Komatsu WA380-8 Wheel Loader Shop Manual SMEW380800-00 PDF

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Komatsu WA380-8 Wheel Loader Shop Manual SMEW380800-00 – PDF DOWNLOAD

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Komatsu WA380-8 Wheel Loader Shop Manual SMEW380800-00 – PDF DOWNLOAD 

Language : English
Pages : 4196
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA380-8 Wheel Loader Shop Manual SMEW380800-00 – PDF DOWNLOAD 

SERIAL NUMBERS DZCQ0001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 27
FOREWORD, SAFETY, BASIC INFORMATION 33
HOW TO READ THE SHOP MANUAL 33
SAFETY NOTICE FOR OPERATION 35
PRECAUTIONS TO PREVENT FIRE 43
ACTIONS IF FIRE OCCURS 45
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 46
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 47
PRECAUTIONS FOR DEF 48
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 48
PRECAUTIONS FOR ADDING 48
PRECAUTIONS FOR STORING 48
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 48
THE OTHER PRECAUTIONS 48
STORE AdBlue/DEF 49
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 60
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 62
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 63
PRACTICAL USE OF KOMTRAX 64
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 65
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 67
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 69
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 73
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 76
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 79
HOW TO READ ELECTRICAL WIRE CODE 80
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 84
STANDARD TIGHTENING TORQUE TABLE 87
CONVERSION TABLE 94
01 SPECIFICATIONS 99
CONTENTS 100
ABBREVIATION LIST 101
SPECIFICATIONS 107
SPECIFICATION DRAWING 107
SPECIFICATION DRAWING: WA380-8 107
SPECIFICATIONS 109
SPECIFICATIONS: WA380-8 109
WEIGHT TABLE 114
WEIGHT TABLE: WA380-8 114
TABLE OF FUEL, COOLANT, AND LUBRICANTS 116
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 125
UREA SCR SYSTEM 131
LAYOUT DRAWING OF UREA SCR SYSTEM 131
UREA SCR SYSTEM DIAGRAM 135
FUNCTION OF UREA SCR SYSTEM 136
FUNCTION OF AdBlue/DEF SYSTEM 136
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 153
AdBlue/DEF MIXING TUBE 153
SCR ASSEMBLY 154
AdBlue/DEF TANK 156
AdBlue/DEF PUMP 158
AdBlue/DEF INJECTOR 159
AdBlue/DEF HOSE 160
AdBlue/DEF TANK HEATING VALVE 161
BOOT-UP SYSTEM 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 162
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 163
SYSTEM OPERATING LAMP SYSTEM 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 165
BATTERY DISCONNECT SWITCH 167
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 167
FUNCTION OF BATTERY DISCONNECT SWITCH 167
PREHEATING SYSTEM 169
PREHEATING SYSTEM DIAGRAM 169
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 169
OPERATION OF AUTOMATIC PREHEATING SYSTEM 169
FUNCTION OF MANUAL PREHEATING SYSTEM 170
OPERATION OF MANUAL PREHEATING SYSTEM 170
ENGINE SYSTEM 171
LAYOUT DRAWING OF ENGINE SYSTEM 171
FUNCTION OF ENGINE SYSTEM 172
ENGINE CONTROL SYSTEM 173
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 173
ENGINE CONTROL SYSTEM DIAGRAM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 174
FUNCTION OF ENGINE CONTROL SYSTEM 175
OPERATION OF ENGINE CONTROL SYSTEM 178
ENGINE POWER MODE SELECTOR SYSTEM 180
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 180
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 180
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 180
AUTOMATIC IDLE STOP SYSTEM 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 182
COMPONENT PARTS OF ENGINE SYSTEM 183
VGT 183
EGR SYSTEM 188
EGR VALVE 190
EGR COOLER 192
KCCV SYSTEM 194
KCCV VENTILATOR 196
KDPF 198
COOLING SYSTEM 202
LAYOUT DRAWING OF COOLING SYSTEM 202
SPECIFICATIONS OF COOLING SYSTEM 203
COOLING FAN CONTROL SYSTEM 205
COOLING FAN CONTROL SYSTEM DIAGRAM 205
FUNCTION OF COOLING FAN CONTROL SYSTEM 205
COMPONENT PARTS OF COOLING SYSTEM 210
BRAKE AND COOLING FAN PUMP 210
COOLING FAN MOTOR 218
CONTROL SYSTEM 224
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 224
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 226
MACHINE MONITOR SYSTEM 228
MACHINE MONITOR SYSTEM DIAGRAM 228
FUNCTION OF MACHINE MONITOR SYSTEM 228
REARVIEW MONITOR SYSTEM 230
REARVIEW MONITOR SYSTEM DIAGRAM 230
FUNCTION OF REARVIEW MONITOR SYSTEM 230
KOMTRAX SYSTEM 231
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 231
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 231
FUNCTION OF KOMTRAX SYSTEM 232
COMPONENT PARTS OF CONTROL SYSTEM 233
MACHINE MONITOR 233
SWITCH PANEL 253
REARVIEW MONITOR 254
REARVIEW CAMERA 256
KOMTRAX TERMINAL 257
GATEWAY FUNCTION CONTROLLER 259
COMMUNICATION TERMINAL 262
TRANSMISSION CONTROLLER 264
WORK EQUIPMENT CONTROLLER 268
MONITOR CONTROLLER 272
CAN TERMINATING RESISTOR 277
ENGINE CONTROLLER 278
ACCELERATOR PEDAL 285
HYDRAULIC SYSTEM 287
LAYOUT DRAWING OF HYDRAULIC SYSTEM 287
CLSS 288
STRUCTURE OF CLSS 288
FUNCTION OF CLSS 289
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 291
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 291
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 291
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 291
COMPONENT PARTS OF HYDRAULIC SYSTEM 292
HYDRAULIC TANK 292
WORK EQUIPMENT PUMP 295
STEERING PUMP 309
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 322
CONTROL VALVE 323
STABILIZER VALVE 359
POWER TRAIN SYSTEM 364
LAYOUT DRAWING OF POWER TRAIN SYSTEM 364
OPERATION OF POWER TRAIN SYSTEM 367
TRANSMISSION CONTROL SYSTEM 368
TRANSMISSION CONTROL SYSTEM DIAGRAM 368
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 370
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 370
ELECTRIC MODULATION FUNCTION 371
DISPLAY FUNCTION OF GEAR SHIFT 371
AUTOMATIC GEAR SHIFT FUNCTION 371
SHIFT HOLD FUNCTION 372
KICKDOWN FUNCTION 372
AUTOMATIC KICKDOWN FUNCTION 373
TORQUE CONVERTER LOCKUP FUNCTION 373
HUNTING PREVENTION FUNCTION 374
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 374
SHIFT POINT CHANGING FUNCTION 374
4TH GEAR SPEED LIMITATION FUNCTION 375
TRANSMISSION PROTECTION FUNCTION 376
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 376
SHIFT DOWN PROTECTION FUNCTION 376
ENGINE OVERRUN PREVENTION FUNCTION 377
MAXIMUM SPEED LIMITATION FUNCTION 377
NEUTRALIZER FUNCTION 377
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 379
TRANSMISSION CUT-OFF FUNCTION 381
COMPONENT PARTS OF POWER TRAIN SYSTEM 383
DRIVE SHAFT 383
TORQUE CONVERTER 385
LOCKUP CLUTCH ECMV 388
TRANSMISSION 391
TRANSMISSION CONTROL VALVE 407
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 409
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 414
AXLE 416
CONVENTIONAL DIFFERENTIAL 419
LIMITED SLIP DIFFERENTIAL 422
FINAL DRIVE 426
COMBINATION SWITCH 428
SHIFT HOLD SWITCH 432
KICKDOWN SWITCH 433
WORK EQUIPMENT SYSTEM 434
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 434
WORK EQUIPMENT SYSTEM DIAGRAM 436
WORK EQUIPMENT CONTROL SYSTEM 438
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 438
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 439
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 440
WORK EQUIPMENT LEVER OPERATION FUNCTION 441
BUCKET PRIORITY CONTROL FUNCTION 441
BOOM STOP MODULATION FUNCTION 441
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 443
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 443
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 443
REMOTE POSITIONER SYSTEM 445
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 445
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 445
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 446
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 446
BUCKET POSITIONER AND BOOM POSITIONER 450
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 450
AUTO-DIGGING SYSTEM 451
AUTO-DIGGING SYSTEM DIAGRAM 451
FUNCTION OF AUTO-DIGGING SYSTEM 451
SEMI AUTO-DIGGING SYSTEM 453
SEMI AUTO-DIGGING SYSTEM DIAGRAM 453
FUNCTION OF SEMI AUTO-DIGGING SYSTEM 453
ECSS 455
ECSS DIAGRAM 455
FUNCTION OF ECSS 455
OPERATION OF ECSS 455
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 457
WORK EQUIPMENT LOCK SOLENOID VALVE 457
PILOT CIRCUIT ACCUMULATOR 458
ECSS CIRCUIT ACCUMULATOR 459
WORK EQUIPMENT ELECTRIC LEVER 461
MULTIFUNCTION MONO-LEVER 464
STEERING SYSTEM 465
LAYOUT DRAWING OF STEERING SYSTEM 465
SECONDARY STEERING SYSTEM 466
SECONDARY STEERING SYSTEM DIAGRAM 466
FUNCTION OF SECONDARY STEERING SYSTEM 466
STEERING COLUMN 468
STRUCTURE OF STEERING COLUMN 468
COMPONENT PARTS OF STEERING SYSTEM 469
ORBITROL VALVE 469
