Komatsu WA270-8 WHEEL LOADER Shop Manual CEBM031302 – PDF DOWNLOAD

Description

Komatsu WA270-8 WHEEL LOADER Shop Manual CEBM031302 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA270-8 WHEEL LOADER Shop Manual CEBM031302 – PDF DOWNLOAD

Language : English
Pages :3256
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA270-8 WHEEL LOADER Shop Manual CEBM031302 – PDF DOWNLOAD

SERIAL NUMBERS WA270-8 A28001 and up
ENGINE 6D107E-3

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
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.

TABLE OF CONTENTS:

Komatsu WA270-8 WHEEL LOADER Shop Manual CEBM031302 – PDF DOWNLOAD

SERIAL NUMBERS WA270-8 A28001 and up
ENGINE 6D107E-3

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: WA270-8 103
SPECIFICATIONS 105
SPECIFICATIONS: WA270-8 105
WEIGHT TABLE 110
WEIGHT TABLE: WA270-8 110
TABLE OF FUEL, COOLANT, AND LUBRICANTS 112
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 132
COMPONENT PARTS OF UREA SCR SYSTEM 146
AdBlue/DEF MIXING TUBE 146
SCR ASSEMBLY 147
AdBlue/DEF TANK 149
AdBlue/DEF PUMP 151
AdBlue/DEF INJECTOR 152
AdBlue/DEF HOSE 153
AdBlue/DEF TANK HEATING VALVE 154
BOOT-UP SYSTEM 155
LAYOUT DRAWING OF BOOT-UP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 157
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 157
BATTERY DISCONNECT SWITCH 158
FUNCTION OF BATTERY DISCONNECT SWITCH 158
PREHEATING SYSTEM 159
PREHEATING SYSTEM DIAGRAM 159
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 159
OPERATION OF AUTOMATIC PREHEATING SYSTEM 159
FUNCTION OF MANUAL PREHEATING SYSTEM 160
OPERATION OF MANUAL PREHEATING SYSTEM 160
ENGINE SYSTEM 161
LAYOUT DRAWING OF ENGINE SYSTEM 161
FUNCTION OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 163
ENGINE CONTROL SYSTEM DIAGRAM 163
FUNCTION OF ENGINE CONTROL SYSTEM 165
OPERATION OF ENGINE CONTROL SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 171
DAMPER 171
VGT 172
EGR SYSTEM 176
EGR VALVE 178
EGR COOLER 180
KCCV SYSTEM 182
KCCV VENTILATOR 184
KDPF 186
COOLING SYSTEM 190
LAYOUT DRAWING OF COOLING SYSTEM 190
SPECIFICATIONS OF COOLING SYSTEM 191
COOLING FAN CONTROL SYSTEM 192
COOLING FAN CONTROL SYSTEM DIAGRAM 192
FUNCTION OF COOLING FAN CONTROL SYSTEM 192
COMPONENT PARTS OF COOLING SYSTEM 197
COOLING FAN MOTOR 197
CONTROL SYSTEM 210
LAYOUT DRAWING OF CONTROL SYSTEM 210
MACHINE MONITOR SYSTEM 212
MACHINE MONITOR SYSTEM DIAGRAM 212
FUNCTION OF MACHINE MONITOR SYSTEM 212
REARVIEW MONITOR SYSTEM 214
REARVIEW MONITOR SYSTEM DIAGRAM 214
FUNCTION OF REARVIEW MONITOR SYSTEM 214
KOMTRAX SYSTEM 215
KOMTRAX SYSTEM DIAGRAM 215
FUNCTION OF KOMTRAX SYSTEM 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
SWITCH PANEL 233
REARVIEW MONITOR 234
REARVIEW CAMERA 236
KOMTRAX TERMINAL 237
MONITOR CONTROLLER 239
HST CONTROLLER 244
CAN TERMINATING RESISTOR 248
ENGINE CONTROLLER 249
ACCELERATOR PEDAL 256
HYDRAULIC SYSTEM 258
LAYOUT DRAWING OF HYDRAULIC SYSTEM 258
CLSS 259
STRUCTURE OF CLSS 259
FUNCTION OF CLSS 260
COMPONENT PARTS OF HYDRAULIC SYSTEM 262
HYDRAULIC TANK 262
HYDRAULIC OIL FILTER 265
STEERING AND WORK EQUIPMENT PUMP 266
BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP 279
CONTROL VALVE 280
POWER TRAIN SYSTEM 310
LAYOUT DRAWING OF POWER TRAIN SYSTEM 310
OPERATION OF POWER TRAIN SYSTEM 312
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 313
HST CONTROL SYSTEM 315
HST CONTROL SYSTEM DIAGRAM 315
ENGINE OVERRUN PREVENTION FUNCTION 316
NEUTRALIZER FUNCTION 316
HST CHARGE SYSTEM 317
SYSTEM DIAGRAM OF HST CHARGE SYSTEM 317
FUNCTION OF HST CHARGE SYSTEM 317
HST PUMP CONTROL SYSTEM 318
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM 318
DIRECTIONAL SELECTION FUNCTION 318
ABSORBING TORQUE CONTROL FUNCTION 318
INCHING CONTROL FUNCTION 319
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED) 319
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION 320
GEAR SHIFT FUNCTION 320
GEAR SHIFT DISPLAY FUNCTION 322
TRAVEL SPEED ADJUSTMENT FUNCTION 322
TRANSFER CLUTCH CONTROL FUNCTION 323
HST SYSTEM PROTECTION FUNCTION 324
TRANSFER PROTECTION FUNCTION 324
DIRECTION PROTECTION FUNCTION 324
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1 324
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2 325
TRAVEL SPEED LIMITATION FUNCTION 326
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL 327
FUNCTION OF MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL 327
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 330
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM 330
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 330
COMPONENT PARTS OF POWER TRAIN SYSTEM 335
DRIVE SHAFT 335
HST PUMP 337
HST CHARGE PUMP 349
HST MOTOR 351
TRANSFER 357
AXLE 365
TORQUE PROPORTIONING DIFFERENTIAL 367
LIMITED SLIP DIFFERENTIAL 371
FINAL DRIVE 375
COMBINATION SWITCH 377
WORK EQUIPMENT SYSTEM 381
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 381
WORK EQUIPMENT CONTROL SYSTEM 383
WORK EQUIPMENT LEVER OPERATION FUNCTION 383
PZ AUTO TILT-IN COMPENSATION CONTROL FUNCTION 383
WORK EQUIPMENT LOCK SYSTEM 384
WORK EQUIPMENT LOCK SYSTEM DIAGRAM 384
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM 384
BUCKET POSITIONER SYSTEM 386
BUCKET POSITIONER SYSTEM DIAGRAM 386
FUNCTION OF BUCKET POSITIONER SYSTEM 386
OPERATION OF BUCKET POSITIONER SYSTEM 388
FORK POSITIONER SYSTEM 390
FORK POSITIONER SYSTEM DIAGRAM 390
FUNCTION OF FORK POSITIONER SYSTEM 390
OPERATION OF FORK POSITIONER SYSTEM 391
REMOTE POSITIONER SYSTEM 394
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 394
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 394
ECSS 397
ECSS DIAGRAM 397
FUNCTION OF ECSS 397
OPERATION OF ECSS 397
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 399
SELF-PRESSURE REDUCING VALVE 399
WORK EQUIPMENT LOCK SOLENOID VALVE 404
PILOT CIRCUIT ACCUMULATOR 405
ECSS CIRCUIT ACCUMULATOR 406
MULTIFUNCTION MONO-LEVER 407
MULTIFUNCTION MONO-LEVER PPC VALVE 409
STEERING SYSTEM 414
LAYOUT DRAWING OF STEERING SYSTEM 414
STEERING COLUMN 415
STRUCTURE OF STEERING COLUMN 415
COMPONENT PARTS OF STEERING SYSTEM 416
PRIORITY VALVE 416
ORBITROL VALVE 419
CUSHION VALVE 424
2-WAY RESTRICTOR VALVE 426
SECONDARY STEERING VALVE 427
BRAKE SYSTEM 430
LAYOUT DRAWING OF BRAKE SYSTEM 430
PARKING BRAKE CONTROL SYSTEM 432
PARKING BRAKE CONTROL SYSTEM DIAGRAM 432
OPERATION OF PARKING BRAKE CONTROL SYSTEM 432
COMPONENT PARTS OF BRAKE SYSTEM 436
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 436
PARKING BRAKE SOLENOID VALVE 440
BRAKE CIRCUIT ACCUMULATOR 442
BRAKE VALVE 444
SLACK ADJUSTER 447
BRAKE 449
PARKING BRAKE 452
AUTO-GREASING SYSTEM 454
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 454
SPECIFICATIONS OF AUTO-GREASING SYSTEM 455
FUNCTION OF AUTO-GREASING SYSTEM 456
COMPONENT PARTS OF AUTO-GREASING SYSTEM 457
AUTO-GREASING PUMP 457
