1004 FAILURE CODE [CA441].............................................................................................................1006 FAILURE CODE [CA442].............................................................................................................1008 FAILURE CODE [CA451].............................................................................................................1009 FAILURE CODE [CA452].............................................................................................................1011 FAILURE CODE [CA488].............................................................................................................1013 FAILURE CODE [CA515].............................................................................................................1014 FAILURE CODE [CA516].............................................................................................................1016 FAILURE CODE [CA553].............................................................................................................1018 FAILURE CODE [CA555].............................................................................................................1019 FAILURE CODE [CA556].............................................................................................................1020 FAILURE CODE [CA559].............................................................................................................1021 FAILURE CODE [CA689].............................................................................................................1024 FAILURE CODE [CA691].............................................................................................................1027 FAILURE CODE [CA692].............................................................................................................1029 FAILURE CODE [CA697].............................................................................................................1031 FAILURE CODE [CA698].............................................................................................................1032 FAILURE CODE [CA731].............................................................................................................1033 FAILURE CODE [CA741].............................................................................................................1035 FAILURE CODE [CA742].............................................................................................................1037 FAILURE CODE [CA743].............................................................................................................1039 FAILURE CODE [CA778].............................................................................................................1040 FAILURE CODE [CA1117]............................................................................................................1045 FAILURE CODE [CA1664]............................................................................................................1047 FAILURE CODE [CA1669]............................................................................................................1050 FAILURE CODE [CA1673]............................................................................................................1051 FAILURE CODE [CA1677]............................................................................................................1052 FAILURE CODE [CA1678]............................................................................................................1053 FAILURE CODE [CA1682]............................................................................................................1054 FAILURE CODE [CA1683]............................................................................................................1059 FAILURE CODE [CA1684]............................................................................................................1061 FAILURE CODE [CA1686]............................................................................................................1063 FAILURE CODE [CA1695]............................................................................................................1064 FAILURE CODE [CA1696]............................................................................................................1065 FAILURE CODE [CA1712]............................................................................................................1068 FAILURE CODE [CA1713]............................................................................................................1071 FAILURE CODE [CA1714]............................................................................................................1074 FAILURE CODE [CA1715]............................................................................................................1075 FAILURE CODE [CA1776]............................................................................................................1076 FAILURE CODE [CA1777]............................................................................................................1079 FAILURE CODE [CA1843]............................................................................................................1082 FAILURE CODE [CA1844]............................................................................................................1084 FAILURE CODE [CA1879]............................................................................................................1087 FAILURE CODE [CA1881]............................................................................................................1089 FAILURE CODE [CA1883]............................................................................................................1091 FAILURE CODE [CA1885]............................................................................................................1094 FAILURE CODE [CA1887]............................................................................................................1096 FAILURE CODE [CA1921]............................................................................................................1098 FAILURE CODE [CA1922]............................................................................................................1101 FAILURE CODE [CA1942]............................................................................................................1106 FAILURE CODE [CA1993]............................................................................................................1107 FAILURE CODE [CA2185]............................................................................................................1110 FAILURE CODE [CA2186]............................................................................................................1112 FAILURE CODE [CA2311]............................................................................................................1114 FAILURE CODE [CA2373]............................................................................................................1115 FAILURE CODE [CA2374]............................................................................................................1117 FAILURE CODE [CA2554]............................................................................................................1119 FAILURE CODE [CA2555]............................................................................................................1121 FAILURE CODE [CA2556]............................................................................................................1123 FAILURE CODE [CA2639]............................................................................................................1125 FAILURE CODE [CA2771]............................................................................................................1127 FAILURE CODE [CA2973]............................................................................................................1131 FAILURE CODE [CA2976]............................................................................................................1132 FAILURE CODE [CA3133]............................................................................................................1134 FAILURE CODE [CA3134]............................................................................................................1136 FAILURE CODE [CA3135]............................................................................................................1138 FAILURE CODE [CA3142]............................................................................................................1142 FAILURE CODE [CA3143]............................................................................................................1143 FAILURE CODE [CA3144]............................................................................................................1144 FAILURE CODE [CA3146]............................................................................................................1147 FAILURE CODE [CA3147]............................................................................................................1148 FAILURE CODE [CA3148]............................................................................................................1149 FAILURE CODE [CA3151]............................................................................................................1152 FAILURE CODE [CA3165]............................................................................................................1160 FAILURE CODE [CA3229]............................................................................................................1162 FAILURE CODE [CA3231]............................................................................................................1164 FAILURE CODE [CA3232]............................................................................................................1166 FAILURE CODE [CA3235]............................................................................................................1170 FAILURE CODE [CA3239]............................................................................................................1172 FAILURE CODE [CA3241]............................................................................................................1175 FAILURE CODE [CA3242]............................................................................................................1178 FAILURE CODE [CA3251]............................................................................................................1181 FAILURE CODE [CA3253]............................................................................................................1183 FAILURE CODE [CA3254]............................................................................................................1186 FAILURE CODE [CA3255]............................................................................................................1188 FAILURE CODE [CA3256]............................................................................................................1192 FAILURE CODE [CA3311]............................................................................................................1194 FAILURE CODE [CA3312]............................................................................................................1196 FAILURE CODE [CA3313]............................................................................................................1199 FAILURE CODE [CA3314]............................................................................................................1200 FAILURE CODE [CA3315]............................................................................................................1201 FAILURE CODE [CA3316]............................................................................................................1204 FAILURE CODE [CA3317]............................................................................................................1205 FAILURE CODE [CA3318]............................................................................................................1206 FAILURE CODE [CA3319]............................................................................................................1209 FAILURE CODE [CA3321]............................................................................................................1210 FAILURE CODE [CA3322]............................................................................................................1212 FAILURE CODE [CA3497]............................................................................................................1215 FAILURE CODE [CA3498]............................................................................................................1216 FAILURE CODE [CA3545]............................................................................................................1217 FAILURE CODE [CA3547]............................................................................................................1219 FAILURE CODE [CA3558]............................................................................................................1220 FAILURE CODE [CA3559]............................................................................................................1222 FAILURE CODE [CA3562]............................................................................................................1224 FAILURE CODE [CA3563]............................................................................................................1226 FAILURE CODE [CA3567]............................................................................................................1229 FAILURE CODE [CA3568]............................................................................................................1233 FAILURE CODE [CA3571]............................................................................................................1239 FAILURE CODE [CA3572]............................................................................................................1241 FAILURE CODE [CA3574]............................................................................................................1243 FAILURE CODE [CA3575]............................................................................................................1246 FAILURE CODE [CA3577]............................................................................................................1248 FAILURE CODE [CA3578]............................................................................................................1250 FAILURE CODE [CA3583]............................................................................................................1252 FAILURE CODE [CA3596]............................................................................................................1254 FAILURE CODE [CA3649]............................................................................................................1258 FAILURE CODE [CA3681]............................................................................................................1260 FAILURE CODE [CA3682]............................................................................................................1265 FAILURE CODE [CA3713]............................................................................................................1270 FAILURE CODE [CA3717]............................................................................................................1273 FAILURE CODE [CA3718]............................................................................................................1274 FAILURE CODE [CA3725]............................................................................................................1275 FAILURE CODE [CA3741]............................................................................................................1278 FAILURE CODE [CA3748]............................................................................................................1279 FAILURE CODE [CA3866]............................................................................................................1281 FAILURE CODE [CA3868]............................................................................................................1285 FAILURE CODE [CA4151]............................................................................................................1289 FAILURE CODE [CA4152]............................................................................................................1293 FAILURE CODE [CA4155]............................................................................................................1297 FAILURE CODE [CA4156]............................................................................................................1300 FAILURE CODE [CA4157]............................................................................................................1303 FAILURE CODE [CA4158]............................................................................................................1305 FAILURE CODE [CA4159]............................................................................................................1306 FAILURE CODE [CA4161]............................................................................................................1307 FAILURE CODE [CA4162]............................................................................................................1310 FAILURE CODE [CA4163]............................................................................................................1313 FAILURE CODE [CA4164]............................................................................................................1315 FAILURE CODE [CA4165]............................................................................................................1317 FAILURE CODE [CA4166]............................................................................................................1319 FAILURE CODE [CA4168]............................................................................................................1320 FAILURE CODE [CA4169]............................................................................................................1323 FAILURE CODE [CA4171]............................................................................................................1325 FAILURE CODE [CA4249]............................................................................................................1327 FAILURE CODE [CA4251]............................................................................................................1329 FAILURE CODE [CA4259]............................................................................................................1331 FAILURE CODE [CA4261]............................................................................................................1334 FAILURE CODE [CA4277]............................................................................................................1337 FAILURE CODE [CA4459]............................................................................................................1341 FAILURE CODE [CA4461]............................................................................................................1343 FAILURE CODE [CA4731]............................................................................................................1346 FAILURE CODE [CA4732]............................................................................................................1347 FAILURE CODE [CA4739]............................................................................................................1348 FAILURE CODE [CA4768]............................................................................................................1349 FAILURE CODE [CA4769]............................................................................................................1351 FAILURE CODE [CA4842]............................................................................................................1354 FAILURE CODE [CA4952]............................................................................................................1357 FAILURE CODE [CA5115]............................................................................................................1359 FAILURE CODE [CA5179]............................................................................................................1362 FAILURE CODE [CA5181]............................................................................................................1364 FAILURE CODE [CA5271]............................................................................................................1366 FAILURE CODE [CA5272]............................................................................................................1368 FAILURE CODE [CA5273]............................................................................................................1370 FAILURE CODE [CA5275]............................................................................................................1371 FAILURE CODE [CA5276]............................................................................................................1373 FAILURE CODE [CA5383]............................................................................................................1375 FAILURE CODE [CA5631]............................................................................................................1377 FAILURE CODE [CA5632]............................................................................................................1379 FAILURE CODE [CA5655]............................................................................................................1381 FAILURE CODE [CA5689]............................................................................................................1387 FAILURE CODE [CA5715]............................................................................................................1389 FAILURE CODE [CA5716]............................................................................................................1392 FAILURE CODE [CA5838]............................................................................................................1395 FAILURE CODE [CA5864]............................................................................................................1397 FAILURE CODE [CA5865]............................................................................................................1399 FAILURE CODE [CA5938]............................................................................................................1401 FAILURE CODE [D110L4]............................................................................................................1403 FAILURE CODE [D160KA]............................................................................................................1405 FAILURE CODE [D160KY]............................................................................................................1407 FAILURE CODE [D191KA]............................................................................................................1408 FAILURE CODE [D191KB]............................................................................................................1410 FAILURE CODE [D191KY]............................................................................................................1412 FAILURE CODE [D192KA]............................................................................................................1413 FAILURE CODE [D192KB]............................................................................................................1414 FAILURE CODE [D192KY]............................................................................................................1415 FAILURE CODE [D19JKZ]............................................................................................................1416 FAILURE CODE [D1B0KA]............................................................................................................1418 FAILURE CODE [D1B0KB]............................................................................................................1420 FAILURE CODE [D1B0KY]............................................................................................................1422 FAILURE CODE [D1B0MC]............................................................................................................1424 FAILURE CODE [D1E6KA]............................................................................................................1426 FAILURE CODE [D1E6KB]............................................................................................................1428 FAILURE CODE [D1E6KY]............................................................................................................1430 FAILURE CODE [D5ZHKA]............................................................................................................1432 FAILURE CODE [D5ZHKB]............................................................................................................1434 FAILURE CODE [D5ZHL6]............................................................................................................1436 FAILURE CODE [D811MC]............................................................................................................1438 FAILURE CODE [D862KA]............................................................................................................1439 FAILURE CODE [D8ALKA]............................................................................................................1440 FAILURE CODE [D8ALKB]............................................................................................................1442 FAILURE CODE [D8AQK4]............................................................................................................1444 FAILURE CODE [D8AQKR]............................................................................................................1448 FAILURE CODE [D8G1KT]............................................................................................................1452 FAILURE CODE [D8G6KT]............................................................................................................1453 FAILURE CODE [DAF0KT]............................................................................................................1454 FAILURE CODE [DAF0MB]............................................................................................................1455 FAILURE CODE [DAF0MC]............................................................................................................1456 FAILURE CODE [DAF3KK]............................................................................................................1457 FAILURE CODE [DAF8KB]............................................................................................................1459 FAILURE CODE [DAFDKB]............................................................................................................1461 FAILURE CODE [DAFGMC]............................................................................................................1463 FAILURE CODE [DAFLKA]............................................................................................................1464 FAILURE CODE [DAFLKB]............................................................................................................1466 FAILURE CODE [DAFQKR]............................................................................................................1468 FAILURE CODE [DAJ0KK]............................................................................................................1473 FAILURE CODE [DAJ0KT]............................................................................................................1476 FAILURE CODE [DAJ0MC]............................................................................................................1477 FAILURE CODE [DAJ1KA]............................................................................................................1478 FAILURE CODE [DAJ2KK]............................................................................................................1480 FAILURE CODE [DAJ4KB]............................................................................................................1483 FAILURE CODE [DAJ4KZ]............................................................................................................1485 FAILURE CODE [DAJ5KX]............................................................................................................1487 FAILURE CODE [DAJ6KX]............................................................................................................1489 FAILURE CODE [DAJ9KQ]............................................................................................................1491 FAILURE CODE [DAJLKA]............................................................................................................1492 FAILURE CODE [DAJLKB]............................................................................................................1494 FAILURE CODE [DAJQKR]............................................................................................................1496 FAILURE CODE [DAJRKR]............................................................................................................1501 FAILURE CODE [DAJRMA]............................................................................................................1506 FAILURE CODE [DAZ9KQ]............................................................................................................1507 FAILURE CODE [DAZQKR]............................................................................................................1508 FAILURE CODE [DB2QKR]............................................................................................................1512 FAILURE CODE [DB2RKR]............................................................................................................1518 FAILURE CODE [DDAAL6]............................................................................................................1523 FAILURE CODE [DDB6L4]............................................................................................................1525 FAILURE CODE [DDD7KA]............................................................................................................1527 FAILURE CODE [DDD7KY]............................................................................................................1529 FAILURE CODE [DDE5MA]............................................................................................................1531 FAILURE CODE [DDE7KA]............................................................................................................1533 FAILURE CODE [DDE7KB]............................................................................................................1535 FAILURE CODE [DDK3KA]............................................................................................................1537 FAILURE CODE [DDK3KB]............................................................................................................1540 FAILURE CODE [DDK6KA]............................................................................................................1543 FAILURE CODE [DDK6KB]............................................................................................................1546 FAILURE CODE [DDNRLD]............................................................................................................1549 FAILURE CODE [DDS5L6]............................................................................................................1551 FAILURE CODE [DF10KA]............................................................................................................1553 FAILURE CODE [DF10KB]............................................................................................................1556 FAILURE CODE [DGH1KX]............................................................................................................1559 FAILURE CODE [DGR2KB]............................................................................................................1561 FAILURE CODE [DGR2KZ]............................................................................................................1563 FAILURE CODE [DHAAMA]............................................................................................................1565 FAILURE CODE [DHACMA]............................................................................................................1567 FAILURE CODE [DHH1KX]............................................................................................................1569 FAILURE CODE [DHH1KY]............................................................................................................1571 FAILURE CODE [DHTCL6]............................................................................................................1573 FAILURE CODE [DJF1KA]............................................................................................................1575 FAILURE CODE [DK55KA]............................................................................................................1576 FAILURE CODE [DK55KY]............................................................................................................1579 FAILURE CODE [DK55L5]............................................................................................................1582 FAILURE CODE [DK5DKA]............................................................................................................1583 FAILURE CODE [DK5DKY]............................................................................................................1586 FAILURE CODE [DK5DL8]............................................................................................................1589 FAILURE CODE [DK5EKA]............................................................................................................1593 FAILURE CODE [DK5EKY]............................................................................................................1596 FAILURE CODE [DLM3KA]............................................................................................................1599 FAILURE CODE [DLM3LC]............................................................................................................1600 FAILURE CODE [DLT3KX]............................................................................................................1602 FAILURE CODE [DLT4KX]............................................................................................................1604 FAILURE CODE [DLT4L0]............................................................................................................1606 FAILURE CODE [DLT4LC]............................................................................................................1607 FAILURE CODE [DPQ1KR]............................................................................................................1609 FAILURE CODE [DPQ2KR]............................................................................................................1612 FAILURE CODE [DPQ3KR]............................................................................................................1615 FAILURE CODE [DSJ0KR]............................................................................................................1619 FAILURE CODE [DT22KB]............................................................................................................1624 FAILURE CODE [DV00KB]............................................................................................................1626 FAILURE CODE [DW26KA]............................................................................................................1627 FAILURE CODE [DW26KB]............................................................................................................1629 FAILURE CODE [DW26KY]............................................................................................................1631 FAILURE CODE [DW44KA]............................................................................................................1633 FAILURE CODE [DW44KB]............................................................................................................1635 FAILURE CODE [DW44KY]............................................................................................................1637 FAILURE CODE [DWM1KA]............................................................................................................1638 FAILURE CODE [DWM1KB]............................................................................................................1639 FAILURE CODE [DWM1KY]............................................................................................................1641 FAILURE CODE [DWN6KA]............................................................................................................1642 FAILURE CODE [DWN6KB]............................................................................................................1644 FAILURE CODE [DWN6KY]............................................................................................................1645 FAILURE CODE [DWN7KA]............................................................................................................1646 FAILURE CODE [DWN7KB]............................................................................................................1648 FAILURE CODE [DWN7KY]............................................................................................................1649 FAILURE CODE [DWN8KA]............................................................................................................1650 FAILURE CODE [DWN8KB]............................................................................................................1652 FAILURE CODE [DWN8KY]............................................................................................................1653 FAILURE CODE [DWPBKA]............................................................................................................1654 FAILURE CODE [DWPBKB]............................................................................................................1656 FAILURE CODE [DWPBKY]............................................................................................................1658 FAILURE CODE [DX19KA]............................................................................................................1660 FAILURE CODE [DX19KB]............................................................................................................1663 FAILURE CODE [DX19KY]............................................................................................................1665 FAILURE CODE [DX20KA]............................................................................................................1667 FAILURE CODE [DX20KB]............................................................................................................1669 FAILURE CODE [DX20KY]............................................................................................................1671 FAILURE CODE [DXH7KA]............................................................................................................1673 FAILURE CODE [DXH7KB]............................................................................................................1675 FAILURE CODE [DXH7KY]............................................................................................................1677 FAILURE CODE [DXH8KA]............................................................................................................1679 FAILURE CODE [DXH8KB]............................................................................................................1681 FAILURE CODE [DXH8KY]............................................................................................................1683 FAILURE CODE [DXHJKA]............................................................................................................1685 FAILURE CODE [DXHJKB]............................................................................................................1687 FAILURE CODE [DXHJKY]............................................................................................................1689 FAILURE CODE [DXHKKA]............................................................................................................1691 FAILURE CODE [DXHKKB]............................................................................................................1693 FAILURE CODE [DXHKKY]............................................................................................................1695 FAILURE CODE [F313KA]............................................................................................................1697 FAILURE CODE [F313KB]............................................................................................................1699 