STOP VALVE 473
STEERING VALVE 474
SECONDARY STEERING PUMP 487
SECONDARY STEERING MOTOR 488
BRAKE SYSTEM 489
LAYOUT DRAWING OF BRAKE SYSTEM 489
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 490
PARKING BRAKE CONTROL SYSTEM 491
PARKING BRAKE CONTROL SYSTEM DIAGRAM 491
OPERATION OF PARKING BRAKE CONTROL SYSTEM 491
BRAKE COOLING CONTROL SYSTEM 493
BRAKE COOLING CONTROL SYSTEM DIAGRAM 493
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 493
COMPONENT PARTS OF BRAKE SYSTEM 494
CHARGE VALVE 494
PARKING BRAKE SOLENOID VALVE 499
PARKING BRAKE EMERGENCY RELEASE VALVE 501
BRAKE CIRCUIT ACCUMULATOR 502
BRAKE VALVE 504
BRAKE 508
PARKING BRAKE 511
FLOW PRIORITY VALVE 513
BRAKE COOLING MOTOR 515
BRAKE COOLING PUMP 516
BRAKE COOLING OIL COOLER 517
AUTO-GREASING SYSTEM 518
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 518
SPECIFICATIONS OF AUTO-GREASING SYSTEM 519
FUNCTION OF AUTO-GREASING SYSTEM 521
COMPONENT PARTS OF AUTO-GREASING SYSTEM 522
AUTO-GREASING PUMP 522
UNDERCARRIAGE AND FRAME 523
FRAME, AXLE MOUNT AND CENTER HINGE PIN 523
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 523
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 524
TIRE 525
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 525
STRUCTURE OF RADIAL TIRE 525
FUNCTION OF RADIAL TIRE 526
STRUCTURE OF BIAS TIRE 526
FUNCTION OF BIAS TIRE 526
WORK EQUIPMENT 527
STRUCTURE OF WORK EQUIPMENT 527
STRUCTURE OF BUCKET 528
CAB AND ITS ATTACHMENTS 529
ROPS CAB 529
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) 529
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 530
FUNCTION OF ROPS CAB 530
20 STANDARD VALUE TABLE 531
CONTENTS 532
ABBREVIATION LIST 533
STANDARD VALUE TABLE FOR ENGINE 539
STANDARD VALUE TABLE FOR ENGINE: WA380-8 539
STANDARD VALUE TABLE FOR MACHINE 543
STANDARD VALUE TABLE FOR MACHINE: WA380-8 543
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 562
STANDARD VALUE TABLE FOR ELECTRICAL 565
STANDARD VALUE TABLE FOR ELECTRICITY 565
30 TESTING AND ADJUSTING 587
CONTENTS 588
ABBREVIATION LIST 592
RELATED INFORMATION ON TESTING AND ADJUSTING 598
TOOLS FOR TESTING AND ADJUSTING 598
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 607
ENGINE AND COOLING SYSTEM 608
TEST ENGINE SPEED 608
METHOD FOR TESTING ENGINE SPEED 608
TEST BOOST PRESSURE 614
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 614
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 615
TEST EXHAUST GAS TEMPERATURE 618
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 618
TEST EXHAUST GAS COLOR 620
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 620
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 621
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 623
TEST MASS AIR FLOW AND TEMPERATURE SENSOR 623
TEST AND ADJUST VALVE CLEARANCE 625
METHOD FOR TESTING VALVE CLEARANCE 625
METHOD FOR ADJUSTING VALVE CLEARANCE 626
TEST COMPRESSION PRESSURE 628
METHOD FOR TESTING COMPRESSION PRESSURE 628
TEST BLOWBY PRESSURE 634
METHOD FOR TESTING BLOWBY PRESSURE 634
TEST ENGINE OIL PRESSURE 637
METHOD FOR TESTING ENGINE OIL PRESSURE 637
TEST EGR VALVE AND VGT OIL PRESSURE 639
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 639
TEST FUEL PRESSURE 641
METHOD FOR TESTING FUEL PRESSURE 642
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 647
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 648
BLEED AIR FROM FUEL SYSTEM 654
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 654
TEST FUEL CIRCUIT FOR LEAKAGE 656
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 656
HANDLE CYLINDER CUT-OUT MODE OPERATION 658
HANDLE NO-INJECTION CRANKING OPERATION 659
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 660
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 660
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 661
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 661
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 662
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 662
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 663
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 663
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 663
TEST ALTERNATOR BELT 665
METHOD FOR TESTING ALTERNATOR BELT 665
TEST AUTOMATIC TENSIONER 667
METHOD FOR TESTING AUTOMATIC TENSIONER 667
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 670
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 670
TEST SCR RELATED FUNCTIONS 671
TEST AdBlue/DEF PUMP RAISED PRESSURE 675
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 678
TEST AdBlue/DEF LINE HEATER RELAY 1 683
TEST AdBlue/DEF LINE HEATER RELAY 2 687
TEST AdBlue/DEF PUMP HEATER RELAY 691
TEST AdBlue/DEF TANK HEATER VALVE 695
TEST SCR NOx REMOVAL EFFICIENCY 699
CLEAN AdBlue/DEF TANK 703
METHOD FOR CLEANING AdBlue/DEF TANK 703
CLEAN AdBlue/DEF PUMP 707
CLEAN AdBlue/DEF PUMP 707
POWER TRAIN 713
TEST AND ADJUST POWER TRAIN OIL PRESSURE 713
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 716
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 729
ADJUST TRANSMISSION INPUT SPEED SENSOR 731
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 731
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 732
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 732
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 733
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 733
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 735
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 735
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 737
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 737
STEERING SYSTEM 738
TEST STEERING WHEEL 738
METHOD FOR TESTING STEERING WHEEL 738
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 740
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 740
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 742
BLEED AIR FROM STEERING CYLINDER CIRCUIT 744
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 744
TEST AND ADJUST STEERING STOP VALVE 745
METHOD FOR TESTING STEERING STOP VALVE 745
METHOD FOR ADJUSTING STEERING STOP VALVE 745
BRAKE SYSTEM 746
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 746
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 746
TEST WHEEL BRAKE OIL PRESSURE 747
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 747
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 749
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 749
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 750
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 751
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 751
CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 754
RELEASE NITROGEN GAS WHEN YOU DISPOSE OF ACCUMULATOR 758
BLEED AIR FROM BRAKE CIRCUIT 760
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 760
TEST BRAKING PERFORMANCE 761
METHOD FOR TESTING BRAKING PERFORMANCE 761
TEST BRAKE PEDAL 762
METHOD FOR TESTING BRAKE PEDAL 762
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 763
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 763
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 763
TEST LOWERING OF WHEEL BRAKE PRESSURE 764
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 765
TEST WEAR OF WHEEL BRAKE DISC 767
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 767
TEST PARKING BRAKE OIL PRESSURE 769
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 769
TEST PARKING BRAKE PERFORMANCE 771
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 771
RELEASE PARKING BRAKE MANUALLY 772
METHOD FOR RELEASING PARKING BRAKE MANUALLY 772
TEST WEAR AMOUNT OF PARKING BRAKE DISC 774
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 774
HYDRAULIC SYSTEM 776
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 776
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 776
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 778
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 778
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 782
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 784
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 784
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 786
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 787
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 787
TEST COOLING FAN SPEED 788
METHOD FOR TESTING COOLING FAN SPEED 788
TEST COOLING FAN CIRCUIT OIL PRESSURE 790
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 790
BLEED AIR FROM COOLING FAN CIRCUIT 793
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 793
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 795
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 795