UNDERCARRIAGE AND FRAME 458
FRAME, AXLE MOUNT AND CENTER HINGE PIN 458
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 458
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 459
TIRE 461
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 461
STRUCTURE OF RADIAL TIRE 461
FUNCTION OF RADIAL TIRE 461
STRUCTURE OF BIAS TIRE 462
FUNCTION OF BIAS TIRE 462
WORK EQUIPMENT 463
STRUCTURE OF WORK EQUIPMENT 463
STRUCTURE OF BUCKET 464
CAB AND ITS ATTACHMENTS 465
ROPS CAB 465
STRUCTURE OF ROPS CAB 465
FUNCTION OF ROPS CAB 465
CAB MOUNT 466
STRUCTURE OF CAB MOUNT 466
FUNCTION OF CAB MOUNT 466
20 STANDARD VALUE TABLE 467
CONTENTS 468
ABBREVIATION LIST 469
STANDARD VALUE TABLE FOR ENGINE 475
STANDARD VALUE TABLE FOR ENGINE: WA270-8 475
STANDARD VALUE TABLE FOR MACHINE 480
STANDARD VALUE TABLE FOR MACHINE: WA270-8 480
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 494
30 TESTING AND ADJUSTING 497
CONTENTS 498
ABBREVIATION LIST 502
RELATED INFORMATION ON TESTING AND ADJUSTING 508
TOOLS FOR TESTING AND ADJUSTING 508
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 517
ENGINE AND COOLING SYSTEM 518
TEST ENGINE SPEED 518
METHOD FOR TESTING ENGINE SPEED 518
TEST BOOST PRESSURE 521
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 521
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 522
TESTING EXHAUST GAS TEMPERATURE 524
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 524
TEST EXHAUST GAS COLOR 526
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 526
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 528
TEST AND ADJUST VALVE CLEARANCE 530
METHOD FOR TESTING VALVE CLEARANCE 530
METHOD FOR ADJUSTING VALVE CLEARANCE 531
TEST COMPRESSION PRESSURE 532
METHOD FOR TESTING COMPRESSION PRESSURE 532
TEST BLOWBY PRESSURE 537
METHOD FOR TESTING BLOWBY PRESSURE 537
TEST ENGINE OIL PRESSURE 540
METHOD FOR TESTING ENGINE OIL PRESSURE 540
TEST EGR VALVE AND VGT OIL PRESSURE 542
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 542
TEST FUEL PRESSURE 544
METHOD FOR TESTING FUEL PRESSURE 545
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 550
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 551
BLEED AIR FROM FUEL SYSTEM 557
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 557
TEST FUEL CIRCUIT FOR LEAKAGE 559
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 559
HANDLE CYLINDER CUT-OUT MODE OPERATION 561
HANDLE NO-INJECTION CRANKING OPERATION 562
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 563
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 563
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 564
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 564
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 565
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 565
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 566
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 566
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 566
TEST ALTERNATOR BELT 568
METHOD FOR TESTING ALTERNATOR BELT 568
TEST AUTOMATIC TENSIONER 570
METHOD FOR TESTING AUTOMATIC TENSIONER 570
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 573
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 573
TEST SCR RELATED FUNCTIONS 574
TEST AdBlue/DEF PUMP RAISED PRESSURE 578
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 581
TEST AdBlue/DEF LINE HEATER RELAY 1 587
TEST AdBlue/DEF LINE HEATER RELAY 2 591
TEST AdBlue/DEF PUMP HEATER RELAY 595
TEST AdBlue/DEF TANK HEATER VALVE 599
TEST SCR NOx REMOVAL EFFICIENCY 603
CLEAN AdBlue/DEF TANK 607
METHOD FOR CLEANING AdBlue/DEF TANK 607
POWER TRAIN 611
TEST AND ADJUST HST OIL PRESSURE 611
METHOD FOR TESTING HST OIL PRESSURE 611
METHOD FOR ADJUSTING HST OIL PRESSURE 613
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH 615
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH 615
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 617
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 617
STEERING SYSTEM 618
TEST STEERING WHEEL 618
METHOD FOR TESTING STEERING WHEEL 618
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 620
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE ON MACHINE MONITOR 620
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE BY TESTING TOOL 621
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 621
BLEED AIR FROM STEERING CYLINDER CIRCUIT 623
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 623
BRAKE SYSTEM 624
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 624
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 624
TEST WHEEL BRAKE OIL PRESSURE 625
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 625
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 627
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 627
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 628
BLEED AIR FROM BRAKE CIRCUIT 629
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 629
TEST BRAKING PERFORMANCE 630
METHOD FOR TESTING BRAKING PERFORMANCE 630
TEST BRAKE PEDAL 631
METHOD FOR TESTING BRAKE PEDAL 631
TEST LOWERING OF WHEEL BRAKE PRESSURE 632
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 633
TEST WEAR OF WHEEL BRAKE DISC 635
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 635
TEST PARKING BRAKE OIL PRESSURE 637
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 637
TEST PARKING BRAKE PERFORMANCE 639
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 639
RELEASE PARKING BRAKE MANUALLY 640
METHOD FOR RELEASING PARKING BRAKE MANUALLY 640
TEST WEAR AMOUNT OF PARKING BRAKE DISC 641
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 641
HYDRAULIC SYSTEM 642
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 642
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 642
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 644
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 644
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 648
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE 650
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE 650
METHOD FOR ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE 652
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 654
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 654
TEST COOLING FAN SPEED 656
METHOD FOR TESTING COOLING FAN SPEED 656
TEST COOLING FAN CIRCUIT OIL PRESSURE 657
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 657
BLEED AIR FROM COOLING FAN CIRCUIT 660
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 660
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 662
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 662
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 664
WORK EQUIPMENT 668
TEST AND ADJUST BUCKET POSITIONER 668
METHOD FOR TESTING BUCKET POSITIONER 668
