Komatsu WA380-8 Wheel Loader Shop Manual VENBM48500 PDF

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Komatsu WA380-8 Wheel Loader Shop Manual VENBM48500  – PDF DOWNLOAD

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Komatsu WA380-8 Wheel Loader Shop Manual VENBM48500  – PDF DOWNLOAD

Language : English
Pages : 3516
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA380-8 Wheel Loader Shop Manual VENBM48500  – PDF DOWNLOAD

• 15001 and up
• H65051 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 25
FOREWORD, SAFETY, BASIC INFORMATION 31
HOW TO READ THE SHOP MANUAL 31
SAFETY NOTICE FOR OPERATION 33
PRECAUTIONS TO PREVENT FIRE 41
ACTIONS IF FIRE OCCURS . 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 45
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 46
PRECAUTIONS FOR ADDING . 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF . 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 60
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 61
PRACTICAL USE OF KOMTRAX . 62
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 77
HOW TO READ ELECTRICAL WIRE CODE . 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 82
STANDARD TIGHTENING TORQUE TABLE . 85
CONVERSION TABLE . 92
01 SPECIFICATIONS 97
CONTENTS . 98
ABBREVIATION LIST 99
SPECIFICATIONS . 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: WA380-8 . 105
SPECIFICATIONS . 107
SPECIFICATIONS: WA380-8 107
WEIGHT TABLE . 112
WEIGHT TABLE: WA380-8 112
TABLE OF FUEL, COOLANT, AND LUBRICANTS . 114
10 STRUCTURE AND FUNCTION 117
CONTENTS . 118
ABBREVIATION LIST 123
UREA SCR SYSTEM 129
LAYOUT DRAWING OF UREA SCR SYSTEM 129
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM . 151
AdBlue/DEF MIXING TUBE . 151
SCR ASSEMBLY . 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM . 160
LAYOUT DRAWING OF BOOT-UP SYSTEM . 160
SYSTEM OPERATING LAMP SYSTEM . 161
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 161
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 161
BATTERY DISCONNECT SWITCH 162
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 162
FUNCTION OF BATTERY DISCONNECT SWITCH 162
PREHEATING SYSTEM 164
PREHEATING SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 164
OPERATION OF AUTOMATIC PREHEATING SYSTEM . 164
FUNCTION OF MANUAL PREHEATING SYSTEM . 165
OPERATION OF MANUAL PREHEATING SYSTEM 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE CONTROL SYSTEM 169
OPERATION OF ENGINE CONTROL SYSTEM . 172
ENGINE POWER MODE SELECTOR SYSTEM 174
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 174
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 174
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM . 174
AUTOMATIC IDLE STOP SYSTEM . 176
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 176
COMPONENT PARTS OF ENGINE SYSTEM . 177
VGT 177
EGR SYSTEM . 181
EGR VALVE 183
EGR COOLER . 185
KCCV SYSTEM 187
KCCV VENTILATOR 189
KDPF . 191
COOLING SYSTEM . 195
LAYOUT DRAWING OF COOLING SYSTEM . 195
SPECIFICATIONS OF COOLING SYSTEM . 196
COOLING FAN CONTROL SYSTEM . 198
COOLING FAN CONTROL SYSTEM DIAGRAM . 198
FUNCTION OF COOLING FAN CONTROL SYSTEM . 198
COMPONENT PARTS OF COOLING SYSTEM 203
BRAKE AND COOLING FAN PUMP . 203
COOLING FAN MOTOR 211
CONTROL SYSTEM . 217
LAYOUT DRAWING OF CONTROL SYSTEM . 217
MACHINE MONITOR SYSTEM . 219
MACHINE MONITOR SYSTEM DIAGRAM . 219
FUNCTION OF MACHINE MONITOR SYSTEM . 219
REARVIEW MONITOR SYSTEM 221
REARVIEW MONITOR SYSTEM DIAGRAM 221
FUNCTION OF REARVIEW MONITOR SYSTEM 221
KOMTRAX SYSTEM . 222
KOMTRAX SYSTEM DIAGRAM . 222
FUNCTION OF KOMTRAX SYSTEM . 222
RDS LOAD METER SYSTEM 223
LAYOUT DRAWING OF RDS LOAD METER SYSTEM 223
FUNCTION OF RDS LOAD METER SYSTEM 224
COMPONENT PARTS OF CONTROL SYSTEM 225
MACHINE MONITOR 225
SWITCH PANEL . 245
REARVIEW MONITOR . 246
REARVIEW CAMERA 248
KOMTRAX TERMINAL . 249
TRANSMISSION CONTROLLER 251
WORK EQUIPMENT CONTROLLER 255
MONITOR CONTROLLER . 259
CAN TERMINATING RESISTOR . 264
ENGINE CONTROLLER 265
ACCELERATOR PEDAL 272
HYDRAULIC SYSTEM . 274
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 274
CLSS . 275
STRUCTURE OF CLSS 275
FUNCTION OF CLSS . 276
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM . 278
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 278
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 278
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT . 278
COMPONENT PARTS OF HYDRAULIC SYSTEM 279
HYDRAULIC TANK . 279
WORK EQUIPMENT PUMP 282
STEERING PUMP 296
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP . 308
CONTROL VALVE 309
STABILIZER VALVE . 347
POWER TRAIN SYSTEM . 353
LAYOUT DRAWING OF POWER TRAIN SYSTEM . 353
OPERATION OF POWER TRAIN SYSTEM 356
TRANSMISSION CONTROL SYSTEM 357
TRANSMISSION CONTROL SYSTEM DIAGRAM 357
TRANSMISSION GEAR SHIFT CONTROL SYSTEM . 359
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 359
ELECTRIC MODULATION FUNCTION . 360
DISPLAY FUNCTION OF GEAR SHIFT . 360