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 797
WORK EQUIPMENT 801
TEST AND ADJUST BUCKET POSITIONER DETECTION LEVER 801
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 801
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 801
TEST AND ADJUST BOOM POTENTIOMETER LEVER 803
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 803
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 803
CAB AND ITS ATTACHMENTS 804
TEST DIRECTIONAL LEVER 804
METHOD FOR TESTING DIRECTIONAL LEVER 804
TEST WORK EQUIPMENT CONTROL LEVER 805
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 805
ELECTRICAL SYSTEM 808
SET AND ADJUST EACH EQUIPMENT 808
SET AND OPERATE MACHINE MONITOR 812
OPERATOR MODE 816
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 816
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 816
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 817
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 818
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 818
SERVICE MODE 822
METHOD FOR OPERATING SERVICE MODE 822
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 825
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 832
ABNORMALITY RECORD MENU 847
METHOD FOR CONFIRMING MAINTENANCE RECORD 852
METHOD FOR OPERATING MAINTENANCE MODE SETTING 854
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 859
DEFAULT MENU 861
DIAGNOSTIC TESTS MENU 877
ADJUSTMENT MENU 889
METHOD FOR PERFORMING NO-INJECTION CRANKING 937
KOMTRAX SETTINGS MENU 939
METHOD FOR DISPLAYING SERVICE MESSAGE 944
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 946
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 950
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 952
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 958
ADJUST REARVIEW CAMERA ANGLE 960
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 960
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 962
SET REGION OF Bluetooth(R) COMPATIBLE RADIO 962
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 964
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) 965
HANDLE BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 966
TEST DIODES 967
METHOD FOR TESTING DIODE USING DIGITAL TESTER 967
METHOD FOR TESTING DIODE USING ANALOG TESTER 967
AUTO-GREASING DEVICE 968
BLEED THE AIR OF AUTO-GREASING SYSTEM 968
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 968
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 971
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 972
Pm CLINIC 974
Pm CLINIC SERVICE 974
Pm CLINIC CHECK SHEET: WA380-8 977
40 TROUBLESHOOTING 987
CONTENTS 988
ABBREVIATION LIST 1002
RELATED INFORMATION ON TROUBLESHOOTING 1008
GENERAL TROUBLESHOOTING POINTS 1008
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 1009
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1024
CHECKS BEFORE TROUBLESHOOTING 1026
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1028
WALK-AROUND CHECK 1028
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1030
CHECK FUEL LEVEL AND TYPE 1030
FUEL – CHECK FOR FOREIGN MATERIAL 1030
CHECK AdBule/DEF LEVEL AND TYPE 1031
CHECK FUEL PREFILTER 1031
CHECK MAIN FILTER 1033
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1034
CHECK COOLANT LEVEL (RESERVOIR TANK) 1035
CHECK CLOGGING OF AIR CLEANER 1036
OUTER ELEMENT – CLEAN 1036
REPLACE ELEMENT 1038
CHECK HYDRAULIC OIL LEVEL 1039
CHECK HYDRAULIC OIL STRAINER 1040
CHECK HYDRAULIC FILTER 1041
CHECK OIL LEVEL IN TRANSMISSION CASE 1043
CHECK OIL LEVEL IN FRONT AXLE CASE 1044
CHECK OIL LEVEL IN REAR AXLE CASE 1045
BLEED AIR FROM FUEL SYSTEM 1046
BLEED AIR FROM HYDRAULIC SYSTEM 1046
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 1046
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1052
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1064
SYMPTOM AND TROUBLESHOOTING NUMBERS 1066
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1071
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1073
CONNECTORS LIST AND LAYOUT (MACHINE WITH KOMTRAX TERMINAL) 1076
CONNECTORS LIST AND LAYOUT (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1096
CONNECTOR CONTACT IDENTIFICATION 1119
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1159
FUSE LOCATION TABLE(MACHINE WITH KOMTRAX TERMINAL) 1165
FUSE LOCATION TABLE(MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1169
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1173
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1177
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1179
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1185
FAILURE CODES TABLE 1187
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1211
FAILURE CODE [1500L0] 1211
FAILURE CODE [15SAL1] 1213
FAILURE CODE [15SALH] 1215
FAILURE CODE [15SBL1] 1218
FAILURE CODE [15SBLH] 1220
FAILURE CODE [15SEL1] 1223
FAILURE CODE [15SELH] 1225
FAILURE CODE [15SFL1] 1227
FAILURE CODE [15SFLH] 1229
FAILURE CODE [15SGL1] 1232
FAILURE CODE [15SGLH] 1235
FAILURE CODE [15SHL1] 1238
FAILURE CODE [15SHLH] 1241
FAILURE CODE [2F00MA] 1244
FAILURE CODE [2F00MB] 1251
FAILURE CODE [2G42ZG] 1255
FAILURE CODE [2G43ZG] 1258
FAILURE CODE [879AKA] 1261
FAILURE CODE [879AKB] 1264
FAILURE CODE [879BKA] 1267
FAILURE CODE [879BKB] 1270
FAILURE CODE [879CKA] 1273
FAILURE CODE [879CKB] 1276
FAILURE CODE [879DKZ] 1279
FAILURE CODE [879EMC] 1282
FAILURE CODE [879FMC] 1285
FAILURE CODE [989A00] 1288
FAILURE CODE [989L00] 1290
FAILURE CODE [989M00] 1291
FAILURE CODE [989N00] 1292
FAILURE CODE [A1U0N3] 1293
FAILURE CODE [A1U0N4] 1296
FAILURE CODE [AA10NX] 1299
FAILURE CODE [AB00KE] 1302
FAILURE CODE [AB00KY] 1304
FAILURE CODE [AQ10N3] 1307
FAILURE CODE [AS00N3] 1309
FAILURE CODE [AS00R2] 1311
FAILURE CODE [AS00R3] 1312
FAILURE CODE [AS00R4] 1314
FAILURE CODE [AS00R5] 1315
FAILURE CODE [AS00R6] 1316
FAILURE CODE [AS00ZK] 1317
FAILURE CODE [AS10KM] 1319
FAILURE CODE [AS10NR] 1320
FAILURE CODE [AS10NT] 1322
FAILURE CODE [B@BAZG] 1323
FAILURE CODE [B@BAZK] 1324
FAILURE CODE [B@BCNS] 1326
FAILURE CODE [B@BCQA] 1327
FAILURE CODE [B@BCZK] 1329
FAILURE CODE [B@C7NS] 1332
FAILURE CODE [B@CENS] 1335
FAILURE CODE [B@HANS] 1337
FAILURE CODE [CA115] 1339
FAILURE CODE [CA122] 1341
FAILURE CODE [CA123] 1345
FAILURE CODE [CA131] 1349
FAILURE CODE [CA132] 1352
FAILURE CODE [CA144] 1356
FAILURE CODE [CA145] 1359
FAILURE CODE [CA153] 1362
FAILURE CODE [CA154] 1366
FAILURE CODE [CA187] 1369
FAILURE CODE [CA221] 1371
FAILURE CODE [CA222] 1375
FAILURE CODE [CA227] 1379
FAILURE CODE [CA234] 1380
FAILURE CODE [CA238] 1382
FAILURE CODE [CA239] 1384
FAILURE CODE [CA249] 1386
FAILURE CODE [CA256] 1389
FAILURE CODE [CA271] 1392
FAILURE CODE [CA272] 1395
FAILURE CODE [CA322] 1397
FAILURE CODE [CA323] 1401
FAILURE CODE [CA324] 1405
FAILURE CODE [CA325] 1409
FAILURE CODE [CA331] 1413
FAILURE CODE [CA332] 1417
FAILURE CODE [CA343] 1421
FAILURE CODE [CA351] 1422
FAILURE CODE [CA352] 1423
FAILURE CODE [CA356] 1426
FAILURE CODE [CA357] 1429
FAILURE CODE [CA386] 1433
FAILURE CODE [CA428] 1434
FAILURE CODE [CA429] 1437
FAILURE CODE [CA431] 1440
FAILURE CODE [CA432] 1444
FAILURE CODE [CA435] 1448
FAILURE CODE [CA441] 1450
FAILURE CODE [CA442] 1453
FAILURE CODE [CA449] 1454
FAILURE CODE [CA451] 1456
FAILURE CODE [CA452] 1459
FAILURE CODE [CA488] 1462
FAILURE CODE [CA515] 1463
FAILURE CODE [CA516] 1466
FAILURE CODE [CA553] 1469
FAILURE CODE [CA555] 1472
FAILURE CODE [CA556] 1474
FAILURE CODE [CA559] 1476
FAILURE CODE [CA595] 1480
FAILURE CODE [CA687] 1481
FAILURE CODE [CA689] 1485
FAILURE CODE [CA691] 1489
FAILURE CODE [CA692] 1492
FAILURE CODE [CA697] 1495
FAILURE CODE [CA698] 1496
FAILURE CODE [CA731] 1497
FAILURE CODE [CA778] 1500
FAILURE CODE [CA1117] 1507
FAILURE CODE [CA1664] 1509
FAILURE CODE [CA1669] 1513
FAILURE CODE [CA1673] 1515
FAILURE CODE [CA1677] 1517
FAILURE CODE [CA1678] 1519
FAILURE CODE [CA1682] 1521
FAILURE CODE [CA1683] 1528
FAILURE CODE [CA1684] 1531
FAILURE CODE [CA1686] 1534
FAILURE CODE [CA1691] 1536
FAILURE CODE [CA1694] 1540
FAILURE CODE [CA1695] 1545
FAILURE CODE [CA1696] 1546
FAILURE CODE [CA1712] 1549
FAILURE CODE [CA1713] 1553
FAILURE CODE [CA1714] 1556
FAILURE CODE [CA1715] 1558
FAILURE CODE [CA1776] 1560
FAILURE CODE [CA1777] 1564
FAILURE CODE [CA1843] 1568
FAILURE CODE [CA1844] 1571
FAILURE CODE [CA1879] 1575
FAILURE CODE [CA1881] 1579
FAILURE CODE [CA1883] 1583
FAILURE CODE [CA1885] 1588
FAILURE CODE [CA1887] 1591
FAILURE CODE [CA1921] 1594
FAILURE CODE [CA1922] 1597
FAILURE CODE [CA1942] 1604
FAILURE CODE [CA1993] 1606
FAILURE CODE [CA2185] 1610
FAILURE CODE [CA2186] 1613
FAILURE CODE [CA2249] 1615
FAILURE CODE [CA2271] 1616
FAILURE CODE [CA2272] 1620
FAILURE CODE [CA2288] 1625
FAILURE CODE [CA2311] 1626