FAILURE CODE [F318KB]............................................................................................................1700 FAILURE CODE [F318KY]............................................................................................................1702 FAILURE CODE [H2K0KA]............................................................................................................1703 FAILURE CODE [H2K0KY]............................................................................................................1705 FAILURE CODE [J141N1]............................................................................................................1707 FAILURE CODE [LA00L3]............................................................................................................1708 FAILURE CODE [M100N1]............................................................................................................1709 FAILURE CODE [M400N1]............................................................................................................1710 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................................................................1711 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)....................................................................................1711 MANUAL PREHEATING SYSTEM DOES NOT WORK...........................................................................................1717 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK........................................................................................1720 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP................................................................1723 THE LCD UNIT, LED UNIT, AND METER UNIT OF THE MACHINE MONITOR SHOW NOTHING.......................................................1725 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING.....................................................................................1728 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)...........................................1730 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY.................................................................................1732 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL................................................................................1734 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL.................................................................1737 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL.....................................................................................1741 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY...........................1743 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION........................................................1746 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL...............................................................................1749 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY.............................................1752 AdBlue/DEF LEVEL IS NOT SHOWN CORRECTLY..........................................................................................1753 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS.........................................................................1756 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY................................................................................1759 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED...................................................................................1764 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL..............................................................................1768 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP............................................................................1770 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION...............................1771 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...........................1775 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP............................1776 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP.................1777 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL.................................................................................1778 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL....................................................................................1780 ALARM BUZZER DOES NOT SOUND......................................................................................................1781 ALARM BUZZER DOES NOT STOP SOUNDING..............................................................................................1782 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH..............................................................1783 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED........................................................................1785 THE BOOM KICK-OUT DOES NOT WORK OR CANNOT BE RELEASED............................................................................1788 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED..................1790 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED...........................................................1793 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX. TRACTION SWITCH IS TURNED ON......................................................1795 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED...........................................................................1797 HORN DOES NOT SOUND..............................................................................................................1799 HORN DOES NOT STOP SOUNDING......................................................................................................1802 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS...........................................................................1804 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT...........................................................................1806 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT....................................................................1810 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT.................................................................................1814 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT................................................................................1816 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT...................................................................................1818 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT....................................................................................1823 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT..............................................................1827 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT......................................................................................1830 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT..........................................................................................1833 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED.......................................................................................1837 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT.................................................................................1841 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND...............................................................................1845 FRONT WIPER DOES NOT OPERATE.....................................................................................................1847 REAR WIPER DOES NOT OPERATE......................................................................................................1851 WINDOW WASHER DOES NOT OPERATE...................................................................................................1854 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY.........................................................................................1857 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...........................................................................1858 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP...........................................................................1859 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP....................................................................................1860 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)........................................................................1861 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)..........................................................................1861 FAILURE MODE AND CAUSE TABLE.....................................................................................................1862 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE...................................................................................1875 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)................................................................1877 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)................................................................1878 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW.......................................................1879 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)..................................................1882 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)..................................................1884 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.......................................................................................1885 MACHINE DOES NOT TURN............................................................................................................1887 STEERING WHEEL IS HEAVY TO OPERATE...............................................................................................1888 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS.......................................................................1889 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS...................................................................1890 WHEEL BRAKES DO NOT WORK OR ARE WEAK.............................................................................................1891 WHEEL BRAKES ARE NOT RELEASED OR DRAG............................................................................................1893 PARKING BRAKE DOES NOT WORK OR IT IS WEAK........................................................................................1894 PARKING BRAKE IS NOT RELEASED OR DRAGS...........................................................................................1895 BOOM DOES NOT RISE...............................................................................................................1897 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE......................................................................................1899 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT.........................................................................................1901 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND.............................................................................1902 HYDRAULIC DRIFT OF BOOM IS LARGE.................................................................................................1904 BOOM MOVES UP AND DOWN DURING OPERATION..........................................................................................1905 BUCKET DOES NOT TILT BACK........................................................................................................1906 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE.......................................................................................1908 BUCKET DECELERATES DURING TILT-BACK OPERATION....................................................................................1910 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND...................................................................................1911 HYDRAULIC DRIFT OF BUCKET IS LARGE...............................................................................................1913 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)..................................................1914 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE........................................................1915 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.........................................................1916 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS...............................................................1917 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES.....................................................1919 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES...........................................................1920 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)...........................................................................1921 UNUSUAL NOISE IS HEARD FROM AROUND FAN...........................................................................................1923 TROUBLESHOOTING OF ENGINE (S-MODE)...................................................................................................1924 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)..........................................................................1924 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...........................................................1925 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.......................................................................................1926 