AUTOMATIC GEAR SHIFT FUNCTION 360
SHIFT HOLD FUNCTION 361
KICKDOWN FUNCTION 361
AUTOMATIC KICKDOWN FUNCTION 362
TORQUE CONVERTER LOCKUP FUNCTION . 362
HUNTING PREVENTION FUNCTION 363
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT . 363
SHIFT POINT CHANGING FUNCTION 363
4TH GEAR SPEED LIMITATION FUNCTION . 363
TRANSMISSION PROTECTION FUNCTION . 365
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED . 365
SHIFT DOWN PROTECTION FUNCTION . 365
ENGINE OVERRUN PREVENTION FUNCTION . 366
MAXIMUM SPEED LIMITATION FUNCTION 366
NEUTRALIZER FUNCTION . 366
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION . 368
TRANSMISSION CUT-OFF FUNCTION 370
COMPONENT PARTS OF POWER TRAIN SYSTEM 372
DRIVE SHAFT 372
TORQUE CONVERTER . 374
LOCKUP CLUTCH ECMV . 377
TRANSMISSION . 380
TRANSMISSION CONTROL VALVE . 396
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV . 398
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 403
AXLE . 405
CONVENTIONAL DIFFERENTIAL 408
LIMITED SLIP DIFFERENTIAL 411
FINAL DRIVE 415
COMBINATION SWITCH . 417
SHIFT HOLD SWITCH 421
KICKDOWN SWITCH 422
WORK EQUIPMENT SYSTEM 423
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 423
WORK EQUIPMENT SYSTEM DIAGRAM 425
WORK EQUIPMENT CONTROL SYSTEM 427
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE . 427
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION . 428
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM . 429
WORK EQUIPMENT LEVER OPERATION FUNCTION 430
BUCKET PRIORITY CONTROL FUNCTION . 430
BOOM STOP MODULATION FUNCTION 430
WORK EQUIPMENT NEUTRAL LOCK SYSTEM . 432
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM . 432
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM . 432
REMOTE POSITIONER SYSTEM . 434
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 434
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 434
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 435
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 435
BUCKET POSITIONER AND BOOM POSITIONER 439
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER . 439
AUTO-DIGGING SYSTEM 440
AUTO-DIGGING SYSTEM DIAGRAM 440
FUNCTION OF AUTO-DIGGING SYSTEM 440
SEMI AUTO-DIGGING SYSTEM . 442
SEMI AUTO-DIGGING SYSTEM DIAGRAM . 442
FUNCTION OF SEMI AUTO-DIGGING SYSTEM . 442
ECSS . 444
ECSS DIAGRAM . 444
FUNCTION OF ECSS . 444
OPERATION OF ECSS 444
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 446
WORK EQUIPMENT LOCK SOLENOID VALVE . 446
PILOT CIRCUIT ACCUMULATOR 447
ECSS CIRCUIT ACCUMULATOR . 448
WORK EQUIPMENT ELECTRIC LEVER 450
MULTIFUNCTION MONO-LEVER . 453
STEERING SYSTEM 454
LAYOUT DRAWING OF STEERING SYSTEM 454
SECONDARY STEERING SYSTEM 455
SECONDARY STEERING SYSTEM DIAGRAM 455
FUNCTION OF SECONDARY STEERING SYSTEM 455
STEERING COLUMN 457
STRUCTURE OF STEERING COLUMN . 457
COMPONENT PARTS OF STEERING SYSTEM . 458
ORBITROL VALVE . 458
STOP VALVE . 462
STEERING VALVE . 463
SECONDARY STEERING PUMP 476
SECONDARY STEERING MOTOR . 477
BRAKE SYSTEM . 478
LAYOUT DRAWING OF BRAKE SYSTEM . 478
LAYOUT DRAWING OF BRAKE COOLING SYSTEM . 479
PARKING BRAKE CONTROL SYSTEM . 480
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 480
OPERATION OF PARKING BRAKE CONTROL SYSTEM 480
BRAKE COOLING CONTROL SYSTEM . 482
BRAKE COOLING CONTROL SYSTEM DIAGRAM . 482
FUNCTION OF BRAKE COOLING CONTROL SYSTEM . 482
COMPONENT PARTS OF BRAKE SYSTEM 483
CHARGE VALVE . 483
PARKING BRAKE SOLENOID VALVE . 489
PARKING BRAKE EMERGENCY RELEASE VALVE 491
BRAKE CIRCUIT ACCUMULATOR 492
BRAKE VALVE 494
BRAKE 498
PARKING BRAKE 501
FLOW PRIORITY VALVE 503
BRAKE COOLING MOTOR 505
BRAKE COOLING PUMP . 506
BRAKE COOLING OIL COOLER . 507
AUTO-GREASING SYSTEM . 508
LAYOUT DRAWING OF AUTO-GREASING SYSTEM . 508
SPECIFICATIONS OF AUTO-GREASING SYSTEM . 509
FUNCTION OF AUTO-GREASING SYSTEM . 511
COMPONENT PARTS OF AUTO-GREASING SYSTEM 512
AUTO-GREASING PUMP . 512
UNDERCARRIAGE AND FRAME 513
FRAME, AXLE MOUNT AND CENTER HINGE PIN . 513
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 513
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN . 514
TIRE . 515
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE . 515
STRUCTURE OF RADIAL TIRE . 515
FUNCTION OF RADIAL TIRE 515
STRUCTURE OF BIAS TIRE . 516
FUNCTION OF BIAS TIRE 516
WORK EQUIPMENT . 517
STRUCTURE OF WORK EQUIPMENT 517
STRUCTURE OF BUCKET 518
CAB AND ITS ATTACHMENTS 519
ROPS CAB . 519
STRUCTURE OF ROPS CAB 519
FUNCTION OF ROPS CAB . 519
20 STANDARD VALUE TABLE 521
CONTENTS . 522
ABBREVIATION LIST 523
STANDARD VALUE TABLE FOR ENGINE 529
STANDARD VALUE TABLE FOR ENGINE: WA380-8 . 529
STANDARD VALUE TABLE FOR MACHINE . 533
STANDARD VALUE TABLE FOR MACHINE: WA380-8 533
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 552
STANDARD VALUE TABLE FOR ELECTRICAL 555
STANDARD VALUE TABLE FOR ELECTRICITY . 555
30 TESTING AND ADJUSTING . 577
CONTENTS . 578
ABBREVIATION LIST 582
RELATED INFORMATION ON TESTING AND ADJUSTING . 588