METHOD FOR ADJUSTING BUCKET POSITIONER 668
TEST AND ADJUST BOOM POTENTIOMETER LEVER 670
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 670
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 670
CAB AND ITS ATTACHMENTS 671
TEST DIRECTIONAL LEVER 671
METHOD FOR TESTING DIRECTIONAL LEVER 671
TEST MULTIFUNCTION MONO-LEVER 672
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER 672
TEST ACCELERATOR PEDAL 674
METHOD FOR TESTING ACCELERATOR PEDAL 674
ELECTRICAL SYSTEM 676
SET AND ADJUST EACH EQUIPMENT 676
SET AND OPERATE MACHINE MONITOR 680
OPERATOR MODE 684
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 684
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 684
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 685
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 686
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 686
SERVICE MODE 690
METHOD FOR OPERATING SERVICE MODE 690
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 693
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 700
ABNORMALITY RECORD MENU 712
METHOD FOR CONFIRMING MAINTENANCE RECORD 717
METHOD FOR OPERATING MAINTENANCE MODE SETTING 720
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 726
DEFAULT MENU 727
DIAGNOSTIC TESTS MENU 741
ADJUSTMENT MENU 753
METHOD FOR PERFORMING NO-INJECTION CRANKING 791
KOMTRAX SETTINGS MENU 793
METHOD FOR DISPLAYING SERVICE MESSAGE 795
METHOD FOR STARTING UP KOMTRAX TERMINAL 797
ADJUST REARVIEW CAMERA ANGLE 802
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 802
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 804
HANDLE BATTERY DISCONNECT SWITCH 805
TEST DIODES 806
METHOD FOR TESTING DIODE USING DIGITAL TESTER 806
METHOD FOR TESTING DIODE USING ANALOG TESTER 806
AUTO-GREASING DEVICE 807
BLEED THE AIR OF AUTO-GREASING SYSTEM 807
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 807
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 810
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 811
Pm CLINIC 813
Pm CLINIC SERVICE 813
Pm CLINIC CHECK SHEET: WA270-8 815
40 TROUBLESHOOTING 825
CONTENTS 826
ABBREVIATION LIST 837
RELATED INFORMATION ON TROUBLESHOOTING 843
GENERAL TROUBLESHOOTING POINTS 843
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 844
SEQUENCE OF EVENTS IN TROUBLESHOOTING 856
CHECKS BEFORE TROUBLESHOOTING 858
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 860
WALK-AROUND CHECK 860
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 862
CHECK FUEL LEVEL AND TYPE 862
FUEL – CHECK FOR FOREIGN MATERIAL 862
CHECK AdBule/DEF LEVEL AND TYPE 863
CHECK FUEL PREFILTER 863
CHECK MAIN FILTER 865
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 866
CHECK COOLANT LEVEL (RESERVOIR TANK) 867
CHECK CLOGGING OF AIR CLEANER 868
OUTER ELEMENT – CLEAN 868
REPLACE ELEMENT 870
CHECK HYDRAULIC OIL LEVEL 872
CHECK HYDRAULIC OIL STRAINER 872
CHECK HYDRAULIC FILTER 875
CHECK THE OIL LEVEL IN THE TRANSFER CASE 875
CHECK OIL LEVEL IN FRONT AXLE CASE 877
CHECK OIL LEVEL IN REAR AXLE CASE 878
BLEED AIR FROM FUEL SYSTEM 878
BLEED AIR FROM HYDRAULIC SYSTEM 878
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 879
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 884
PROCEDURE FOR TESTING AND TROUBLESHOOTING 892
SYMPTOM AND TROUBLESHOOTING NUMBERS 894
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 898
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 900
CONNECTORS LIST AND LAYOUT 903
CONNECTOR CONTACT IDENTIFICATION 923
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 963
FUSE LOCATION TABLE 969
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 972
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 976
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 978
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 984
FAILURE CODES TABLE 986
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1005
FAILURE CODE [2F00MA]1005
FAILURE CODE [2F00MB]1008
FAILURE CODE [2G42ZG]1010
FAILURE CODE [2G43ZG]1012
FAILURE CODE [6091NX]1014
FAILURE CODE [7RHYKA]1016
FAILURE CODE [7RHYKB]1018
FAILURE CODE [7RHYKY]1020
FAILURE CODE [879AKA]1022
FAILURE CODE [879AKB]1024
FAILURE CODE [879BKA]1026
FAILURE CODE [879BKB]1028
FAILURE CODE [879CKA]1030
FAILURE CODE [879CKB]1032
FAILURE CODE [879DKZ]1034
FAILURE CODE [879EMC]1036
FAILURE CODE [879FMC]1037
FAILURE CODE [989FN1]1038
FAILURE CODE [989L00]1039
FAILURE CODE [989M00]1040
FAILURE CODE [989N00]1041
FAILURE CODE [A1U0N3]1042
FAILURE CODE [A1U0N4]1044
FAILURE CODE [AB00KE]1046
FAILURE CODE [AB00KY]1048
FAILURE CODE [AQ10N3]1050
FAILURE CODE [AS00N3]1052
FAILURE CODE [AS00R2]1054
FAILURE CODE [AS00R3]1055
FAILURE CODE [AS00R4]1056
FAILURE CODE [AS00R5]1057
FAILURE CODE [AS00R6]1058
FAILURE CODE [AS00ZK]1059
FAILURE CODE [AS10KM]1060
FAILURE CODE [AS10NR]1061
FAILURE CODE [AS10NT]1062
FAILURE CODE [B@BAZG]1063
FAILURE CODE [B@BCNS]1064
FAILURE CODE [B@BCZK]1065
FAILURE CODE [B@C6NS]1067
FAILURE CODE [B@CRNS]1069
FAILURE CODE [CA115]1070
FAILURE CODE [CA122]1071
FAILURE CODE [CA123]1073
FAILURE CODE [CA131]1075
FAILURE CODE [CA132]1077
FAILURE CODE [CA144]1080
FAILURE CODE [CA145]1082
FAILURE CODE [CA153]1084
FAILURE CODE [CA154]1087
FAILURE CODE [CA187]1089
FAILURE CODE [CA221]1091
FAILURE CODE [CA222]1093
FAILURE CODE [CA227]1095
FAILURE CODE [CA234]1096
FAILURE CODE [CA238]1097
FAILURE CODE [CA239]1099
FAILURE CODE [CA249]1101
FAILURE CODE [CA256]1103
FAILURE CODE [CA271]1105
FAILURE CODE [CA272]1107
FAILURE CODE [CA322]1109
FAILURE CODE [CA323]1111
FAILURE CODE [CA324]1113
FAILURE CODE [CA325]1115
FAILURE CODE [CA331]1117
FAILURE CODE [CA332]1119
FAILURE CODE [CA343]1121
FAILURE CODE [CA351]1122
FAILURE CODE [CA352]1123
FAILURE CODE [CA356]1126
FAILURE CODE [CA357]1128
FAILURE CODE [CA386]1131
FAILURE CODE [CA428]1132
FAILURE CODE [CA429]1134
FAILURE CODE [CA431]1136
FAILURE CODE [CA432]1139
FAILURE CODE [CA435]1143
FAILURE CODE [CA441]1145
FAILURE CODE [CA442]1147
FAILURE CODE [CA449]1148
FAILURE CODE [CA451]1149
FAILURE CODE [CA452]1151
FAILURE CODE [CA488]1153
FAILURE CODE [CA515]1154
FAILURE CODE [CA516]1156
FAILURE CODE [CA553]1158
FAILURE CODE [CA555]1159
FAILURE CODE [CA556]1160
FAILURE CODE [CA559]1161
FAILURE CODE [CA595]1164
FAILURE CODE [CA687]1165
FAILURE CODE [CA689]1167
FAILURE CODE [CA691]1170
FAILURE CODE [CA692]1172
FAILURE CODE [CA697]1174
FAILURE CODE [CA698]1175
FAILURE CODE [CA731]1176
FAILURE CODE [CA778]1178
FAILURE CODE [CA1117]1183
FAILURE CODE [CA1664]1184
FAILURE CODE [CA1669]1186
FAILURE CODE [CA1673]1187
FAILURE CODE [CA1677]1188
FAILURE CODE [CA1678]1189
FAILURE CODE [CA1682]1190
FAILURE CODE [CA1683]1194
FAILURE CODE [CA1684]1196
FAILURE CODE [CA1686]1198
FAILURE CODE [CA1691]1199
FAILURE CODE [CA1694]1202
FAILURE CODE [CA1695]1205
FAILURE CODE [CA1696]1206
FAILURE CODE [CA1712]1208