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...................................1927 ENGINE STARTABILITY IS POOR......................................................................................................1929 ENGINE DOES NOT PICK UP SMOOTHLY.................................................................................................1931 ENGINE STOPS DURING OPERATION....................................................................................................1933 ENGINE RUNNING IS NOT STABLE.....................................................................................................1935 OUTPUT IS NOT SUFFICIENT (POWER IS LOW)..........................................................................................1936 EXHAUST IS BLACK (KDPF GETS CLOGGED IN A SHORT TIME).............................................................................1938 ENGINE OIL CONSUMPTION IS EXCESSIVE..............................................................................................1940 ENGINE OIL BECOMES CONTAMINATED QUICKLY..........................................................................................1941 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................1942 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)............................................................1943 OIL PRESSURE DROPS...............................................................................................................1944 FUEL MIXES INTO ENGINE OIL.......................................................................................................1946 WATER MIXES INTO ENGINE OIL (MILKY)..............................................................................................1947 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING).................................................................................1948 THERE IS AN UNUSUAL NOISE........................................................................................................1949 VIBRATION IS EXCESSIVE...........................................................................................................1950 AIR CANNOT BE BLED FROM FUEL CIRCUIT.............................................................................................1951 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.......................................................................................1952 ACTIVE REGENERATION TAKES LONG...................................................................................................1953 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................................................................1954 AdBlue/DEF CONSUMPTION IS EXCESSIVE..............................................................................................1955 THERE IS AN UNUSUAL SMELL (IRRITATING ODOR)......................................................................................1957 FOREIGN MATERIAL MIXES INTO AdBlue/DEF (AdBlue/DEF LEVEL INCREASES)..............................................................1958 TROUBLESHOOTING FOR AUTO-GREASING SYSTEM.............................................................................................1959 OUTLINE OF FAILURE DISPLAY.......................................................................................................1959 TROUBLESHOOTING FOR FCS..........................................................................................................1960 REPLACEMENT OF PUMP ELEMENT......................................................................................................1961 TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM.........................................................................................1962 REPLACEMENT OF AUTO-GREASING CONTROLLER..........................................................................................1964 PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING..................................................................1965 50 DISASSEMBLY AND ASSEMBLY..............................................................................................................1967 CONTENTS.............................................................................................................................1968 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY......................................................................................1973 HOW TO READ THIS MANUAL..........................................................................................................1973 COATING MATERIALS LIST...........................................................................................................1975 SPECIAL TOOLS LIST...............................................................................................................1979 SKETCHES OF SPECIAL TOOLS........................................................................................................1998 PREPARATION..........................................................................................................................2007 DRAIN AND ADD COOLANT............................................................................................................2007 DRAIN COOLANT................................................................................................................2007 ADD COOLANT..................................................................................................................2009 DRAIN AND ADD HYDRAULIC OIL......................................................................................................2011 DRAIN HYDRAULIC OIL..........................................................................................................2012 ADD HYDRAULIC OIL............................................................................................................2012 DRAIN AND ADD FUEL...............................................................................................................2014 DRAIN FUEL...................................................................................................................2014 ADD FUEL.....................................................................................................................2015 COLLECT AND REFILL REFRIGERANT...................................................................................................2016 COLLECT REFRIGERANT..........................................................................................................2016 REFILL REFRIGERANT...........................................................................................................2017 ENGINE AND COOLING SYSTEM............................................................................................................2019 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY..........................................................................................2019 REMOVE SUPPLY PUMP ASSEMBLY..................................................................................................2020 INSTALL SUPPLY PUMP ASSEMBLY.................................................................................................2024 REMOVE AND INSTALL INJECTOR ASSEMBLY.............................................................................................2029 REMOVE INJECTOR ASSEMBLY.....................................................................................................2030 INSTALL INJECTOR ASSEMBLY....................................................................................................2038 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY........................................................................................2047 REMOVE CYLINDER HEAD ASSEMBLY................................................................................................2049 INSTALL CYLINDER HEAD ASSEMBLY...............................................................................................2067 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY.......................................................................................2091 REMOVE STARTING MOTOR ASSEMBLY...............................................................................................2092 INSTALL STARTING MOTOR ASSEMBLY..............................................................................................2094 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT...............................................................................2097 REMOVE AIR CONDITIONER COMPRESSOR BELT.......................................................................................2097 INSTALL AIR CONDITIONER COMPRESSOR BELT......................................................................................2099 REMOVE AND INSTALL ALTERNATOR BELT...............................................................................................2101 REMOVE ALTERNATOR BELT.......................................................................................................2101 INSTALL ALTERNATOR BELT......................................................................................................2105 REMOVE AND INSTALL ALTERNATOR ASSEMBLY...........................................................................................2110 REMOVE ALTERNATOR ASSEMBLY...................................................................................................2110 INSTALL ALTERNATOR ASSEMBLY..................................................................................................2112 REMOVE AND INSTALL AUTO-TENSIONER................................................................................................2115 REMOVE AUTO-TENSIONER........................................................................................................2115 INSTALL AUTO-TENSIONER.......................................................................................................2116 REMOVE AND INSTALL RADIATOR ASSEMBLY.............................................................................................2117 REMOVE RADIATOR ASSEMBLY.....................................................................................................2118 INSTALL RADIATOR ASSEMBLY....................................................................................................2125 REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY............................................................................2134 REMOVE COOLING FAN MOTOR ASSEMBLY............................................................................................2135 INSTALL COOLING FAN MOTOR ASSEMBLY...........................................................................................2140 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.................................................................................2146 REMOVE HYDRAULIC OIL COOLER ASSEMBLY.........................................................................................2146 INSTALL HYDRAULIC OIL COOLER ASSEMBLY........................................................................................2148 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY..........................................................................................2151 REMOVE AFTERCOOLER ASSEMBLY..................................................................................................2151 INSTALL AFTERCOOLER ASSEMBLY.................................................................................................2153 REMOVE AND INSTALL ENGINE ASSEMBLY...............................................................................................2155 REMOVE ENGINE ASSEMBLY.......................................................................................................2157 INSTALL ENGINE ASSEMBLY......................................................................................................2182 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.........................................................................................2211 REMOVE ENGINE FRONT OIL SEAL.................................................................................................2211 INSTALL ENGINE FRONT OIL SEAL................................................................................................2213 REMOVE AND INSTALL ENGINE REAR OIL SEAL..........................................................................................2215 REMOVE ENGINE REAR OIL SEAL..................................................................................................2216 INSTALL ENGINE REAR OIL SEAL.................................................................................................2220 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY..........................................................................................2226 REMOVE ENGINE HOOD ASSEMBLY..................................................................................................2227 INSTALL ENGINE HOOD ASSEMBLY.................................................................................................2236 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY.........................................................................................2245 REMOVE BELLOWS PIPE ASSEMBLY.................................................................................................2246 INSTALL BELLOWS PIPE ASSEMBLY................................................................................................2251 REMOVE AND INSTALL FUEL TANK ASSEMBLY............................................................................................2257 REMOVE FUEL TANK ASSEMBLY....................................................................................................2258 INSTALL FUEL TANK ASSEMBLY...................................................................................................2263 