TOOLS FOR TESTING AND ADJUSTING 588
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 597
ENGINE AND COOLING SYSTEM 598
TEST ENGINE SPEED 598
METHOD FOR TESTING ENGINE SPEED 598
TEST BOOST PRESSURE 604
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR . 604
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 605
TEST EXHAUST GAS TEMPERATURE . 608
METHOD FOR TESTING EXHAUST GAS TEMPERATURE . 608
TEST EXHAUST GAS COLOR . 610
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 610
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 611
TEST AND ADJUST VALVE CLEARANCE 613
METHOD FOR TESTING VALVE CLEARANCE . 613
METHOD FOR ADJUSTING VALVE CLEARANCE . 614
TEST COMPRESSION PRESSURE 616
METHOD FOR TESTING COMPRESSION PRESSURE 616
TEST BLOWBY PRESSURE . 621
METHOD FOR TESTING BLOWBY PRESSURE . 621
TEST ENGINE OIL PRESSURE . 624
METHOD FOR TESTING ENGINE OIL PRESSURE . 624
TEST EGR VALVE AND VGT OIL PRESSURE 626
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 626
TEST FUEL PRESSURE . 628
METHOD FOR TESTING FUEL PRESSURE . 629
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 634
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 635
BLEED AIR FROM FUEL SYSTEM . 641
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 641
TEST FUEL CIRCUIT FOR LEAKAGE 643
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 643
HANDLE CYLINDER CUT-OUT MODE OPERATION . 645
HANDLE NO-INJECTION CRANKING OPERATION . 646
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 647
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 647
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 648
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 648
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 649
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 649
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 650
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 650
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT . 650
TEST ALTERNATOR BELT . 652
METHOD FOR TESTING ALTERNATOR BELT . 652
TEST AUTOMATIC TENSIONER . 654
METHOD FOR TESTING AUTOMATIC TENSIONER . 654
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 657
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 657
TEST SCR RELATED FUNCTIONS . 658
TEST AdBlue/DEF PUMP RAISED PRESSURE . 662
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 665
TEST AdBlue/DEF LINE HEATER RELAY 1 670
TEST AdBlue/DEF LINE HEATER RELAY 2 674
TEST AdBlue/DEF PUMP HEATER RELAY 678
TEST AdBlue/DEF TANK HEATER VALVE 682
TEST SCR NOx REMOVAL EFFICIENCY 686
CLEAN AdBlue/DEF TANK 690
METHOD FOR CLEANING AdBlue/DEF TANK 690
POWER TRAIN 694
TEST AND ADJUST POWER TRAIN OIL PRESSURE . 694
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 697
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 710
ADJUST TRANSMISSION INPUT SPEED SENSOR . 712
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR . 712
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 713
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 713
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 714
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 714
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 716
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE . 716
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 718
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 718
STEERING SYSTEM 719
TEST STEERING WHEEL 719
METHOD FOR TESTING STEERING WHEEL 719
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 721
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE . 721
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE . 723
BLEED AIR FROM STEERING CYLINDER CIRCUIT . 725
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT . 725
TEST AND ADJUST STEERING STOP VALVE 726
METHOD FOR TESTING STEERING STOP VALVE . 726
METHOD FOR ADJUSTING STEERING STOP VALVE . 726
BRAKE SYSTEM . 727
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 727
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT . 727
TEST WHEEL BRAKE OIL PRESSURE 728
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 728
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 730
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE . 730
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE . 731
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 732
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE . 732
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 734
BLEED AIR FROM BRAKE CIRCUIT . 737
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT . 737
TEST BRAKING PERFORMANCE . 738
METHOD FOR TESTING BRAKING PERFORMANCE . 738
TEST BRAKE PEDAL . 739
METHOD FOR TESTING BRAKE PEDAL . 739
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 740
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE . 740
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE . 740
TEST LOWERING OF WHEEL BRAKE PRESSURE 741