FAILURE CODE [CA1713]1211
FAILURE CODE [CA1714]1213
FAILURE CODE [CA1715]1214
FAILURE CODE [CA1776]1215
FAILURE CODE [CA1777]1218
FAILURE CODE [CA1843]1221
FAILURE CODE [CA1844]1223
FAILURE CODE [CA1879]1226
FAILURE CODE [CA1881]1229
FAILURE CODE [CA1883]1231
FAILURE CODE [CA1885]1235
FAILURE CODE [CA1887]1237
FAILURE CODE [CA1921]1239
FAILURE CODE [CA1922]1242
FAILURE CODE [CA1942]1247
FAILURE CODE [CA1993]1248
FAILURE CODE [CA2185]1251
FAILURE CODE [CA2186]1253
FAILURE CODE [CA2249]1255
FAILURE CODE [CA2271]1256
FAILURE CODE [CA2272]1259
FAILURE CODE [CA2288]1262
FAILURE CODE [CA2311]1263
FAILURE CODE [CA2349]1264
FAILURE CODE [CA2353]1267
FAILURE CODE [CA2357]1269
FAILURE CODE [CA2381]1270
FAILURE CODE [CA2382]1273
FAILURE CODE [CA2383]1276
FAILURE CODE [CA2386]1279
FAILURE CODE [CA2387]1281
FAILURE CODE [CA2555]1282
FAILURE CODE [CA2556]1285
FAILURE CODE [CA2637]1287
FAILURE CODE [CA2639]1289
FAILURE CODE [CA2771]1292
FAILURE CODE [CA2777]1298
FAILURE CODE [CA2976]1301
FAILURE CODE [CA3133]1303
FAILURE CODE [CA3134]1306
FAILURE CODE [CA3135]1308
FAILURE CODE [CA3142]1312
FAILURE CODE [CA3143]1313
FAILURE CODE [CA3144]1314
FAILURE CODE [CA3146]1317
FAILURE CODE [CA3147]1318
FAILURE CODE [CA3148]1319
FAILURE CODE [CA3151]1321
FAILURE CODE [CA3165]1327
FAILURE CODE [CA3229]1329
FAILURE CODE [CA3231]1331
FAILURE CODE [CA3232]1333
FAILURE CODE [CA3235]1337
FAILURE CODE [CA3239]1339
FAILURE CODE [CA3241]1342
FAILURE CODE [CA3242]1345
FAILURE CODE [CA3251]1348
FAILURE CODE [CA3253]1350
FAILURE CODE [CA3254]1353
FAILURE CODE [CA3255]1356
FAILURE CODE [CA3256]1360
FAILURE CODE [CA3311]1362
FAILURE CODE [CA3312]1364
FAILURE CODE [CA3313]1367
FAILURE CODE [CA3314]1368
FAILURE CODE [CA3315]1369
FAILURE CODE [CA3316]1372
FAILURE CODE [CA3317]1373
FAILURE CODE [CA3318]1374
FAILURE CODE [CA3319]1377
FAILURE CODE [CA3321]1378
FAILURE CODE [CA3322]1380
FAILURE CODE [CA3419]1383
FAILURE CODE [CA3421]1385
FAILURE CODE [CA3497]1387
FAILURE CODE [CA3498]1388
FAILURE CODE [CA3543]1389
FAILURE CODE [CA3545]1396
FAILURE CODE [CA3547]1398
FAILURE CODE [CA3558]1399
FAILURE CODE [CA3559]1401
FAILURE CODE [CA3562]1403
FAILURE CODE [CA3563]1405
FAILURE CODE [CA3567]1408
FAILURE CODE [CA3568]1411
FAILURE CODE [CA3571]1417
FAILURE CODE [CA3572]1419
FAILURE CODE [CA3574]1421
FAILURE CODE [CA3575]1424
FAILURE CODE [CA3577]1426
FAILURE CODE [CA3578]1428
FAILURE CODE [CA3582]1430
FAILURE CODE [CA3583]1438
FAILURE CODE [CA3596]1440
FAILURE CODE [CA3649]1443
FAILURE CODE [CA3681]1445
FAILURE CODE [CA3682]1450
FAILURE CODE [CA3713]1456
FAILURE CODE [CA3717]1459
FAILURE CODE [CA3718]1460
FAILURE CODE [CA3725]1461
FAILURE CODE [CA3741]1464
FAILURE CODE [CA3748]1465
FAILURE CODE [CA3751]1468
FAILURE CODE [CA3755]1470
FAILURE CODE [CA3866]1472
FAILURE CODE [CA3867]1475
FAILURE CODE [CA3868]1478
FAILURE CODE [CA3899]1482
FAILURE CODE [CA3911]1484
FAILURE CODE [CA3912]1488
FAILURE CODE [CA3932]1490
FAILURE CODE [CA3933]1492
FAILURE CODE [CA3934]1494
FAILURE CODE [CA3935]1497
FAILURE CODE [CA3936]1499
FAILURE CODE [CA4151]1501
FAILURE CODE [CA4152]1505
FAILURE CODE [CA4155]1509
FAILURE CODE [CA4156]1511
FAILURE CODE [CA4157]1514
FAILURE CODE [CA4158]1516
FAILURE CODE [CA4159]1517
FAILURE CODE [CA4161]1518
FAILURE CODE [CA4162]1521
FAILURE CODE [CA4163]1524
FAILURE CODE [CA4164]1526
FAILURE CODE [CA4165]1528
FAILURE CODE [CA4166]1530
FAILURE CODE [CA4168]1532
FAILURE CODE [CA4169]1535
FAILURE CODE [CA4171]1537
FAILURE CODE [CA4249]1540
FAILURE CODE [CA4251]1542
FAILURE CODE [CA4259]1544
FAILURE CODE [CA4261]1547
FAILURE CODE [CA4277]1550
FAILURE CODE [CA4281]1553
FAILURE CODE [CA4459]1556
FAILURE CODE [CA4461]1559
FAILURE CODE [CA4658]1562
FAILURE CODE [CA4731]1566
FAILURE CODE [CA4732]1567
FAILURE CODE [CA4739]1568
FAILURE CODE [CA4768]1569
FAILURE CODE [CA4769]1571
FAILURE CODE [CA4842]1574
FAILURE CODE [CA4952]1577
FAILURE CODE [CA5115]1579
FAILURE CODE [CA5179]1582
FAILURE CODE [CA5181]1584
FAILURE CODE [CA5383]1586
FAILURE CODE [D110L4]1588
FAILURE CODE [D160KA]1590
FAILURE CODE [D160KY]1592
FAILURE CODE [D191KA]1593
FAILURE CODE [D191KB]1595
FAILURE CODE [D191KY]1597
FAILURE CODE [D192KA]1598
FAILURE CODE [D192KB]1599
FAILURE CODE [D192KY]1600
FAILURE CODE [D19JKZ]1601
FAILURE CODE [D1B0KA]1603
FAILURE CODE [D1B0KB]1605
FAILURE CODE [D1B0KY]1607
FAILURE CODE [D1B0MC]1609
FAILURE CODE [D1E6KA]1611
FAILURE CODE [D1E6KB]1613
FAILURE CODE [D1E6KY]1615
FAILURE CODE [D5ZHKA]1617
FAILURE CODE [D5ZHKB]1619
FAILURE CODE [D5ZHL6]1621
FAILURE CODE [D811MC]1622
FAILURE CODE [D862KA]1623
FAILURE CODE [D8ALKA]1624
FAILURE CODE [D8ALKB]1626
FAILURE CODE [D8AQK4]1628
FAILURE CODE [D8AQKR]1632
FAILURE CODE [DAF0KT]1636
FAILURE CODE [DAF0MB]1637
FAILURE CODE [DAF0MC]1638
FAILURE CODE [DAF3KK]1639
FAILURE CODE [DAF8KB]1641
FAILURE CODE [DAFDKB]1642
FAILURE CODE [DAFGMC]1644
FAILURE CODE [DAFLKA]1645
FAILURE CODE [DAFLKB]1647
FAILURE CODE [DAFQKR]1649
FAILURE CODE [DAJ0KK]1654
FAILURE CODE [DAJ0KT]1657
FAILURE CODE [DAJ0MC]1658
FAILURE CODE [DAJ1KA]1659
FAILURE CODE [DAJ2KK]1661
FAILURE CODE [DAJ4KB]1664
FAILURE CODE [DAJ4KZ]1666
FAILURE CODE [DAJ5KX]1668
FAILURE CODE [DAJ6KX]1670
FAILURE CODE [DAJ9KQ]1672
FAILURE CODE [DAJLKA]1673
FAILURE CODE [DAJLKB]1675
FAILURE CODE [DAJQKR]1677
FAILURE CODE [DAJRKR]1682
FAILURE CODE [DAJRMA]1687
FAILURE CODE [DAZ9KQ]1688
FAILURE CODE [DAZQKR]1689
FAILURE CODE [DB2QKR]1693
FAILURE CODE [DB2RKR]1699
FAILURE CODE [DD1ALD]1704
FAILURE CODE [DDAAL6]1706
FAILURE CODE [DDB2L4]1708
FAILURE CODE [DDB6L4]1710
FAILURE CODE [DDD7KA]1712
FAILURE CODE [DDD7KY]1714
FAILURE CODE [DDK3KA]1716
FAILURE CODE [DDK3KB]1719
FAILURE CODE [DDK6KA]1722
FAILURE CODE [DDK6KB]1725
FAILURE CODE [DDNRLD]1728
FAILURE CODE [DF10KA]1730
FAILURE CODE [DF10KB]1733
FAILURE CODE [DGH1KX]1736
FAILURE CODE [DGR2KB]1738
FAILURE CODE [DGR2KZ]1740
FAILURE CODE [DHHBKA]1742
FAILURE CODE [DHHBKY]1744
FAILURE CODE [DHHCKA]1746
FAILURE CODE [DHHCKY]1748
FAILURE CODE [DHPCKA]1750
FAILURE CODE [DHPCKY]1752
FAILURE CODE [DHPEKA]1754
FAILURE CODE [DHPEKY]1756
FAILURE CODE [DHS8KA]1758
FAILURE CODE [DHS8KY]1760
FAILURE CODE [DHS9KA]1762
FAILURE CODE [DHS9KY]1764
FAILURE CODE [DHSDKA]1766
FAILURE CODE [DHSDKY]1768
FAILURE CODE [DHSNKA]1770
FAILURE CODE [DHSNKY]1772
FAILURE CODE [DHT8ZG]1774
FAILURE CODE [DHTCL6]1775
FAILURE CODE [DJF1KA]1777
FAILURE CODE [DK55KA]1778
FAILURE CODE [DK55KY]1780
FAILURE CODE [DK55L5]1782
FAILURE CODE [DK5DKA]1783
FAILURE CODE [DK5DKY]1786
FAILURE CODE [DK5DL8]1789
FAILURE CODE [DK5EKA]1793
FAILURE CODE [DK5EKY]1796
FAILURE CODE [DK70KA]1799
FAILURE CODE [DK70KY]1801
FAILURE CODE [DKA0KA]1803
FAILURE CODE [DKA0KY]1806
FAILURE CODE [DKA0L0]1808
FAILURE CODE [DLM3KA]1810
FAILURE CODE [DLM3LC]1811
FAILURE CODE [DLT3KX]1813
FAILURE CODE [DLT4KX]1815
FAILURE CODE [DLT4L0]1817