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY......................................................................................2268 REMOVE AdBlue/DEF TANK ASSEMBLY..............................................................................................2270 INSTALL AdBlue/DEF TANK ASSEMBLY.............................................................................................2276 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY........................................................................2281 REMOVE AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................................2281 INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...............................................................................2283 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR........................................................................................2287 REMOVE AdBlue/DEF TANK SENSOR................................................................................................2287 INSTALL AdBlue/DEF TANK SENSOR...............................................................................................2288 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER......................................................................................2295 REMOVE AdBlue/DEF TANK STRAINER..............................................................................................2295 INSTALL AdBlue/DEF TANK STRAINER.............................................................................................2295 REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................................2297 REMOVE KDPF ASSEMBLY.........................................................................................................2298 INSTALL KDPF ASSEMBLY........................................................................................................2308 DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY...........................................................................................2322 DISASSEMBLE KDPF ASSEMBLY....................................................................................................2322 ASSEMBLE KDPF ASSEMBLY.......................................................................................................2326 REMOVE AND INSTALL SCR ASSEMBLY..................................................................................................2332 REMOVE SCR ASSEMBLY..........................................................................................................2333 INSTALL SCR ASSEMBLY.........................................................................................................2341 REMOVE AND INSTALL KDPF AND SCR ASSEMBLY.........................................................................................2353 REMOVE KDPF AND SCR ASSEMBLY.................................................................................................2354 INSTALL KDPF AND SCR ASSEMBLY................................................................................................2364 REMOVE AND INSTALL EXHAUST THROTTLE VALVE........................................................................................2375 REMOVE EXHAUST THROTTLE VALVE................................................................................................2376 INSTALL EXHAUST THROTTLE VALVE...............................................................................................2381 REMOVE AND INSTALL AdBlue/DEF INJECTOR...........................................................................................2387 REMOVE AdBlue/DEF INJECTOR...................................................................................................2388 INSTALL AdBlue/DEF INJECTOR..................................................................................................2392 REMOVE AND INSTALL AdBlue/DEF PUMP...............................................................................................2399 REMOVE AdBlue/DEF PUMP.......................................................................................................2400 INSTALL AdBlue/DEF PUMP......................................................................................................2406 REMOVE AND INSTALL AdBlue/DEF HOSE...............................................................................................2411 REMOVE AdBlue/DEF HOSE.......................................................................................................2412 INSTALL AdBlue/DEF HOSE......................................................................................................2427 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..........................................................................................2442 REMOVE AIR CLEANER ASSEMBLY..................................................................................................2443 INSTALL AIR CLEANER ASSEMBLY.................................................................................................2446 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...........................................................................2450 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................................2450 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................2452 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY............................................................................2454 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY....................................................................................2454 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...................................................................................2457 REMOVE AND INSTALL OIL CATCH TANK................................................................................................2460 REMOVE OIL CATCH TANK........................................................................................................2461 INSTALL OIL CATCH TANK.......................................................................................................2462 REMOVE AND INSTALL EXHAUST PIPE COVER............................................................................................2464 REMOVE EXHAUST PIPE COVER....................................................................................................2464 INSTALL EXHAUST PIPE COVER...................................................................................................2466 POWER TRAIN..........................................................................................................................2469 REMOVE AND INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY....2469 REMOVE HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY............2471 INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLY...........2479 REMOVE AND INSTALL HST MOTOR 1 ASSEMBLY..........................................................................................2489 REMOVE HST MOTOR 1 ASSEMBLY..................................................................................................2490 INSTALL HST MOTOR 1 ASSEMBLY.................................................................................................2492 REMOVE AND INSTALL HST MOTOR 2 ASSEMBLY..........................................................................................2495 REMOVE HST MOTOR 2 ASSEMBLY..................................................................................................2496 INSTALL HST MOTOR 2 ASSEMBLY.................................................................................................2500 REMOVE AND INSTALL TRANSFER ASSEMBLY.............................................................................................2504 REMOVE TRANSFER ASSEMBLY.....................................................................................................2505 INSTALL TRANSFER ASSEMBLY....................................................................................................2513 DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY.......................................................................................2521 METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY...................................................................................2522 METHOD FOR ASSEMBLING TRANSFER ASSEMBLY......................................................................................2537 REMOVE AND INSTALL PARKING BRAKE ASSEMBLY........................................................................................2555 REMOVE PARKING BRAKE ASSEMBLY................................................................................................2556 INSTALL PARKING BRAKE ASSEMBLY...............................................................................................2557 REMOVE AND INSTALL PARKING BRAKE CYLINDER ASSEMBLY...............................................................................2559 REMOVE PARKING BRAKE CYLINDER ASSEMBLY.......................................................................................2559 INSTALL PARKING BRAKE CYLINDER ASSEMBLY......................................................................................2561 DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY..................................................................................2562 METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY..............................................................................2562 METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY.................................................................................2565 REMOVE AND INSTALL FRONT AXLE ASSEMBLY...........................................................................................2569 REMOVE FRONT AXLE ASSEMBLY...................................................................................................2570 INSTALL FRONT AXLE ASSEMBLY..................................................................................................2573 REMOVE AND INSTALL REAR AXLE ASSEMBLY............................................................................................2576 REMOVE REAR AXLE ASSEMBLY....................................................................................................2577 INSTALL REAR AXLE ASSEMBLY...................................................................................................2581 DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY...................................................................................2587 METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY...............................................................................2587 METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY..................................................................................2592 DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY...................................................................................2600 METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY...............................................................................2601 METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY..................................................................................2614 UNDERCARRIAGE AND FRAME..............................................................................................................2636 REMOVE AND INSTALL CENTER HINGE PIN..............................................................................................2636 REMOVE CENTER HINGE PIN......................................................................................................2638 INSTALL CENTER HINGE PIN.....................................................................................................2647 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY........................................................................................2658 REMOVE COUNTERWEIGHT ASSEMBLY................................................................................................2659 INSTALL COUNTERWEIGHT ASSEMBLY...............................................................................................2670 HYDRAULIC SYSTEM.....................................................................................................................2682 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY.......................................................................................2682 REMOVE HYDRAULIC TANK ASSEMBLY...............................................................................................2683 INSTALL HYDRAULIC TANK ASSEMBLY..............................................................................................2689 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY........................................................................................2695 REMOVE CONTROL VALVE ASSEMBLY................................................................................................2697 INSTALL CONTROL VALVE ASSEMBLY...............................................................................................2703 DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY.............................................................................2710 METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY.........................................................................2711 METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY............................................................................2714 WORK EQUIPMENT.......................................................................................................................2721 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY.......................................................................................2721 REMOVE WORK EQUIPMENT ASSEMBLY...............................................................................................2722 