FAILURE CODE [CA2349] 1627
FAILURE CODE [CA2353] 1631
FAILURE CODE [CA2357] 1634
FAILURE CODE [CA2381] 1637
FAILURE CODE [CA2382] 1641
FAILURE CODE [CA2383] 1646
FAILURE CODE [CA2386] 1650
FAILURE CODE [CA2387] 1653
TROUBLESHOOTING FLOWCHART 1657
FAILURE CODE [CA2555] 1658
FAILURE CODE [CA2556] 1662
FAILURE CODE [CA2637] 1665
FAILURE CODE [CA2639] 1669
FAILURE CODE [CA2771] 1672
FAILURE CODE [CA2777] 1681
FAILURE CODE [CA2976] 1684
FAILURE CODE [CA3133] 1687
FAILURE CODE [CA3134] 1691
FAILURE CODE [CA3135] 1694
FAILURE CODE [CA3142] 1699
FAILURE CODE [CA3143] 1700
FAILURE CODE [CA3144] 1701
FAILURE CODE [CA3146] 1704
FAILURE CODE [CA3147] 1705
FAILURE CODE [CA3148] 1706
FAILURE CODE [CA3151] 1710
FAILURE CODE [CA3165] 1719
FAILURE CODE [CA3229] 1722
FAILURE CODE [CA3231] 1725
FAILURE CODE [CA3232] 1728
FAILURE CODE [CA3235] 1733
FAILURE CODE [CA3239] 1736
FAILURE CODE [CA3241] 1740
FAILURE CODE [CA3242] 1745
FAILURE CODE [CA3251] 1749
FAILURE CODE [CA3253] 1753
FAILURE CODE [CA3254] 1756
FAILURE CODE [CA3255] 1760
FAILURE CODE [CA3256] 1764
FAILURE CODE [CA3311] 1768
FAILURE CODE [CA3312] 1772
FAILURE CODE [CA3313] 1777
FAILURE CODE [CA3314] 1779
FAILURE CODE [CA3315] 1780
FAILURE CODE [CA3316] 1784
FAILURE CODE [CA3317] 1786
FAILURE CODE [CA3318] 1787
FAILURE CODE [CA3319] 1791
FAILURE CODE [CA3321] 1792
FAILURE CODE [CA3322] 1794
FAILURE CODE [CA3419] 1798
FAILURE CODE [CA3421] 1800
FAILURE CODE [CA3497] 1803
FAILURE CODE [CA3498] 1805
FAILURE CODE [CA3543] 1807
FAILURE CODE [CA3545] 1815
FAILURE CODE [CA3547] 1818
FAILURE CODE [CA3558] 1820
FAILURE CODE [CA3559] 1822
FAILURE CODE [CA3562] 1825
FAILURE CODE [CA3563] 1828
FAILURE CODE [CA3567] 1832
FAILURE CODE [CA3568] 1836
FAILURE CODE [CA3571] 1845
FAILURE CODE [CA3572] 1849
FAILURE CODE [CA3574] 1852
FAILURE CODE [CA3575] 1857
FAILURE CODE [CA3577] 1860
FAILURE CODE [CA3578] 1863
FAILURE CODE [CA3582] 1866
FAILURE CODE [CA3583] 1877
FAILURE CODE [CA3596] 1880
FAILURE CODE [CA3649] 1886
FAILURE CODE [CA3681] 1889
FAILURE CODE [CA3682] 1896
FAILURE CODE [CA3713] 1903
FAILURE CODE [CA3717] 1907
FAILURE CODE [CA3718] 1909
FAILURE CODE [CA3725] 1911
FAILURE CODE [CA3741] 1916
FAILURE CODE [CA3748] 1917
FAILURE CODE [CA3751] 1921
FAILURE CODE [CA3755] 1923
FAILURE CODE [CA3866] 1926
FAILURE CODE [CA3867] 1931
FAILURE CODE [CA3868] 1935
FAILURE CODE [CA3899] 1940
FAILURE CODE [CA3911] 1943
FAILURE CODE [CA3912] 1948
FAILURE CODE [CA3932] 1951
FAILURE CODE [CA3933] 1954
FAILURE CODE [CA3934] 1957
FAILURE CODE [CA3935] 1961
FAILURE CODE [CA3936] 1964
FAILURE CODE [CA4151] 1966
FAILURE CODE [CA4152] 1971
FAILURE CODE [CA4155] 1976
FAILURE CODE [CA4156] 1979
FAILURE CODE [CA4157] 1983
FAILURE CODE [CA4158] 1986
FAILURE CODE [CA4159] 1988
FAILURE CODE [CA4161] 1990
FAILURE CODE [CA4162] 1993
FAILURE CODE [CA4163] 1996
FAILURE CODE [CA4164] 1998
FAILURE CODE [CA4165] 2001
FAILURE CODE [CA4166] 2004
FAILURE CODE [CA4168] 2006
FAILURE CODE [CA4169] 2010
FAILURE CODE [CA4171] 2013
FAILURE CODE [CA4249] 2017
FAILURE CODE [CA4251] 2020
FAILURE CODE [CA4259] 2023
FAILURE CODE [CA4261] 2027
FAILURE CODE [CA4277] 2031
FAILURE CODE [CA4281] 2036
FAILURE CODE [CA4459] 2041
FAILURE CODE [CA4461] 2045
FAILURE CODE [CA4658] 2049
FAILURE CODE [CA4731] 2055
FAILURE CODE [CA4732] 2057
FAILURE CODE [CA4739] 2059
FAILURE CODE [CA4768] 2061
FAILURE CODE [CA4769] 2063
FAILURE CODE [CA4842] 2066
FAILURE CODE [CA4952](MACHINE WITH KOMTRAX TERMINAL) 2071
FAILURE CODE [CA4952](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2074
FAILURE CODE [CA5115] 2077
FAILURE CODE [CA5179] 2082
FAILURE CODE [CA5181] 2085
FAILURE CODE [CA5383] 2088
FAILURE CODE [D150KA] 2090
FAILURE CODE [D150KB] 2093
FAILURE CODE [D150KY] 2096
FAILURE CODE [D160KA] 2099
FAILURE CODE [D160KB] 2102
FAILURE CODE [D160KY] 2105
FAILURE CODE [D191KA] 2108
FAILURE CODE [D191KB] 2111
FAILURE CODE [D191KY] 2114
FAILURE CODE [D192KA] 2117
FAILURE CODE [D192KB] 2119
FAILURE CODE [D192KY] 2121
FAILURE CODE [D19JKZ] 2123
FAILURE CODE [D1E6KA] 2126
FAILURE CODE [D1E6KB] 2129
FAILURE CODE [D1E6KY] 2132
FAILURE CODE [D5ZHKA] 2135
FAILURE CODE [D5ZHKB] 2138
FAILURE CODE [D5ZHKZ] 2141
FAILURE CODE [D5ZHL6] 2144
FAILURE CODE [D5ZMLD] 2146
FAILURE CODE [D811MC](MACHINE WITH KOMTRAX TERMINAL) 2149
FAILURE CODE [D811MC](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2150
FAILURE CODE [D862KA](MACHINE WITH KOMTRAX TERMINAL) 2151
FAILURE CODE [D862KA](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2153
FAILURE CODE [D8ALKA](MACHINE WITH KOMTRAX TERMINAL) 2154
FAILURE CODE [D8ALKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2157
FAILURE CODE [D8ALKB](MACHINE WITH KOMTRAX TERMINAL) 2160
FAILURE CODE [D8ALKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2163
FAILURE CODE [D8AQK4](MACHINE WITH KOMTRAX TERMINAL) 2166
FAILURE CODE [D8AQK4](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2167
FAILURE CODE [D8AQKR](MACHINE WITH KOMTRAX TERMINAL) 2169
FAILURE CODE [D8AQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2172
FAILURE CODE [D8G1KT] 2175
FAILURE CODE [D8G6KT] 2176
FAILURE CODE [DAF0KT] 2177
FAILURE CODE [DAF0MB] 2178
FAILURE CODE [DAF0MC] 2179
FAILURE CODE [DAF3KK] 2180
FAILURE CODE [DAF8KB] 2183
FAILURE CODE [DAFDKB] 2185
FAILURE CODE [DAFGMC](MACHINE WITH KOMTRAX TERMINAL) 2187
FAILURE CODE [DAFGMC](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2188
FAILURE CODE [DAFLKA](MACHINE WITH KOMTRAX TERMINAL) 2189
FAILURE CODE [DAFLKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2192
FAILURE CODE [DAFLKB](MACHINE WITH KOMTRAX TERMINAL) 2195
FAILURE CODE [DAFLKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2198
FAILURE CODE [DAFQKR](MACHINE WITH KOMTRAX TERMINAL) 2201
FAILURE CODE [DAFQKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2202
FAILURE CODE [DAQ0KK] 2204
FAILURE CODE [DAQ0KT] 2208
FAILURE CODE [DAQ0MC] 2209
FAILURE CODE [DAQ1KA] 2210
FAILURE CODE [DAQ2KK] 2213
FAILURE CODE [DAQ4KB] 2217
FAILURE CODE [DAQ9KQ] 2220
FAILURE CODE [DAQLKA](MACHINE WITH KOMTRAX TERMINAL) 2222
FAILURE CODE [DAQLKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2225
FAILURE CODE [DAQLKB](MACHINE WITH KOMTRAX TERMINAL) 2228
FAILURE CODE [DAQLKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2231
FAILURE CODE [DAQQKR] 2234
FAILURE CODE [DAQRKR] 2236
FAILURE CODE [DAQRMA] 2238
FAILURE CODE [DAZ9KQ] 2239
FAILURE CODE [DAZQKR] 2240
FAILURE CODE [DB2QKR](MACHINE WITH KOMTRAX TERMINAL) 2242
FAILURE CODE [DB2QKR](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2252
FAILURE CODE [DB2RKR] 2262
FAILURE CODE [DB90KK](MACHINE WITH KOMTRAX TERMINAL) 2270
FAILURE CODE [DB90KK](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2274
FAILURE CODE [DB90KT] 2278
FAILURE CODE [DB90MC] 2279
FAILURE CODE [DB91KA] 2280
FAILURE CODE [DB92KK](MACHINE WITH KOMTRAX TERMINAL) 2283
FAILURE CODE [DB92KK](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2286
FAILURE CODE [DB95KX] 2289
FAILURE CODE [DB96KX] 2293
FAILURE CODE [DB99KQ] 2296
FAILURE CODE [DB9LKA](MACHINE WITH KOMTRAX TERMINAL) 2298
FAILURE CODE [DB9LKA](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2301
FAILURE CODE [DB9LKB](MACHINE WITH KOMTRAX TERMINAL) 2304
FAILURE CODE [DB9LKB](MACHINE WITH GATEWAY FUNCTION CONTROLLER) 2307
FAILURE CODE [DB9QKR] 2310
FAILURE CODE [DB9RKR] 2312
FAILURE CODE [DB9RMA] 2314
FAILURE CODE [DBE5KX] 2316
FAILURE CODE [DBE6KX] 2319
FAILURE CODE [DD1ALD] 2322
FAILURE CODE [DDAAL6] 2325
FAILURE CODE [DDB6L4] 2328
FAILURE CODE [DDD1LD] 2332
FAILURE CODE [DDK3KA] 2335
FAILURE CODE [DDK3KB] 2339
FAILURE CODE [DDK6KA] 2343
FAILURE CODE [DDK6KB] 2347
FAILURE CODE [DDKLKA] 2351
FAILURE CODE [DDKLKB] 2354
FAILURE CODE [DDNRKY] 2357
FAILURE CODE [DDNTKY] 2360
FAILURE CODE [DDT0L4] 2363
FAILURE CODE [DDT4LD] 2366
FAILURE CODE [DDT9LD] 2369
FAILURE CODE [DDTALD] 2372
FAILURE CODE [DDW9LD] 2375
FAILURE CODE [DDWLLD] 2378
FAILURE CODE [DF10KA] 2381
FAILURE CODE [DF10KB] 2385
FAILURE CODE [DGF1KA] 2389
FAILURE CODE [DGF1KB] 2391
FAILURE CODE [DGH2KX] 2393
FAILURE CODE [DGR2KB] 2395
FAILURE CODE [DGR2KZ] 2397
FAILURE CODE [DGT1KA] 2400
FAILURE CODE [DGT1KB] 2402
FAILURE CODE [DH21KA] 2404
FAILURE CODE [DH21KB] 2407
FAILURE CODE [DHA4KA] 2410
FAILURE CODE [DHAAMA] 2413
FAILURE CODE [DHACMA] 2415
FAILURE CODE [DHPCKX] 2417
FAILURE CODE [DHPDKX] 2421
FAILURE CODE [DHT1KX] 2425
FAILURE CODE [DHT5KX] 2428
FAILURE CODE [DHT7KX] 2431
FAILURE CODE [DHT8KA] 2434
FAILURE CODE [DHT8KB] 2437
FAILURE CODE [DHT8ZG] 2439
FAILURE CODE [DHUDKA] 2440
FAILURE CODE [DHUDKB] 2444
FAILURE CODE [DJF1KA] 2447
FAILURE CODE [DK55KA] 2449
FAILURE CODE [DK55KY] 2453
FAILURE CODE [DK55L5] 2456