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 742
TEST WEAR OF WHEEL BRAKE DISC 744
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 744
TEST PARKING BRAKE OIL PRESSURE 746
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 746
TEST PARKING BRAKE PERFORMANCE . 748
METHOD FOR TESTING PARKING BRAKE PERFORMANCE . 748
RELEASE PARKING BRAKE MANUALLY . 749
METHOD FOR RELEASING PARKING BRAKE MANUALLY 749
TEST WEAR AMOUNT OF PARKING BRAKE DISC . 751
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC . 751
HYDRAULIC SYSTEM . 753
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 753
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 753
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 755
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE . 755
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE . 759
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 761
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE . 761
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE . 763
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 764
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 764
TEST COOLING FAN SPEED . 765
METHOD FOR TESTING COOLING FAN SPEED . 765
TEST COOLING FAN CIRCUIT OIL PRESSURE 767
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 767
BLEED AIR FROM COOLING FAN CIRCUIT . 770
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT . 770
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS . 772
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 772
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS . 774
WORK EQUIPMENT . 778
TEST AND ADJUST BUCKET POSITIONER DETECTION LEVER 778
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 778
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 778
TEST AND ADJUST BOOM POTENTIOMETER LEVER . 780
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 780
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 780
CAB AND ITS ATTACHMENTS 781
TEST DIRECTIONAL LEVER . 781
METHOD FOR TESTING DIRECTIONAL LEVER . 781
TEST WORK EQUIPMENT CONTROL LEVER 782
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 782
ADJUST RATTLING OPERATOR’S SEAT 785
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 785
ELECTRICAL SYSTEM 786
SET AND ADJUST EACH EQUIPMENT 786
SET AND OPERATE MACHINE MONITOR 790
OPERATOR MODE 794
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 794
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 794
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 795
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 796
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 796
SERVICE MODE . 800
METHOD FOR OPERATING SERVICE MODE 800
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 803
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 810
ABNORMALITY RECORD MENU 825
METHOD FOR CONFIRMING MAINTENANCE RECORD . 830
METHOD FOR OPERATING MAINTENANCE MODE SETTING 832
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 837
DEFAULT MENU . 839
DIAGNOSTIC TESTS MENU 855
ADJUSTMENT MENU 867
METHOD FOR PERFORMING NO-INJECTION CRANKING 915
KOMTRAX SETTINGS MENU 917
METHOD FOR DISPLAYING SERVICE MESSAGE 919
METHOD FOR STARTING UP KOMTRAX TERMINAL 921
ADJUST REARVIEW CAMERA ANGLE . 926
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 926
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 928
HANDLE BATTERY DISCONNECT SWITCH . 929
TEST DIODES 930
METHOD FOR TESTING DIODE USING DIGITAL TESTER 930
METHOD FOR TESTING DIODE USING ANALOG TESTER . 930
AUTO-GREASING DEVICE . 931
BLEED THE AIR OF AUTO-GREASING SYSTEM 931
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 931
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 934
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 935
Pm CLINIC 937
Pm CLINIC SERVICE 937
Pm CLINIC CHECK SHEET: WA380-8 . 940
40 TROUBLESHOOTING . 951
CONTENTS . 952
ABBREVIATION LIST 965
RELATED INFORMATION ON TROUBLESHOOTING . 971
GENERAL TROUBLESHOOTING POINTS . 971
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 972
SEQUENCE OF EVENTS IN TROUBLESHOOTING 984
CHECKS BEFORE TROUBLESHOOTING 986
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 988
WALK-AROUND CHECK 988
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 990
CHECK FUEL LEVEL AND TYPE 990
FUEL – CHECK FOR FOREIGN MATERIAL 990
CHECK AdBule/DEF LEVEL AND TYPE 991
CHECK FUEL PREFILTER . 991
CHECK MAIN FILTER 993
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 994
CHECK COOLANT LEVEL (RESERVOIR TANK) . 995
CHECK CLOGGING OF AIR CLEANER 996
OUTER ELEMENT – CLEAN 996
REPLACE ELEMENT 998
CHECK HYDRAULIC OIL LEVEL 999
CHECK HYDRAULIC OIL STRAINER .1000
CHECK HYDRAULIC FILTER .1001
CHECK OIL LEVEL IN TRANSMISSION CASE .1003
CHECK OIL LEVEL IN FRONT AXLE CASE .1004
CHECK OIL LEVEL IN REAR AXLE CASE 1005
BLEED AIR FROM FUEL SYSTEM .1006
BLEED AIR FROM HYDRAULIC SYSTEM 1006
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod .1006