FAILURE CODE [DLT4LC]1818
FAILURE CODE [DPQ1KR]1820
FAILURE CODE [DPQ2KR]1823
FAILURE CODE [DPQ3KR]1826
FAILURE CODE [DSJ0KR]1830
FAILURE CODE [DT22KB]1835
FAILURE CODE [DV00KB]1837
FAILURE CODE [DW26KA]1838
FAILURE CODE [DW26KB]1840
FAILURE CODE [DW26KY]1842
FAILURE CODE [DW4BKA]1844
FAILURE CODE [DW4BKB]1846
FAILURE CODE [DW4BKY]1848
FAILURE CODE [DW4RKA]1849
FAILURE CODE [DW4RKB]1851
FAILURE CODE [DW4RKY]1853
FAILURE CODE [DWM1KA]1855
FAILURE CODE [DWM1KB]1856
FAILURE CODE [DWM1KY]1858
FAILURE CODE [DWN6KA]1859
FAILURE CODE [DWN6KB]1861
FAILURE CODE [DWN6KY]1863
FAILURE CODE [DWN8KA]1864
FAILURE CODE [DWN8KB]1865
FAILURE CODE [DWN8KY]1866
FAILURE CODE [DX19KA]1867
FAILURE CODE [DX19KB]1869
FAILURE CODE [DX19KY]1871
FAILURE CODE [DX20KA]1873
FAILURE CODE [DX20KB]1875
FAILURE CODE [DX20KY]1877
FAILURE CODE [DXAWKA]1878
FAILURE CODE [DXAWKB]1881
FAILURE CODE [DXAWKY]1884
FAILURE CODE [DXH7KA]1887
FAILURE CODE [DXH7KB]1889
FAILURE CODE [DXH7KY]1891
FAILURE CODE [DXH8KA]1893
FAILURE CODE [DXH8KB]1895
FAILURE CODE [DXH8KY]1897
FAILURE CODE [DXHJKA]1899
FAILURE CODE [DXHJKB]1901
FAILURE CODE [DXHJKY]1903
FAILURE CODE [DXHKKA]1904
FAILURE CODE [DXHKKB]1906
FAILURE CODE [DXHKKY]1908
FAILURE CODE [H2K0KA]1909
FAILURE CODE [H2K0KY]1911
FAILURE CODE [J141N1]1913
FAILURE CODE [LA00L3]1914
FAILURE CODE [M100N1]1915
FAILURE CODE [M400N1]1916
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1917
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1917
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1925
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1928
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1931
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING1933
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING1936
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)1938
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY1940
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL1942
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL1945
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL1949
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY1951
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION1954
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL1957
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY1960
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY1961
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS1964
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY1967
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED1971
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL1975
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP1977
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION1979
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1983
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1984
E-25 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP1985
E-26 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES1986
E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1988
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL1990
E-29 ALARM BUZZER DOES NOT SOUND1991
E-30 ALARM BUZZER DOES NOT STOP SOUNDING1993
E-31 WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS1994
E-32 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH1997
E-33 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED1999
E-34 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED2001
E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED2004
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED2008
E-37 PZ AUTO TILT-IN DOES NOT WORK2010
E-38 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX TRACTION SWITCH IS TURNED ON2013
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED2015
E-40 HORN DOES NOT SOUND2017
E-41 HORN DOES NOT STOP SOUNDING2020
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2022
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT2024
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2028
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT2032
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2036
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2040
E-48 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2042
E-49 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2044
E-50 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2046
E-51 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT2048
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT2053
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT2057
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT2060
E-55 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2063
E-56 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT2066
E-57 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2070
E-58 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED2074
E-59 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION)2078
E-60 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT2082
E-61 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION)2086
E-62 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND2090
E-63 FRONT WIPER DOES NOT OPERATE2092
E-64 REAR WIPER DOES NOT OPERATE2096
E-65 WINDOW WASHER DOES NOT OPERATE2099
E-66 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2102
E-67 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2103
E-68 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2104
E-69 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP2105
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2106
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2106
FAILURE MODE AND CAUSE TABLE2107
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE2121
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)2124
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)2125
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW2126
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)2130
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)2131
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2132
H-8 MACHINE DOES NOT TURN2134
H-9 STEERING WHEEL IS HEAVY TO OPERATE2136
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS2138
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS2139
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK2140
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG2142
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK2143
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS2144
H-16 BOOM DOES NOT RISE2146
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE2149
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT2152
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND2153
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE2155
H-21 BOOM MOVES UP AND DOWN DURING OPERATION2156