FAILURE CODE [DK59KA] 2458
FAILURE CODE [DK59KY] 2461
FAILURE CODE [DK59L8] 2464
FAILURE CODE [DK5AKA] 2467
FAILURE CODE [DK5AKY] 2470
FAILURE CODE [DK5BKA] 2473
FAILURE CODE [DK5BKY] 2476
FAILURE CODE [DK5BL8] 2479
FAILURE CODE [DK5CKA] 2482
FAILURE CODE [DK5CKY] 2485
FAILURE CODE [DK5DKA] 2488
FAILURE CODE [DK5DKY] 2491
FAILURE CODE [DK5DL8] 2494
FAILURE CODE [DK5EKA] 2498
FAILURE CODE [DK5EKY] 2501
FAILURE CODE [DK5KKA] 2504
FAILURE CODE [DK5KKY] 2507
FAILURE CODE [DK5KL8] 2510
FAILURE CODE [DK5LKA] 2514
FAILURE CODE [DK5LKY] 2517
FAILURE CODE [DKA0KA] 2520
FAILURE CODE [DKA0KY] 2523
FAILURE CODE [DKA0L0] 2526
FAILURE CODE [DKA1KA] 2529
FAILURE CODE [DKA1KY] 2532
FAILURE CODE [DLF1KA] 2534
FAILURE CODE [DLF1LC] 2537
FAILURE CODE [DLM3KA] 2540
FAILURE CODE [DLM3LC] 2542
FAILURE CODE [DLT3KA] 2545
FAILURE CODE [DLT3LC] 2548
FAILURE CODE [DPQ1KR] 2551
FAILURE CODE [DPQ2KR] 2555
FAILURE CODE [DPQ3KR] 2559
FAILURE CODE [DSJ0KR] 2563
FAILURE CODE [DT20KB] 2567
FAILURE CODE [DT22KB] 2570
FAILURE CODE [DT23KB] 2573
FAILURE CODE [DV00KB] 2576
FAILURE CODE [DW4PKA] 2579
FAILURE CODE [DW4PKB] 2582
FAILURE CODE [DW4PKY] 2585
FAILURE CODE [DW4QKA] 2588
FAILURE CODE [DW4QKB] 2591
FAILURE CODE [DW4QKY] 2594
FAILURE CODE [DW4RKA] 2597
FAILURE CODE [DW4RKB] 2600
FAILURE CODE [DW4RKY] 2603
FAILURE CODE [DW4SKA] 2606
FAILURE CODE [DW4SKB] 2608
FAILURE CODE [DW4SKY] 2611
FAILURE CODE [DW7BKA] 2614
FAILURE CODE [DW7BKB] 2616
FAILURE CODE [DW7BKY] 2619
FAILURE CODE [DWM1KA] 2621
FAILURE CODE [DWM1KB] 2624
FAILURE CODE [DWM1KY] 2627
FAILURE CODE [DWN6KA] 2630
FAILURE CODE [DWN6KB] 2633
FAILURE CODE [DWN6KY] 2636
FAILURE CODE [DWN8KA] 2639
FAILURE CODE [DWN8KB] 2641
FAILURE CODE [DWN8KY] 2644
FAILURE CODE [DX16KA] 2647
FAILURE CODE [DX16KB] 2649
FAILURE CODE [DX16KY] 2652
FAILURE CODE [DXA1KA] 2654
FAILURE CODE [DXA1KB] 2656
FAILURE CODE [DXA1KY] 2659
FAILURE CODE [DXANKA] 2661
FAILURE CODE [DXANKB] 2664
FAILURE CODE [DXANKY] 2667
FAILURE CODE [DXH1KA] 2669
FAILURE CODE [DXH1KB] 2671
FAILURE CODE [DXH1KY] 2673
FAILURE CODE [DXH4KA] 2675
FAILURE CODE [DXH4KB] 2677
FAILURE CODE [DXH4KY] 2679
FAILURE CODE [DXH5KA] 2681
FAILURE CODE [DXH5KB] 2683
FAILURE CODE [DXH5KY] 2685
FAILURE CODE [DXH6KA] 2687
FAILURE CODE [DXH6KB] 2689
FAILURE CODE [DXH6KY] 2692
FAILURE CODE [DXH7KA] 2694
FAILURE CODE [DXH7KB] 2697
FAILURE CODE [DXH7KY] 2700
FAILURE CODE [DXH8KA] 2702
FAILURE CODE [DXH8KB] 2705
FAILURE CODE [DXH8KY] 2708
FAILURE CODE [DXHHKA] 2710
FAILURE CODE [DXHHKB] 2712
FAILURE CODE [DXHHKY] 2715
FAILURE CODE [DXHJKA] 2717
FAILURE CODE [DXHJKB] 2720
FAILURE CODE [DXHJKY] 2723
FAILURE CODE [DXHKKA] 2726
FAILURE CODE [DXHKKB] 2729
FAILURE CODE [DXHKKY] 2732
FAILURE CODE [DXJEKA] 2735
FAILURE CODE [DXJEKB] 2737
FAILURE CODE [DXJEKY] 2740
FAILURE CODE [DXJFKA] 2743
FAILURE CODE [DXJFKB] 2745
FAILURE CODE [DXJFKY] 2748
FAILURE CODE [DY30MA] 2751
FAILURE CODE [DY30MC] 2756
FAILURE CODE [DY30ME] 2764
FAILURE CODE [F313KA] 2766
FAILURE CODE [F313KB] 2768
FAILURE CODE [F314KA] 2770
FAILURE CODE [F314KB] 2772
FAILURE CODE [F315KB] 2774
FAILURE CODE [F315KY] 2776
FAILURE CODE [F316KB] 2778
FAILURE CODE [F316KY] 2780
FAILURE CODE [F318KB] 2782
FAILURE CODE [F318KY] 2784
FAILURE CODE [F31AKB] 2786
FAILURE CODE [F31AKY] 2788
FAILURE CODE [F31BKB] 2790
FAILURE CODE [F31BKY] 2792
FAILURE CODE [F31CKB] 2794
FAILURE CODE [F31CKY] 2796
FAILURE CODE [F31DKB] 2798
FAILURE CODE [F31DKY] 2800
FAILURE CODE [F31EKB] 2802
FAILURE CODE [F31EKY] 2804
FAILURE CODE [FS10ZE] 2806
FAILURE CODE [LA00L3] 2807
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2808
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2808
MANUAL PREHEATING SYSTEM DOES NOT WORK 2815
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2818
WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2821
ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2823
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2826
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2829
LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2832
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2835
NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2838
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2842
NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2844
2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2847
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2850
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2853
AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2854
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2857
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2860
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2863
NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2867
AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP 2869
RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 2871
PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2873
WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2877
WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2878
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2879
TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2881
INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 2882
SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2884
ALARM BUZZER DOES NOT SOUND 2885
ALARM BUZZER DOES NOT STOP SOUNDING 2887
KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2888
HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2890
BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 2892
TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED 2896
TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED 2898
DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2900
ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2902
FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE 2904
ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2905
HORN DOES NOT SOUND 2907
HORN DOES NOT STOP SOUNDING 2910
NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2912
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2914
BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 2918
LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2922
HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2924
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2926
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2931
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2936
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2940
ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 2945
TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 2948
HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 2951
BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2955
BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2959
BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2962
FRONT WIPER DOES NOT OPERATE 2964
REAR WIPER DOES NOT OPERATE 2968
FAN DOES NOT ROTATE IN REVERSE 2971
FAN REMAINS ROTATED IN REVERSE 2972
WINDOW WASHER DOES NOT OPERATE 2973
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2976
[FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2977
[FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2979
AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP 2980
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2982
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2982
FAILURE MODE AND CAUSE TABLE 2983
MACHINE DOES NOT START 2996
LOCKUP IS NOT RELEASED 3000
TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 3001
TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 3002
LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 3006
LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 3009
OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 3012
MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 3016
TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 3019
STEERING WHEEL IS HEAVY TO OPERATE 3022
MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 3023
TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS 3025
WHEEL BRAKES DO NOT WORK OR ARE WEAK 3026
WHEEL BRAKES ARE NOT RELEASED OR DRAG 3028
PARKING BRAKE DOES NOT WORK OR IT IS WEAK 3029
PARKING BRAKE IS NOT RELEASED OR DRAGS 3030
BOOM DOES NOT RISE 3032
BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 3035
RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 3038
LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 3039
HYDRAULIC DRIFT OF BOOM IS LARGE 3041
BOOM MOVES UP AND DOWN DURING OPERATION 3042
BUCKET DOES NOT TILT BACK 3043
BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 3046
BUCKET DECELERATES DURING TILT-BACK OPERATION 3049
BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 3050
HYDRAULIC DRIFT OF BUCKET IS LARGE 3052
BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 3053
BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (2-LEVER TYPE OR 3-LEVER TYPE) 3054
BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE) 3055
WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 3056
LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 3057
WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 3059
E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 3060
BUCKET DOES NOT STOP AT THE POSITION WHICH IS SET WITH REMOTE BUCKET POSITIONER 3061
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 3062
UNUSUAL NOISE IS HEARD FROM AROUND FAN 3064
TROUBLESHOOTING OF ENGINE (S-MODE) 3065
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 3065
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 3066
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 3067
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 3068
ENGINE STARTABILITY IS POOR 3070
ENGINE DOES NOT PICK UP SMOOTHLY 3072
ENGINE STOPS DURING OPERATION 3074
ENGINE RUNS ROUGH OR IS UNSTABLE 3076
ENGINE LACKS POWER 3077
KDPF GETS CLOGGED IN A SHORT TIME 3079
ENGINE OIL CONSUMPTION IS EXCESSIVE 3081
OIL BECOMES CONTAMINATED QUICKLY 3082
FUEL CONSUMPTION IS EXCESSIVE 3083
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 3084
OIL PRESSURE DROPS 3085
FUEL MIXES INTO ENGINE OIL 3087
WATER MIXES INTO ENGINE OIL (MILKY) 3088
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 3089
UNUSUAL NOISE IS HEARD 3090
VIBRATION IS EXCESSIVE 3091
AIR CANNOT BE BLED FROM FUEL CIRCUIT 3092
ACTIVE REGENERATION IS EXECUTED FREQUENTLY 3093
ACTIVE REGENERATION TAKES TIME 3095
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 3096
AdBlue/DEF CONSUMPTION IS EXCESSIVE 3097
FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 3099
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM 3100
OUTLINE OF FAILURE DISPLAY 3100
TROUBLESHOOTING FOR FCS 3101
TROUBLESHOOTING FOR AUTO-GREASING PUMP 3102
REPLACE PUMP ELEMENT 3104
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM 3105
REPLACEMENT OF AUTO-GREASING CONTROLLER 3107
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 3108
TROUBLESHOOTING FOR RDS LOAD METER SYSTEM 3109
OUTLINE OF FAILURE DISPLAY 3109
METHOD FOR DISPLAYING DIAGNOSTICS SCREEN 3110
TROUBLESHOOTING FOR RDS LOAD METER 3111
50 DISASSEMBLY AND ASSEMBLY 3115
CONTENTS 3116
ABBREVIATION LIST 3121
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 3127
HOW TO READ THIS MANUAL 3127
COATING MATERIALS LIST 3129
SPECIAL TOOLS LIST 3134
SKETCHES OF SPECIAL TOOLS 3153
ENGINE AND COOLING SYSTEM 3160
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 3160
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 3160
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 3162
REMOVE AND INSTALL INJECTOR ASSEMBLY 3166
METHOD FOR REMOVING INJECTOR ASSEMBLY 3166
METHOD FOR INSTALLING INJECTOR ASSEMBLY 3173
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 3183
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 3184
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 3196
REMOVE AND INSTALL EGR VALVE ASSEMBLY 3214
METHOD FOR REMOVING EGR VALVE ASSEMBLY 3214
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 3216
REMOVE AND INSTALL EGR COOLER ASSEMBLY 3218
METHOD FOR REMOVING EGR COOLER ASSEMBLY 3218
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 3221
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 3225
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 3225
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 3226
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 3228
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 3228
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 3228
REMOVE AND INSTALL ALTERNATOR BELT 3230
METHOD FOR REMOVING ALTERNATOR BELT 3230
METHOD FOR INSTALLING ALTERNATOR BELT 3231
REMOVE AND INSTALL AUTOMATIC TENSIONER 3232
METHOD FOR REMOVING AUTOMATIC TENSIONER 3232
METHOD FOR INSTALLING AUTOMATIC TENSIONER 3232
REMOVE AND INSTALL RADIATOR CORE 3233
METHOD FOR REMOVING RADIATOR CORE 3234
METHOD FOR INSTALLING RADIATOR CORE 3240
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 3247
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 3247
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 3250
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 3254
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 3254
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 3256
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 3258
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 3258
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 3263
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 3268
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 3268
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 3271
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3275
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3276
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3292
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3308
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3308
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 3309
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 3311
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 3311
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 3312
REMOVE AND INSTALL ENGINE REAR OIL SEAL 3314
METHOD FOR REMOVING ENGINE REAR OIL SEAL 3314
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 3315
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 3319
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 3319
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 3323
REMOVE AND INSTALL FUEL TANK ASSEMBLY 3328
METHOD FOR REMOVING FUEL TANK ASSEMBLY 3328
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 3330
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 3334
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 3334
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 3339
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3344
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3344
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 3344
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 3346
REMOVE AdBlue/DEF TANK SENSOR 3346
INSTALL AdBlue/DEF TANK SENSOR 3347
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 3354
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 3354
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 3354
REMOVE AND INSTALL KDPF ASSEMBLY 3356
METHOD FOR REMOVING KDPF ASSEMBLY 3357
METHOD FOR INSTALLING KDPF ASSEMBLY 3367
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY 3380
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 3380
METHOD FOR ASSEMBLING KDPF ASSEMBLY 3384
REMOVE AND INSTALL SCR ASSEMBLY 3388
METHOD FOR REMOVING SCR ASSEMBLY 3389
METHOD FOR INSTALLING SCR ASSEMBLY 3398
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 3410
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 3411
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 3419
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 3429
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 3429
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 3435
REMOVE AND INSTALL KCCV ASSEMBLY 3443
METHOD FOR REMOVING KCCV ASSEMBLY 3443
METHOD FOR INSTALLING KCCV ASSEMBLY 3444
REMOVE AND INSTALL VGT ASSEMBLY 3448
METHOD FOR REMOVING VGT ASSEMBLY 3448
METHOD FOR INSTALLING VGT ASSEMBLY 3452
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3457
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3458
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3465
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3473
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3473
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3476
REMOVE AND INSTALL AdBlue/DEF PUMP 3479
METHOD FOR REMOVING AdBlue/DEF PUMP 3479
METHOD FOR INSTALLING AdBlue/DEF PUMP 3482
REMOVE AND INSTALL AdBlue/DEF HOSE 3485
REMOVE AdBlue/DEF HOSE 3486
INSTALL AdBlue/DEF HOSE 3492
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3501
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3501
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3503
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3505
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3505
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3508
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3511
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3511
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3512
POWER TRAIN 3514