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1012
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1024
SYMPTOM AND TROUBLESHOOTING NUMBERS 1026
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .1031
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1033
CONNECTORS LIST AND LAYOUT .1036
CONNECTOR CONTACT IDENTIFICATION .1056
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1096
FUSE LOCATION TABLE 1102
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1106
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR .1110
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1112
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1118
FAILURE CODES TABLE 1120
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1144
FAILURE CODE [1500L0] 1144
FAILURE CODE [15SAL1] 1145
FAILURE CODE [15SALH] 1147
FAILURE CODE [15SBL1] 1149
FAILURE CODE [15SBLH] 1151
FAILURE CODE [15SEL1] 1153
FAILURE CODE [15SELH] 1155
FAILURE CODE [15SFL1] 1157
FAILURE CODE [15SFLH] 1159
FAILURE CODE [15SGL1] 1161
FAILURE CODE [15SGLH] 1163
FAILURE CODE [15SHL1] 1165
FAILURE CODE [15SHLH] 1167
FAILURE CODE [2F00MA] 1170
FAILURE CODE [2F00MB] 1174
FAILURE CODE [2G42ZG] 1177
FAILURE CODE [2G43ZG] 1179
FAILURE CODE [879AKA] 1181
FAILURE CODE [879AKB] 1183
FAILURE CODE [879BKA] 1185
FAILURE CODE [879BKB] 1187
FAILURE CODE [879CKA] 1189
FAILURE CODE [879CKB] 1191
FAILURE CODE [879DKZ] 1193
FAILURE CODE [879EMC] 1195
FAILURE CODE [879FMC] 1198
FAILURE CODE [989A00] 1201
FAILURE CODE [989L00] 1202
FAILURE CODE [989M00] 1203
FAILURE CODE [989N00] 1204
FAILURE CODE [A1U0N3] 1205
FAILURE CODE [A1U0N4] 1207
FAILURE CODE [AA10NX] 1209
FAILURE CODE [AB00KE] 1211
FAILURE CODE [AB00KY] 1213
FAILURE CODE [AQ10N3] 1215
FAILURE CODE [AS00N3] 1217
FAILURE CODE [AS00R2] 1219
FAILURE CODE [AS00R3] 1220
FAILURE CODE [AS00R4] 1221
FAILURE CODE [AS00R5] 1222
FAILURE CODE [AS00R6] 1223
FAILURE CODE [AS00ZK] 1224
FAILURE CODE [AS10KM] 1225
FAILURE CODE [AS10NR] 1226
FAILURE CODE [AS10NT] 1227
FAILURE CODE [B@BAZG] 1228
FAILURE CODE [B@BAZK] 1229
FAILURE CODE [B@BCNS] 1231
FAILURE CODE [B@BCZK] 1232
FAILURE CODE [B@C7NS] 1234
FAILURE CODE [B@CENS] 1236
FAILURE CODE [B@HANS] 1237
FAILURE CODE [CA115] .1238
FAILURE CODE [CA122] .1239
FAILURE CODE [CA123] .1241
FAILURE CODE [CA131] .1243
FAILURE CODE [CA132] .1245
FAILURE CODE [CA144] .1248
FAILURE CODE [CA145] .1250
FAILURE CODE [CA153] .1252
FAILURE CODE [CA154] .1255
FAILURE CODE [CA187] .1257
FAILURE CODE [CA221] .1259
FAILURE CODE [CA222] .1261
FAILURE CODE [CA227] .1263
FAILURE CODE [CA234] .1264
FAILURE CODE [CA238] .1265
FAILURE CODE [CA239] .1267
FAILURE CODE [CA249] .1269
FAILURE CODE [CA256] .1271
FAILURE CODE [CA271] .1273
FAILURE CODE [CA272] .1275
FAILURE CODE [CA322] .1277
FAILURE CODE [CA323] .1279
FAILURE CODE [CA324] .1281
FAILURE CODE [CA325] .1283
FAILURE CODE [CA331] .1285
FAILURE CODE [CA332] .1287
FAILURE CODE [CA343] .1289
FAILURE CODE [CA351] .1290
FAILURE CODE [CA352] .1291
FAILURE CODE [CA356] .1294
FAILURE CODE [CA357] .1296
FAILURE CODE [CA386] .1299
FAILURE CODE [CA428] .1300
FAILURE CODE [CA429] .1302
FAILURE CODE [CA431] .1304
FAILURE CODE [CA432] .1307
FAILURE CODE [CA435] .1311
FAILURE CODE [CA441] .1313
FAILURE CODE [CA442] .1315
FAILURE CODE [CA449] .1316
FAILURE CODE [CA451] .1317
FAILURE CODE [CA452] .1319
FAILURE CODE [CA488] .1321
FAILURE CODE [CA515] .1322
FAILURE CODE [CA516] .1324
FAILURE CODE [CA553] .1326
FAILURE CODE [CA555] .1327
FAILURE CODE [CA556] .1328
FAILURE CODE [CA559] .1329
FAILURE CODE [CA595] .1332
FAILURE CODE [CA687] .1333
FAILURE CODE [CA689] .1335
FAILURE CODE [CA691] .1338
FAILURE CODE [CA692] .1340
FAILURE CODE [CA697] .1342
FAILURE CODE [CA698] .1343
FAILURE CODE [CA731] .1344
FAILURE CODE [CA778] .1346
FAILURE CODE [CA1117] 1351
FAILURE CODE [CA1664] 1352
FAILURE CODE [CA1669] 1355
FAILURE CODE [CA1673] 1356
FAILURE CODE [CA1677] 1357
FAILURE CODE [CA1678] 1358
FAILURE CODE [CA1682] 1359
FAILURE CODE [CA1683] 1363
FAILURE CODE [CA1684] 1365
FAILURE CODE [CA1686] 1367
FAILURE CODE [CA1691] 1368
FAILURE CODE [CA1694] 1371
FAILURE CODE [CA1695] 1374
FAILURE CODE [CA1696] 1375
FAILURE CODE [CA1712] 1377
FAILURE CODE [CA1713] 1380
FAILURE CODE [CA1714] 1382
FAILURE CODE [CA1715] 1383
FAILURE CODE [CA1776] 1384
FAILURE CODE [CA1777] 1387
FAILURE CODE [CA1843] 1390
FAILURE CODE [CA1844] 1392
FAILURE CODE [CA1879] 1395
FAILURE CODE [CA1881] 1398
FAILURE CODE [CA1883] 1400
FAILURE CODE [CA1885] 1404
FAILURE CODE [CA1887] 1406
FAILURE CODE [CA1921] 1408
FAILURE CODE [CA1922] 1411
FAILURE CODE [CA1942] 1416
FAILURE CODE [CA1993] 1417
FAILURE CODE [CA2185] 1420
FAILURE CODE [CA2186] 1422
FAILURE CODE [CA2249] 1424
FAILURE CODE [CA2271] 1425
FAILURE CODE [CA2272] 1428
FAILURE CODE [CA2288] 1431
FAILURE CODE [CA2311] 1432
FAILURE CODE [CA2349] 1433
FAILURE CODE [CA2353] 1436
FAILURE CODE [CA2357] 1438
FAILURE CODE [CA2381] 1439
FAILURE CODE [CA2382] 1442