H-22 BUCKET DOES NOT TILT BACK2157
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE2160
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION2163
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND2164
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE2166
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)2167
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE2168
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2169
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS2170
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2172
H-32 ECSS (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES2173
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2174
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN2177
TROUBLESHOOTING OF ENGINE (S-MODE)2178
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2178
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2179
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2180
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2181
S-4 ENGINE STARTABILITY IS POOR2183
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2185
S-6 ENGINE STOPS DURING OPERATION2187
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2189
S-8 ENGINE LACKS POWER2190
S-9 KDPF GETS CLOGGED IN A SHORT TIME2192
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2194
S-11 OIL BECOMES CONTAMINATED QUICKLY2195
S-12 FUEL CONSUMPTION IS EXCESSIVE2196
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2197
S-14 OIL PRESSURE DROPS2198
S-15 FUEL MIXES INTO ENGINE OIL2200
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2201
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2202
S-18 UNUSUAL NOISE IS HEARD2203
S-19 VIBRATION IS EXCESSIVE2204
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2205
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2206
S-22 ACTIVE REGENERATION TAKES TIME2208
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2209
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2210
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2212
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM2213
OUTLINE OF FAILURE DISPLAY2213
TROUBLESHOOTING FOR FCS2214
REPLACEMENT OF PUMP ELEMENT2215
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM2216
REPLACEMENT OF AUTO-GREASING CONTROLLER2218
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING2219
50 DISASSEMBLY AND ASSEMBLY2221
CONTENTS2222
ABBREVIATION LIST2226
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2232
HOW TO READ THIS MANUAL2232
COATING MATERIALS LIST2234
SPECIAL TOOLS LIST2238
SKETCHES OF SPECIAL TOOLS2261
ENGINE AND COOLING SYSTEM2281
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2281
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2282
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2287
REMOVE AND INSTALL INJECTOR ASSEMBLY2294
METHOD FOR REMOVING INJECTOR ASSEMBLY2294
METHOD FOR INSTALLING INJECTOR ASSEMBLY2302
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2312
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2313
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2324
REMOVE AND INSTALL EGR VALVE ASSEMBLY2339
METHOD FOR REMOVING EGR VALVE ASSEMBLY2339
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2343
REMOVE AND INSTALL EGR COOLER ASSEMBLY2347
METHOD FOR REMOVING EGR COOLER ASSEMBLY2347
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2350
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2355
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2355
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2357
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2360
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2360
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2361
REMOVE AND INSTALL ALTERNATOR BELT2363
METHOD FOR REMOVING ALTERNATOR BELT2363
METHOD FOR INSTALLING ALTERNATOR BELT2366
REMOVE AND INSTALL ALTERNATOR ASSEMBLY2368
METHOD FOR REMOVING ALTERNATOR ASSEMBLY2368
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY2370
REMOVE AND INSTALL AUTOMATIC TENSIONER2375
METHOD FOR REMOVING AUTOMATIC TENSIONER2375
METHOD FOR INSTALLING AUTOMATIC TENSIONER2375
REMOVE AND INSTALL RADIATOR ASSEMBLY2376
METHOD FOR REMOVING RADIATOR ASSEMBLY2376
METHOD FOR INSTALLING RADIATOR ASSEMBLY2379
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2383
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2383
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2386
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2390
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2390
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2392
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2394
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2394
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2395
REMOVE AND INSTALL ENGINE ASSEMBLY2397
METHOD FOR REMOVING ENGINE ASSEMBLY2398
METHOD FOR INSTALLING ENGINE ASSEMBLY2416
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2436
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2436
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2438
REMOVE AND INSTALL ENGINE REAR OIL SEAL2441
METHOD FOR REMOVING ENGINE REAR OIL SEAL2441
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2443
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2447
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2447
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2453
REMOVE AND INSTALL FUEL TANK ASSEMBLY2460
METHOD FOR REMOVING FUEL TANK ASSEMBLY2460
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2464
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2469
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2470
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2477
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2483
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2483
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2485
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2488
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2488
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2489
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2491
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2491
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2492
REMOVE AND INSTALL KDPF ASSEMBLY2493
METHOD FOR REMOVING KDPF ASSEMBLY2494
METHOD FOR INSTALLING KDPF ASSEMBLY2504
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2516
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2516
METHOD FOR ASSEMBLING KDPF ASSEMBLY2521
REMOVE AND INSTALL SCR ASSEMBLY2526
METHOD FOR REMOVING SCR ASSEMBLY2527
METHOD FOR INSTALLING SCR ASSEMBLY2537
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2550
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2551