INSTALL WORK EQUIPMENT ASSEMBLY..............................................................................................2726 CAB RELATED PARTS....................................................................................................................2735 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY.........................................................................................2735 REMOVE OPERATOR CAB ASSEMBLY.................................................................................................2737 INSTALL OPERATOR CAB ASSEMBLY................................................................................................2748 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)............................................................................2759 METHOD FOR REMOVING OPERATOR'S CAB GLASS (ADHERED GLASS).....................................................................2759 METHOD FOR INSTALLING OPERATOR'S CAB GLASS (ADHERED GLASS)...................................................................2760 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.................................................................................2769 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY............................................................................2769 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY..........................................................................2775 REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLY......................................................................................2782 METHOD FOR REMOVING OPERATOR'S SEAT ASSEMBLY.................................................................................2782 METHOD FOR INSTALLING OPERATOR'S SEAT ASSEMBLY...............................................................................2782 REMOVE AND INSTALL SEAT BELT.....................................................................................................2784 METHOD FOR REMOVING SEAT BELT................................................................................................2784 METHOD FOR INSTALLING SEAT BELT..............................................................................................2784 ELECTRICAL SYSTEM....................................................................................................................2786 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY....................................................................................2786 REMOVE ENGINE CONTROLLER ASSEMBLY............................................................................................2787 INSTALL ENGINE CONTROLLER ASSEMBLY...........................................................................................2791 REMOVE AND INSTALL HST CONTROLLER ASSEMBLY.......................................................................................2796 METHOD FOR REMOVING HST CONTROLLER ASSEMBLY..................................................................................2796 METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY................................................................................2798 REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY...........................................................................2800 METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY......................................................................2800 METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY....................................................................2801 REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY...................................................................................2803 METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY..............................................................................2803 METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY............................................................................2806 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY......................................................................................2808 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.................................................................................2808 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...............................................................................2811 REMOVE AND INSTALL INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR...............................................................2814 REMOVE INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR.......................................................................2814 INSTALL INTAKE MANIFOLD PRESSURE AND TEMPERATURE SENSOR......................................................................2815 REMOVE AND INSTALL KDPF TEMPERATURE SENSOR.......................................................................................2817 REMOVE KDPF TEMPERATURE SENSOR...............................................................................................2818 INSTALL KDPF TEMPERATURE SENSOR..............................................................................................2825 REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR.............................................................................2832 REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR.....................................................................................2833 INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR....................................................................................2836 REMOVE AND INSTALL SCR TEMPERATURE SENSOR........................................................................................2839 REMOVE SCR TEMPERATURE SENSOR................................................................................................2840 INSTALL SCR TEMPERATURE SENSOR...............................................................................................2846 REMOVE AND INSTALL SCR OUTLET NOx SENSOR.........................................................................................2854 REMOVE SCR OUTLET NOx SENSOR.................................................................................................2855 INSTALL SCR OUTLET NOx SENSOR................................................................................................2860 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER...................................................................................2866 REMOVE GATEWAY FUNCTION CONTROLLER...........................................................................................2866 INSTALL GATEWAY FUNCTION CONTROLLER..........................................................................................2868 REMOVE AND INSTALL COMMUNICATION TERMINAL........................................................................................2869 REMOVE COMMUNICATION TERMINAL................................................................................................2869 INSTALL COMMUNICATION TERMINAL...............................................................................................2871 60 MAINTENANCE STANDARD..................................................................................................................2875 CONTENTS.............................................................................................................................2876 ENGINE AND COOLING SYSTEM............................................................................................................2877 MAINTENANCE STANDARD OF ENGINE MOUNT.............................................................................................2877 MAINTENANCE STANDARD OF DAMPER...................................................................................................2878 MAINTENANCE STANDARD OF COOLING FAN MOTOR........................................................................................2879 POWER TRAIN..........................................................................................................................2883 MAINTENANCE STANDARD OF DRIVE SHAFT..............................................................................................2883 MAINTENANCE STANDARD OF TRANSFER.................................................................................................2884 MAINTENANCE STANDARD OF TRANSFER MOUNT...........................................................................................2893 MAINTENANCE STANDARD OF FRONT AXLE...............................................................................................2894 MAINTENANCE STANDARD OF REAR AXLE................................................................................................2895 MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL..................................................................2896 MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL...................................................................2898 MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL................................................................................2900 MAINTENANCE STANDARD OF FRONT FINAL DRIVE........................................................................................2902 MAINTENANCE STANDARD OF REAR FINAL DRIVE.........................................................................................2904 STEERING SYSTEM......................................................................................................................2906 MAINTENANCE STANDARD OF STEERING COLUMN..........................................................................................2906 MAINTENANCE STANDARD OF PRIORITY VALVE...........................................................................................2907 MAINTENANCE STANDARD OF STEERING CYLINDER........................................................................................2908 MAINTENANCE STANDARD OF SECONDARY STEERING VALVE.................................................................................2910 BRAKE SYSTEM.........................................................................................................................2911 MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE...................................................................2911 MAINTENANCE STANDARD OF SLACK ADJUSTER...........................................................................................2912 MAINTENANCE STANDARD OF FRONT BRAKE..............................................................................................2913 MAINTENANCE STANDARD OF REAR BRAKE...............................................................................................2914 MAINTENANCE STANDARD OF PARKING BRAKE............................................................................................2915 UNDERCARRIAGE AND FRAME..............................................................................................................2916 MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN...................................................................2916 HYDRAULIC SYSTEM.....................................................................................................................2921 MAINTENANCE STANDARD OF HYDRAULIC TANK...........................................................................................2921 MAINTENANCE STANDARD OF STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP...........................2922 MAINTENANCE STANDARD OF CONTROL VALVE............................................................................................2924 MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE.......................................................................2927 MAINTENANCE STANDARD OF ATTACHMENT EPC SOLENOID VALVE............................................................................2929 WORK EQUIPMENT.......................................................................................................................2930 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...................................................................................2930 MAINTENANCE STANDARD OF BUCKET...................................................................................................2933 MAINTENANCE STANDARD OF LIFT CYLINDER............................................................................................2934 MAINTENANCE STANDARD OF BUCKET CYLINDER..........................................................................................2935 MAINTENANCE STANDARD OF COUPLER PLUNGER..........................................................................................2936 CAB AND ITS ATTACHMENTS..............................................................................................................2937 MAINTENANCE STANDARD OF CAB MOUNT................................................................................................2937 80 OTHERS................................................................................................................................2939 CONTENTS.............................................................................................................................2940 AIR CONDITIONER SYSTEM...............................................................................................................2942 PRECAUTIONS FOR REFRIGERANT......................................................................................................2942 AIR CONDITIONER COMPONENT........................................................................................................2943 SPECIFICATIONS OF AIR CONDITIONER................................................................................................2945 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE................................................................................2946 