FAILURE CODE [CA2383] 1445
FAILURE CODE [CA2386] 1448
FAILURE CODE [CA2387] 1450
FAILURE CODE [CA2555] 1451
FAILURE CODE [CA2556] 1454
FAILURE CODE [CA2637] 1456
FAILURE CODE [CA2639] 1458
FAILURE CODE [CA2771] 1461
FAILURE CODE [CA2777] 1467
FAILURE CODE [CA2976] 1470
FAILURE CODE [CA3133] 1472
FAILURE CODE [CA3134] 1475
FAILURE CODE [CA3135] 1477
FAILURE CODE [CA3142] 1481
FAILURE CODE [CA3143] 1482
FAILURE CODE [CA3144] 1483
FAILURE CODE [CA3146] 1486
FAILURE CODE [CA3147] 1487
FAILURE CODE [CA3148] 1488
FAILURE CODE [CA3151] 1490
FAILURE CODE [CA3165] 1496
FAILURE CODE [CA3229] 1498
FAILURE CODE [CA3231] 1500
FAILURE CODE [CA3232] 1502
FAILURE CODE [CA3235] 1506
FAILURE CODE [CA3239] 1508
FAILURE CODE [CA3241] 1511
FAILURE CODE [CA3242] 1514
FAILURE CODE [CA3251] 1517
FAILURE CODE [CA3253] 1519
FAILURE CODE [CA3254] 1522
FAILURE CODE [CA3255] 1525
FAILURE CODE [CA3256] 1529
FAILURE CODE [CA3311] 1531
FAILURE CODE [CA3312] 1533
FAILURE CODE [CA3313] 1536
FAILURE CODE [CA3314] 1537
FAILURE CODE [CA3315] 1538
FAILURE CODE [CA3316] 1541
FAILURE CODE [CA3317] 1542
FAILURE CODE [CA3318] 1543
FAILURE CODE [CA3319] 1546
FAILURE CODE [CA3321] 1547
FAILURE CODE [CA3322] 1549
FAILURE CODE [CA3419] 1552
FAILURE CODE [CA3421] 1554
FAILURE CODE [CA3497] 1556
FAILURE CODE [CA3498] 1557
FAILURE CODE [CA3543] 1558
FAILURE CODE [CA3545] 1565
FAILURE CODE [CA3547] 1567
FAILURE CODE [CA3558] 1568
FAILURE CODE [CA3559] 1570
FAILURE CODE [CA3562] 1572
FAILURE CODE [CA3563] 1574
FAILURE CODE [CA3567] 1577
FAILURE CODE [CA3568] 1580
FAILURE CODE [CA3571] 1586
FAILURE CODE [CA3572] 1588
FAILURE CODE [CA3574] 1590
FAILURE CODE [CA3575] 1592
FAILURE CODE [CA3577] 1594
FAILURE CODE [CA3578] 1596
FAILURE CODE [CA3582] 1598
FAILURE CODE [CA3583] 1606
FAILURE CODE [CA3596] 1608
FAILURE CODE [CA3649] 1611
FAILURE CODE [CA3681] 1613
FAILURE CODE [CA3682] 1618
FAILURE CODE [CA3713] 1624
FAILURE CODE [CA3717] 1627
FAILURE CODE [CA3718] 1628
FAILURE CODE [CA3725] 1629
FAILURE CODE [CA3741] 1632
FAILURE CODE [CA3748] 1633
FAILURE CODE [CA3751] 1636
FAILURE CODE [CA3755] 1638
FAILURE CODE [CA3866] 1640
FAILURE CODE [CA3867] 1644
FAILURE CODE [CA3868] 1647
FAILURE CODE [CA3899] 1651
FAILURE CODE [CA3911] 1653
FAILURE CODE [CA3912] 1657
FAILURE CODE [CA3932] 1659
FAILURE CODE [CA3933] 1661
FAILURE CODE [CA3934] 1663
FAILURE CODE [CA3935] 1666
FAILURE CODE [CA3936] 1668
FAILURE CODE [CA4151] 1670
FAILURE CODE [CA4152] 1674
FAILURE CODE [CA4155] 1678
FAILURE CODE [CA4156] 1680
FAILURE CODE [CA4157] 1683
FAILURE CODE [CA4158] 1685
FAILURE CODE [CA4159] 1686
FAILURE CODE [CA4161] 1687
FAILURE CODE [CA4162] 1690
FAILURE CODE [CA4163] 1693
FAILURE CODE [CA4164] 1695
FAILURE CODE [CA4165] 1697
FAILURE CODE [CA4166] 1699
FAILURE CODE [CA4168] 1701
FAILURE CODE [CA4169] 1704
FAILURE CODE [CA4171] 1706
FAILURE CODE [CA4249] 1709
FAILURE CODE [CA4251] 1711
FAILURE CODE [CA4259] 1713
FAILURE CODE [CA4261] 1716
FAILURE CODE [CA4277] 1719
FAILURE CODE [CA4281] 1723
FAILURE CODE [CA4459] 1726
FAILURE CODE [CA4461] 1729
FAILURE CODE [CA4658] 1732
FAILURE CODE [CA4731] 1736
FAILURE CODE [CA4732] 1737
FAILURE CODE [CA4739] 1738
FAILURE CODE [CA4768] 1739
FAILURE CODE [CA4769] 1741
FAILURE CODE [CA4842] 1744
FAILURE CODE [CA4952] 1748
FAILURE CODE [CA5115] 1750
FAILURE CODE [CA5179] 1753
FAILURE CODE [CA5181] 1755
FAILURE CODE [CA5383] 1757
FAILURE CODE [D150KA] 1759
FAILURE CODE [D150KB] 1761
FAILURE CODE [D150KY] 1763
FAILURE CODE [D160KA] 1765
FAILURE CODE [D160KB] 1767
FAILURE CODE [D160KY] 1769
FAILURE CODE [D191KA] 1771
FAILURE CODE [D191KB] 1774
FAILURE CODE [D191KY] 1777
FAILURE CODE [D192KA] 1779
FAILURE CODE [D192KB] 1781
FAILURE CODE [D192KY] 1783
FAILURE CODE [D19JKZ] 1784
FAILURE CODE [D1E6KA] 1786
FAILURE CODE [D1E6KB] 1788
FAILURE CODE [D1E6KY] 1790
FAILURE CODE [D5ZHKA] 1792
FAILURE CODE [D5ZHKB] 1794
FAILURE CODE [D5ZHKZ] 1796
FAILURE CODE [D5ZHL6] 1799
FAILURE CODE [D5ZMLD] 1801
FAILURE CODE [D811MC] 1803
FAILURE CODE [D862KA] 1804
FAILURE CODE [D8ALKA] 1805
FAILURE CODE [D8ALKB] 1807
FAILURE CODE [D8AQK4] 1809
FAILURE CODE [D8AQKR] 1810
FAILURE CODE [DAF0KT] 1812
FAILURE CODE [DAF0MB] 1813
FAILURE CODE [DAF0MC] 1814
FAILURE CODE [DAF3KK] 1815
FAILURE CODE [DAF8KB] 1817
FAILURE CODE [DAFDKB] 1819
FAILURE CODE [DAFGMC] 1821
FAILURE CODE [DAFLKA] 1822
FAILURE CODE [DAFLKB] 1824
FAILURE CODE [DAFQKR] 1826
FAILURE CODE [DAQ0KK] 1827
FAILURE CODE [DAQ0KT] 1830
FAILURE CODE [DAQ0MC] 1831
FAILURE CODE [DAQ1KA] 1832
FAILURE CODE [DAQ2KK] 1834
FAILURE CODE [DAQ4KB] 1837
FAILURE CODE [DAQ9KQ] 1839
FAILURE CODE [DAQLKA] 1840
FAILURE CODE [DAQLKB] 1842
FAILURE CODE [DAQQKR] 1844
FAILURE CODE [DAQRKR] 1845
FAILURE CODE [DAQRMA] 1846
FAILURE CODE [DAZ9KQ] 1847
FAILURE CODE [DAZQKR] 1848
FAILURE CODE [DB2QKR] 1849
FAILURE CODE [DB2RKR] 1854
FAILURE CODE [DB90KK] 1860
FAILURE CODE [DB90KT] 1863
FAILURE CODE [DB90MC] 1864
FAILURE CODE [DB91KA] 1865
FAILURE CODE [DB92KK] 1867