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 3514
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 3514
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3517
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 3523
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3524
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 3532
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3544
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3545
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3554
DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY 3566
METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY 3567
METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY 3569
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 3577
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3577
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3579
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3581
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3581
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3585
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 3590
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY 3591
ASSEMBLE AXLE HOUSING ASSEMBLY 3596
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 3604
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY 3605
ASSEMBLE DIFFERENTIAL ASSEMBLY 3615
STEERING SYSTEM 3637
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 3637
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3637
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3639
BRAKE SYSTEM 3643
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3643
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE 3643
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE 3645
UNDERCARRIAGE AND FRAME 3648
REMOVE AND INSTALL CENTER HINGE PIN 3648
METHOD FOR REMOVING CENTER HINGE PIN 3648
METHOD FOR INSTALLING CENTER HINGE PIN 3654
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3663
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3663
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3668
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY 3674
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3674
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3675
HYDRAULIC SYSTEM 3676
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3676
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3677
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3680
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3684
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3684
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3686
REMOVE AND INSTALL STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3688
METHOD FOR REMOVING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3688
METHOD FOR INSTALLING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3690
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3693
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3693
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3697
WORK EQUIPMENT 3702
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3702
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3703
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3707
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 3713
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3714
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3717
CAB AND ITS ATTACHMENTS 3723
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3723
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3723
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3728
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3734
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3734
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3735
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3745
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3745
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3751
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3757
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3757
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3759
REMOVE AND INSTALL SEAT BELT 3761
METHOD FOR REMOVING SEAT BELT 3761
METHOD FOR INSTALLING SEAT BELT 3761
ELECTRICAL SYSTEM 3763
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3763
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3763
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3766
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3769
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3769
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3770
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3773
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3773
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3773
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3775
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3775
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3777
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3779
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3779
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3781
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3783
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3783
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3783
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3785
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3785
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3786
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR 3788
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3788
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3791
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3795
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3795
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3798
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3801
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3801
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3804
REMOVE AND INSTALL AMMONIA SENSOR 3808
METHOD FOR REMOVING AMMONIA SENSOR 3808
METHOD FOR INSTALLING AMMONIA SENSOR 3809
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 3811
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3811
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3812
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3814
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3814
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3815
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3816
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY 3816
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 3817
REMOVE AND INSTALL COMMUNICATION TERMINAL 3818
REMOVE COMMUNICATION TERMINAL 3818
INSTALL COMMUNICATION TERMINAL 3823
60 MAINTENANCE STANDARD 3829
CONTENTS 3830
ABBREVIATION LIST 3832
ENGINE AND COOLING SYSTEM 3838
MAINTENANCE STANDARD OF ENGINE MOUNT 3838
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP 3839
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3841
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3842
POWER TRAIN 3844
MAINTENANCE STANDARD OF DRIVE SHAFT 3844
MAINTENANCE STANDARD OF TORQUE CONVERTER 3845
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3847
MAINTENANCE STANDARD OF TRANSMISSION 3848
MAINTENANCE STANDARD OF F, R CLUTCH 3853
MAINTENANCE STANDARD OF 1ST, 4TH CLUTCH 3854
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH 3855
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3856
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3857
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3858
MAINTENANCE STANDARD OF FRONT AXLE 3859
MAINTENANCE STANDARD OF REAR AXLE 3860
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3862
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL 3863
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3866
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL 3868
MAINTENANCE STANDARD OF FINAL DRIVE 3870
STEERING SYSTEM 3872
MAINTENANCE STANDARD OF STEERING COLUMN 3872
MAINTENANCE STANDARD OF STEERING PUMP 3873
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP 3876
MAINTENANCE STANDARD OF STEERING VALVE 3877
MAINTENANCE STANDARD OF STEERING CYLINDER 3879
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3881
BRAKE SYSTEM 3882
MAINTENANCE STANDARD OF CHARGE VALVE 3882
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3884
MAINTENANCE STANDARD OF FRONT BRAKE 3885
MAINTENANCE STANDARD OF REAR BRAKE 3886
MAINTENANCE STANDARD OF PARKING BRAKE 3887
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE 3888
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3889