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2561
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2576
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2576
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2579
REMOVE AND INSTALL KCCV ASSEMBLY2584
METHOD FOR REMOVING KCCV ASSEMBLY2584
METHOD FOR INSTALLING KCCV ASSEMBLY2586
REMOVE AND INSTALL VGT ASSEMBLY2589
METHOD FOR REMOVING VGT ASSEMBLY2589
METHOD FOR INSTALLING VGT ASSEMBLY2596
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2605
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2606
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2611
REMOVE AND INSTALL AdBlue/DEF INJECTOR2618
METHOD FOR REMOVING AdBlue/DEF INJECTOR2618
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2620
REMOVE AND INSTALL AdBlue/DEF PUMP2624
METHOD FOR REMOVING AdBlue/DEF PUMP2624
METHOD FOR INSTALLING AdBlue/DEF PUMP2627
REMOVE AND INSTALL AdBlue/DEF HOSE2631
METHOD FOR REMOVING AdBlue/DEF HOSE2631
METHOD FOR INSTALLING AdBlue/DEF HOSE2641
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2651
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2651
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2654
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2657
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2658
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2660
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2663
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2663
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2665
POWER TRAIN2668
REMOVE AND INSTALL HST PUMP ASSEMBLY2668
METHOD FOR REMOVING HST PUMP ASSEMBLY2669
METHOD FOR INSTALLING HST PUMP ASSEMBLY2675
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY2684
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY2684
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY2687
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY2690
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY2691
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY2699
REMOVE AND INSTALL TRANSFER ASSEMBLY2708
METHOD FOR REMOVING TRANSFER ASSEMBLY2709
METHOD FOR INSTALLING TRANSFER ASSEMBLY2713
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY2718
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY2721
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY2740
REMOVE AND INSTALL FRONT AXLE ASSEMBLY2765
METHOD FOR REMOVING FRONT AXLE ASSEMBLY2765
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY2767
REMOVE AND INSTALL REAR AXLE ASSEMBLY2770
METHOD FOR REMOVING REAR AXLE ASSEMBLY2770
METHOD FOR INSTALLING REAR AXLE ASSEMBLY2774
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY2778
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY2779
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY2787
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY2797
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY2798
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY2811
UNDERCARRIAGE AND FRAME2831
REMOVE AND INSTALL CENTER HINGE PIN2831
METHOD FOR REMOVING CENTER HINGE PIN2832
METHOD FOR INSTALLING CENTER HINGE PIN2838
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2849
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2849
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2855
HYDRAULIC SYSTEM2860
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2860
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2860
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2870
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2879
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2879
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2885
REMOVE AND INSTALL QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2891
METHOD FOR REMOVING QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2891
METHOD FOR INSTALLING QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2894
WORK EQUIPMENT2897
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2897
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2898
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2902
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2913
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2914
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2918
CAB AND ITS ATTACHMENTS2925
REMOVE AND INSTALL OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2925
METHOD FOR REMOVING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2926
METHOD FOR INSTALLING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2933
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2942
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)2942
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)2943
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2952
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2952
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2958
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY2965
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY2965
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY2965
REMOVE AND INSTALL SEAT BELT2967
METHOD FOR REMOVING SEAT BELT2967
METHOD FOR INSTALLING SEAT BELT2967
ELECTRICAL SYSTEM2969
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2969
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2969
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2973
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY2978
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2978
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2980
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY2982
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY2982
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY2983
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY2985
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY2985
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY2988
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2990
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2990
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2993
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2996
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2996
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2997
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2998
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2998
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2999
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR3001
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR3001
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR3003
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR3006
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR3006
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR3009