FAILURE CODE [DB95KX] 1870
FAILURE CODE [DB96KX] 1873
FAILURE CODE [DB99KQ] 1875
FAILURE CODE [DB9LKA] 1876
FAILURE CODE [DB9LKB] 1878
FAILURE CODE [DB9QKR] 1880
FAILURE CODE [DB9RKR] 1881
FAILURE CODE [DB9RMA] 1882
FAILURE CODE [DBE5KX] 1883
FAILURE CODE [DBE6KX] 1885
FAILURE CODE [DD1ALD] 1887
FAILURE CODE [DDAAL6] 1889
FAILURE CODE [DDB6L4] 1891
FAILURE CODE [DDD1LD] 1894
FAILURE CODE [DDK3KA] 1896
FAILURE CODE [DDK3KB] 1899
FAILURE CODE [DDK6KA] 1902
FAILURE CODE [DDK6KB] 1905
FAILURE CODE [DDKLKA] 1908
FAILURE CODE [DDKLKB] 1911
FAILURE CODE [DDNRKY] 1913
FAILURE CODE [DDNTKY] 1915
FAILURE CODE [DDT0L4] 1917
FAILURE CODE [DDT4LD] 1919
FAILURE CODE [DDT9LD] 1921
FAILURE CODE [DDTALD] 1923
FAILURE CODE [DDW9LD] 1925
FAILURE CODE [DDWLLD] 1927
FAILURE CODE [DF10KA] 1929
FAILURE CODE [DF10KB] 1932
FAILURE CODE [DGF1KA] 1935
FAILURE CODE [DGF1KB] 1937
FAILURE CODE [DGH2KX] 1939
FAILURE CODE [DGR2KB] 1941
FAILURE CODE [DGR2KZ] 1943
FAILURE CODE [DGT1KA] 1945
FAILURE CODE [DGT1KB] 1947
FAILURE CODE [DH21KA] 1949
FAILURE CODE [DH21KB] 1952
FAILURE CODE [DHA4KA] 1954
FAILURE CODE [DHAAMA] 1956
FAILURE CODE [DHACMA] 1958
FAILURE CODE [DHPCKX] 1960
FAILURE CODE [DHPDKX] 1963
FAILURE CODE [DHT1KX] 1966
FAILURE CODE [DHT5KX] 1969
FAILURE CODE [DHT7KX] 1972
FAILURE CODE [DHT8KA] 1975
FAILURE CODE [DHT8KB] 1978
FAILURE CODE [DHT8ZG] 1980
FAILURE CODE [DHUDKA] 1981
FAILURE CODE [DHUDKB] 1984
FAILURE CODE [DJF1KA] 1986
FAILURE CODE [DK55KA] 1988
FAILURE CODE [DK55KY] 1991
FAILURE CODE [DK55L5] 1993
FAILURE CODE [DK59KA] 1994
FAILURE CODE [DK59KY] 1998
FAILURE CODE [DK59L8] 2002
FAILURE CODE [DK5AKA] 2007
FAILURE CODE [DK5AKY] 2011
FAILURE CODE [DK5BKA] 2015
FAILURE CODE [DK5BKY] 2019
FAILURE CODE [DK5BL8] 2023
FAILURE CODE [DK5CKA] 2028
FAILURE CODE [DK5CKY] 2032
FAILURE CODE [DK5DKA] 2036
FAILURE CODE [DK5DKY] 2039
FAILURE CODE [DK5DL8] 2042
FAILURE CODE [DK5EKA] 2046
FAILURE CODE [DK5EKY] 2049
FAILURE CODE [DK5KKA] 2052
FAILURE CODE [DK5KKY] 2055
FAILURE CODE [DK5KL8] 2058
FAILURE CODE [DK5LKA] 2062
FAILURE CODE [DK5LKY] 2065
FAILURE CODE [DKA0KA] 2068
FAILURE CODE [DKA0KY] 2071
FAILURE CODE [DKA0L0] 2074
FAILURE CODE [DKA1KA] 2077
FAILURE CODE [DKA1KY] 2080
FAILURE CODE [DLF1KA] 2083
FAILURE CODE [DLF1LC] 2085
FAILURE CODE [DLM3KA] 2087
FAILURE CODE [DLM3LC] 2089
FAILURE CODE [DLT3KA] 2091
FAILURE CODE [DLT3LC] 2093
FAILURE CODE [DPQ1KR] 2095
FAILURE CODE [DPQ2KR] 2098
FAILURE CODE [DPQ3KR] 2101
FAILURE CODE [DSJ0KR] 2104
FAILURE CODE [DT20KB] 2107
FAILURE CODE [DT22KB] 2109
FAILURE CODE [DT23KB] 2111
FAILURE CODE [DV00KB] 2113
FAILURE CODE [DW4PKA] 2115
FAILURE CODE [DW4PKB] 2117
FAILURE CODE [DW4PKY] 2119
FAILURE CODE [DW4QKA] 2121
FAILURE CODE [DW4QKB] 2123
FAILURE CODE [DW4QKY] 2125
FAILURE CODE [DW4RKA] 2127
FAILURE CODE [DW4RKB] 2129
FAILURE CODE [DW4RKY] 2131
FAILURE CODE [DW4SKA] 2133
FAILURE CODE [DW4SKB] 2135
FAILURE CODE [DW4SKY] 2137
FAILURE CODE [DW7BKA] 2139
FAILURE CODE [DW7BKB] 2141
FAILURE CODE [DW7BKY] 2143
FAILURE CODE [DWM1KA] 2145
FAILURE CODE [DWM1KB] 2147
FAILURE CODE [DWM1KY] 2149
FAILURE CODE [DWN6KA] 2151
FAILURE CODE [DWN6KB] 2153
FAILURE CODE [DWN6KY] 2155
FAILURE CODE [DWN8KA] 2157
FAILURE CODE [DWN8KB] 2159
FAILURE CODE [DWN8KY] 2161
FAILURE CODE [DX16KA] 2163
FAILURE CODE [DX16KB] 2165
FAILURE CODE [DX16KY] 2167
FAILURE CODE [DXA1KA] 2169
FAILURE CODE [DXA1KB] 2171
FAILURE CODE [DXA1KY] 2173
FAILURE CODE [DXANKA] 2175
FAILURE CODE [DXANKB] 2177
FAILURE CODE [DXANKY] 2179
FAILURE CODE [DXH1KA] 2181
FAILURE CODE [DXH1KB] 2183
FAILURE CODE [DXH1KY] 2185
FAILURE CODE [DXH4KA] 2187
FAILURE CODE [DXH4KB] 2189
FAILURE CODE [DXH4KY] 2191
FAILURE CODE [DXH5KA] 2193
FAILURE CODE [DXH5KB] 2195
FAILURE CODE [DXH5KY] 2197
FAILURE CODE [DXH6KA] 2199
FAILURE CODE [DXH6KB] 2201
FAILURE CODE [DXH6KY] 2203
FAILURE CODE [DXH7KA] 2205
FAILURE CODE [DXH7KB] 2207
FAILURE CODE [DXH7KY] 2209
FAILURE CODE [DXH8KA] 2211
FAILURE CODE [DXH8KB] 2213
FAILURE CODE [DXH8KY] 2215
FAILURE CODE [DXHHKA] 2217
FAILURE CODE [DXHHKB] 2219
FAILURE CODE [DXHHKY] 2221
FAILURE CODE [DXHJKA] 2223
FAILURE CODE [DXHJKB] 2225
FAILURE CODE [DXHJKY] 2227
FAILURE CODE [DXHKKA] 2229
FAILURE CODE [DXHKKB] 2231
FAILURE CODE [DXHKKY] 2233
FAILURE CODE [DXJEKA] 2235
FAILURE CODE [DXJEKB] 2237
FAILURE CODE [DXJEKY] 2239
FAILURE CODE [DXJFKA] 2241
FAILURE CODE [DXJFKB] 2243
FAILURE CODE [DXJFKY] 2245
FAILURE CODE [DY30MA] 2247
FAILURE CODE [DY30MC] 2251
FAILURE CODE [DY30ME] 2256
FAILURE CODE [LA00L3] 2258
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2259
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2259
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .2266
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2269
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2272
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING .2274
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING .2277
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) .2280