OUTLINE OF REFRIGERATION CYCLE...................................................................................................2947 COMPONENT PARTS OF AIR CONDITIONER SYSTEM............................................................................................2949 AIR CONDITIONER UNIT.............................................................................................................2949 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT................................................................................2949 FUNCTION OF AIR CONDITIONER UNIT.............................................................................................2950 COMPONENT PARTS OF AIR CONDITIONER UNIT..........................................................................................2951 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT.....................................................................2951 FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT..................................................2951 FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT...............................................................2952 FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT...............................................................2952 FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT........................................................2952 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT....................................................................2952 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT..................................................2952 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2953 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT................................................................2953 FUNCTION OF DUAL PRESSURE SWITCH.............................................................................................2954 AIR CONDITIONER CONTROLLER.......................................................................................................2955 STRUCTURE OF AIR CONDITIONER CONTROLLER......................................................................................2955 COMPRESSOR.......................................................................................................................2956 STRUCTURE OF COMPRESSOR......................................................................................................2956 SPECIFICATIONS OF COMPRESSOR.................................................................................................2956 FUNCTION OF COMPRESSOR.......................................................................................................2956 CONDENSER........................................................................................................................2957 STRUCTURE OF CONDENSER.......................................................................................................2957 SPECIFICATIONS OF CONDENSER..................................................................................................2957 FUNCTION OF CONDENSER........................................................................................................2957 RECEIVER DRIER...................................................................................................................2958 STRUCTURE OF RECEIVER DRIER..................................................................................................2958 SPECIFICATIONS OF RECEIVER DRIER.............................................................................................2958 FUNCTION OF RECEIVER DRIER...................................................................................................2958 SENSORS FOR AIR CONDITIONER SYSTEM...............................................................................................2959 FUNCTION OF SUNLIGHT SENSOR..................................................................................................2959 FUNCTION OF AMBIENT TEMPERATURE SENSOR.......................................................................................2959 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER..........................................................2960 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER................................................................2962 AIR CONDITIONER SYSTEM DIAGRAM.......................................................................................................2965 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...........................................................................2966 FUNCTION OF AIR CONDITIONER CONTROLLER.......................................................................................2967 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS........................................................2968 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................................................2974 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...................................2975 CHECK TEMPERATURE CONTROL FUNCTION...................................................................................................2976 METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION.................................................................................2976 TEST VENT (MODE) CHANGEOVER..........................................................................................................2978 METHOD FOR TESTING VENT (MODE) CHANGEOVER........................................................................................2978 TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................................2980 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...................................................................................2980 TEST EVAPORATOR TEMPERATURE SENSOR...................................................................................................2982 TEST RELAYS..........................................................................................................................2984 METHOD FOR TESTING RELAYS........................................................................................................2984 AIR CONDITIONER TROUBLESHOOTING CHART 1..............................................................................................2986 AIR CONDITIONER TROUBLESHOOTING CHART 2..............................................................................................2987 FAILURE CODE [879AKA]................................................................................................................2990 FAILURE CODE [879AKB]................................................................................................................2992 FAILURE CODE [879BKA]................................................................................................................2994 FAILURE CODE [879BKB]................................................................................................................2996 FAILURE CODE [879CKA]................................................................................................................2998 FAILURE CODE [879CKB]................................................................................................................3000 FAILURE CODE [879DKZ]................................................................................................................3002 FAILURE CODE [879EMC]................................................................................................................3004 FAILURE CODE [879FMC]................................................................................................................3005 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...........................................................3006 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)............................................................3009 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...................................................3012 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER......................................................................................3016 TROUBLESHOOTING USING GAUGE PRESSURE.................................................................................................3018 CONNECTION OF SERVICE TOOL...........................................................................................................3021 METHOD FOR CONNECTING SERVICE TOOL...............................................................................................3022 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS..............................................3023 HANDLE COMPRESSOR OIL................................................................................................................3025 90 CIRCUIT DIAGRAMS......................................................................................................................3027 CONTENTS.............................................................................................................................3028 HOW TO READ THE CODES FOR ELECTRIC CABLE.............................................................................................3029 HYDRAULIC CIRCUIT DIAGRAM............................................................................................................3033 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM........................................................................................3033 HYDRAULIC CIRCUIT DIAGRAM (1/2)..................................................................................................3037 HYDRAULIC CIRCUIT DIAGRAM (2/2)..................................................................................................3039 ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................3041 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM.........................................................................................3041 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/13).................................................................................3045 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/13).................................................................................3047 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/13).................................................................................3049 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/13).................................................................................3051 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/13).................................................................................3053 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/13).................................................................................3055 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/13).................................................................................3057 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/13).................................................................................3059 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/13).................................................................................3061 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/13)................................................................................3063 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (11/13)................................................................................3065 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (12/13)................................................................................3067 ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (13/13)................................................................................3069 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/10)...................................................................................3071 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/10)...................................................................................3073 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/10)...................................................................................3075 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/10)...................................................................................3077 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/10)...................................................................................3079 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/10)...................................................................................3081 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/10)...................................................................................3083 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/10)...................................................................................3085 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/10)...................................................................................3087 ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (10/10)..................................................................................3089 INDEX.....................................................................................................................................3091
DESCRIPTION:
KOMATSU WA200-8E0 WHEEL LOADER SHOP MANUAL VENBM35000 – PDF DOWNLOAD
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 SPECIFICATIONS
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.
50 DISASSEMBLY AND ASSEMBLY
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 THE OTHER INFORMATION
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.
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