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3012
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3012
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3013
REMOVE AND INSTALL AMMONIA SENSOR3015
METHOD FOR REMOVING AMMONIA SENSOR3015
METHOD FOR INSTALLING AMMONIA SENSOR3017
REMOVE AND INSTALL SCR OUTLET NOx SENSOR3020
METHOD FOR REMOVING SCR OUTLET NOx SENSOR3020
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR3022
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3025
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3025
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3026
60 MAINTENANCE STANDARD3027
CONTENTS3028
ABBREVIATION LIST3029
ENGINE AND COOLING SYSTEM3035
MAINTENANCE STANDARD OF ENGINE MOUNT3035
MAINTENANCE STANDARD OF DAMPER3036
MAINTENANCE STANDARD OF COOLING FAN MOTOR3037
POWER TRAIN3039
MAINTENANCE STANDARD OF DRIVE SHAFT3039
MAINTENANCE STANDARD OF TRANSFER3040
MAINTENANCE STANDARD OF TRANSFER MOUNT3048
MAINTENANCE STANDARD OF FRONT AXLE3049
MAINTENANCE STANDARD OF REAR AXLE3050
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL3051
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL3053
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL3055
MAINTENANCE STANDARD OF FRONT FINAL DRIVE3057
MAINTENANCE STANDARD OF REAR FINAL DRIVE3059
STEERING SYSTEM3061
MAINTENANCE STANDARD OF STEERING COLUMN3061
MAINTENANCE STANDARD OF PRIORITY VALVE3062
MAINTENANCE STANDARD OF STEERING CYLINDER3063
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE3066
BRAKE SYSTEM3067
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE3067
MAINTENANCE STANDARD OF SLACK ADJUSTER3068
MAINTENANCE STANDARD OF FRONT BRAKE3069
MAINTENANCE STANDARD OF REAR BRAKE3070
MAINTENANCE STANDARD OF PARKING BRAKE3071
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE3073
UNDERCARRIAGE AND FRAME3074
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN3074
HYDRAULIC SYSTEM3080
MAINTENANCE STANDARD OF HYDRAULIC TANK3080
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP3081
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP3082
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP3085
MAINTENANCE STANDARD OF CONTROL VALVE3086
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE3098
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE3100
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE3102
WORK EQUIPMENT3103
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3103
MAINTENANCE STANDARD OF BUCKET3107
MAINTENANCE STANDARD OF LIFT CYLINDER3108
MAINTENANCE STANDARD OF BUCKET CYLINDER3109
CAB AND ITS ATTACHMENTS3110
MAINTENANCE STANDARD OF CAB MOUNT3110
80 APPENDIX3111
CONTENTS3112
ABBREVIATION LIST3114
AIR CONDITIONER SYSTEM3120
PRECAUTIONS FOR REFRIGERANT3120
AIR CONDITIONER COMPONENT3121
SPECIFICATIONS OF AIR CONDITIONER3123
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3124
OUTLINE OF REFRIGERATION CYCLE3125
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3127
AIR CONDITIONER UNIT3127
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3127
FUNCTION OF AIR CONDITIONER UNIT3128
COMPONENT PARTS OF AIR CONDITIONER UNIT3129
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3129
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3129
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3130
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3131
FUNCTION OF DUAL PRESSURE SWITCH3131
AIR CONDITIONER CONTROLLER3132
STRUCTURE OF AIR CONDITIONER CONTROLLER3132
COMPRESSOR3133
STRUCTURE OF COMPRESSOR3133
SPECIFICATIONS OF COMPRESSOR3133
FUNCTION OF COMPRESSOR3133
CONDENSER3134
STRUCTURE OF CONDENSER3134
SPECIFICATIONS OF CONDENSER3134
FUNCTION OF CONDENSER3134
RECEIVER DRIER3135
STRUCTURE OF RECEIVER DRIER3135
SPECIFICATIONS OF RECEIVER DRIER3135
FUNCTION OF RECEIVER DRIER3135
SENSORS FOR AIR CONDITIONER SYSTEM3136
FUNCTION OF SUNLIGHT SENSOR3136
FUNCTION OF AMBIENT TEMPERATURE SENSOR3136
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3137
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3139
AIR CONDITIONER SYSTEM DIAGRAM3142
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3143
FUNCTION OF AIR CONDITIONER CONTROLLER3144
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3145
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3151
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3152
CHECK TEMPERATURE CONTROL FUNCTION3153
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION3153
TEST VENT (MODE) CHANGEOVER3155
METHOD FOR TESTING VENT (MODE) CHANGEOVER3155
TESTING FRESH/RECIRC AIR CHANGEOVER3157
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3157
TEST EVAPORATOR TEMPERATURE SENSOR3159
TEST RELAYS3161
METHOD FOR TESTING RELAYS3161
AIR CONDITIONER TROUBLESHOOTING CHART 13163
AIR CONDITIONER TROUBLESHOOTING CHART 23164
FAILURE CODE [879AKA]3167
FAILURE CODE [879AKB]3169
FAILURE CODE [879BKA]3171
FAILURE CODE [879BKB]3173
FAILURE CODE [879CKA]3175
FAILURE CODE [879CKB]3177
FAILURE CODE [879DKZ]3179
FAILURE CODE [879EMC]3181
FAILURE CODE [879FMC]3182
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3183
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3186
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3189
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3193
TROUBLESHOOTING USING GAUGE PRESSURE3195
CONNECTION OF SERVICE TOOL3198
METHOD FOR CONNECTING SERVICE TOOL3199
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3200
HANDLE COMPRESSOR OIL3202
90 CIRCUIT DIAGRAMS3205
CONTENTS3206
ABBREVIATION LIST3207
HYDRAULIC CIRCUIT DIAGRAM3213
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3213
HYDRAULIC CIRCUIT DIAGRAM3217
HYDRAULIC AUTO-GREASING DIAGRAM3218
ELECTRICAL CIRCUIT DIAGRAM3219
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3219
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7)3223
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7)3224
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7)3225
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7)3226
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7)3227
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7)3228
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7)3229
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)3230
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)3231
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)3232
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)3233
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)3234
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)3235
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)3236
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)3237
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)3238
INDEX3239

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24