MAINTENANCE STANDARD OF BRAKE COOLING PUMP 3890
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER 3891
UNDERCARRIAGE AND FRAME 3892
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 3892
HYDRAULIC SYSTEM 3897
MAINTENANCE STANDARD OF HYDRAULIC TANK 3897
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3898
MAINTENANCE STANDARD OF SERVO VALVEWORK OF EQUIPMENT PUMP 3901
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 3903
MAINTENANCE STANDARD OF CONTROL VALVE 3904
MAINTENANCE STANDARD OF STABILIZER VALVE 3916
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 3917
WORK EQUIPMENT 3918
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3918
MAINTENANCE STANDARD OF BUCKET 3921
MAINTENANCE STANDARD OF LIFT CYLINDER 3922
MAINTENANCE STANDARD OF BUCKET CYLINDER 3923
80 APPENDIX 3925
CONTENTS 3926
ABBREVIATION LIST 3928
AIR CONDITIONER SYSTEM 3934
PRECAUTIONS FOR REFRIGERANT 3934
AIR CONDITIONER COMPONENT 3935
SPECIFICATIONS OF AIR CONDITIONER 3937
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3938
OUTLINE OF REFRIGERATION CYCLE 3939
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3941
AIR CONDITIONER UNIT 3941
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3941
FUNCTION OF AIR CONDITIONER UNIT 3942
COMPONENT PARTS OF AIR CONDITIONER UNIT 3943
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3943
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3943
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 3944
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 3944
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3944
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3944
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3944
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3945
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3945
FUNCTION OF DUAL PRESSURE SWITCH 3945
AIR CONDITIONER CONTROLLER 3946
STRUCTURE OF AIR CONDITIONER CONTROLLER 3946
COMPRESSOR 3947
STRUCTURE OF COMPRESSOR 3947
SPECIFICATIONS OF COMPRESSOR 3947
FUNCTION OF COMPRESSOR 3947
CONDENSER 3948
STRUCTURE OF CONDENSER 3948
SPECIFICATIONS OF CONDENSER 3948
FUNCTION OF CONDENSER 3948
RECEIVER DRIER 3949
STRUCTURE OF RECEIVER DRIER 3949
SPECIFICATIONS OF RECEIVER DRIER 3949
FUNCTION OF RECEIVER DRIER 3949
SENSORS FOR AIR CONDITIONER SYSTEM 3950
FUNCTION OF SUNLIGHT SENSOR 3950
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3950
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3951
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3953
AIR CONDITIONER SYSTEM DIAGRAM 3956
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3957
FUNCTION OF AIR CONDITIONER CONTROLLER 3958
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3959
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3965
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3966
CHECK TEMPERATURE CONTROL FUNCTION 3967
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 3967
TEST VENT (MODE) CHANGEOVER 3969
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3969
TESTING FRESH/RECIRC AIR CHANGEOVER 3971
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3971
TEST EVAPORATOR TEMPERATURE SENSOR 3973
TEST RELAYS 3975
METHOD FOR TESTING RELAYS 3975
AIR CONDITIONER TROUBLESHOOTING CHART 1 3977
AIR CONDITIONER TROUBLESHOOTING CHART 2 3978
FAILURE CODE [879AKA] 3981
FAILURE CODE [879AKB] 3984
FAILURE CODE [879BKA] 3987
FAILURE CODE [879BKB] 3990
FAILURE CODE [879CKA] 3993
FAILURE CODE [879CKB] 3996
FAILURE CODE [879DKZ] 3999
FAILURE CODE [879EMC] 4002
FAILURE CODE [879FMC] 4005
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 4008
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 4010
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 4013
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 4015
TROUBLESHOOTING USING GAUGE PRESSURE 4017
CONNECTION OF SERVICE TOOL 4020
METHOD FOR CONNECTING SERVICE TOOL 4021
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 4022
HANDLE COMPRESSOR OIL 4024
90 CIRCUIT DIAGRAMS 4027
CONTENTS 4028
ABBREVIATION LIST 4031
HYDRAULIC CIRCUIT DIAGRAM 4037
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 4037
HYDRAULIC CIRCUIT DIAGRAM 4041
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 4043
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM 4045
HYDRAULIC AUTO-GREASING DIAGRAM 4047
HYDRAULIC CIRCUIT DIAGRAM (BOOM RAISE, TILT) 4049
HYDRAULIC CIRCUIT DIAGRAM (BOOM LOWER, LEFT TURN, LEFT BRAKE) 4051
ELECTRICAL CIRCUIT DIAGRAM 4053
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 4053
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (1/10) 4057
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (2/10) 4059
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (3/10) 4061
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (4/10) 4063
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (5/10) 4065
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (6/10) 4067
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (7/10) 4069
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (8/10) 4071
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (9/10) 4073
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH KOMTRAX TERMINAL) (10/10) 4075
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/12) 4077
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/12) 4079
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/12) 4081
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/12) 4083
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/12) 4085
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/12) 4087
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/12) 4089
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/12) 4091
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/12) 4093
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/12) 4095
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (11/12) 4097
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (12/12) 4099
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (1/8) 4101
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (2/8) 4103
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (3/8) 4105
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (4/8) 4107
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (5/8) 4109
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (6/8) 4111
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (7/8) 4113
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH KOMTRAX TERMINAL) (8/8) 4115
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/9) 4117
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/9) 4119
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/9) 4121
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/9) 4123
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/9) 4125
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/9) 4127
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/9) 4129
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/9) 4131
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/9) 4133
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (1/9) 4135
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (2/9) 4137
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (3/9) 4139
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (4/9) 4141
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (5/9) 4143
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (6/9) 4145
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (7/9) 4147
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (8/9) 4149
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (MACHINE WITH KOMTRAX TERMINAL) (9/9) 4151
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (1/10) 4153
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (2/10) 4155
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (3/10) 4157
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (4/10) 4159
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (5/10) 4161
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (6/10) 4163
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (7/10) 4165
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (8/10) 4167
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (9/10) 4169
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (EU SPECIFICATIONS AND INDIA AUTOMOBILE-INSPECTION SPECIFICATIONS) (MACHINE WITH GATEWAY FUNCTION CONTROLLER) (10/10) 4171
INDEX 4173

DESCRIPTION:

Komatsu WA380-8 Wheel Loader Shop Manual SMEW380800-00 – PDF DOWNLOAD 

SERIAL NUMBERS DZCQ0001 and up

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.

S.V 31/12/24