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY .2283
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2286
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2289
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2293
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2295
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION .2298
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2301
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2304
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2305
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2308
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY .2311
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2314
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL .2318
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP .2320
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP .2322
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2324
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2328
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .2329
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2330
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2332
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT .2333
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL .2335
E-30 ALARM BUZZER DOES NOT SOUND .2336
E-31 ALARM BUZZER DOES NOT STOP SOUNDING .2338
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2339
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2341
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED .2343
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED .2347
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED .2349
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2351
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2353
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE .2355
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2356
E-41 HORN DOES NOT SOUND .2358
E-42 HORN DOES NOT STOP SOUNDING .2361
E-43 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2363
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2365
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT .2369
E-46 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2373
E-47 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT .2375
E-48 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2377
E-49 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) .2382
E-50 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT .2387
E-51 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2391
E-52 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT .2396
E-53 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT .2399
E-54 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT .2402
E-55 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2406
E-56 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2410
E-57 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2413
E-58 FRONT WIPER DOES NOT OPERATE 2415
E-59 REAR WIPER DOES NOT OPERATE .2419
E-60 FAN DOES NOT ROTATE IN REVERSE 2422
E-61 FAN REMAINS ROTATED IN REVERSE 2423
E-62 WINDOW WASHER DOES NOT OPERATE 2424
E-63 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2427
E-64 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2428
E-65 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2430
E-66 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP .2431
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2433
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2433
FAILURE MODE AND CAUSE TABLE .2434
H-1 MACHINE DOES NOT START .2447
H-2 LOCKUP IS NOT RELEASED .2451
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE .2452
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2453
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2457
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED .2460
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2463
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2467
H-9 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) .2470
H-10 STEERING WHEEL IS HEAVY TO OPERATE 2473
H-11 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2474
H-12 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS .2476
H-13 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2477
H-14 WHEEL BRAKES ARE NOT RELEASED OR DRAG .2479
H-15 PARKING BRAKE DOES NOT WORK OR IT IS WEAK .2480
H-16 PARKING BRAKE IS NOT RELEASED OR DRAGS 2481
H-17 BOOM DOES NOT RISE 2483
H-18 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE .2486
H-19 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2489
H-20 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2490
H-21 HYDRAULIC DRIFT OF BOOM IS LARGE 2492
H-22 BOOM MOVES UP AND DOWN DURING OPERATION .2493
H-23 BUCKET DOES NOT TILT BACK .2494
H-24 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2497
H-25 BUCKET DECELERATES DURING TILT-BACK OPERATION .2500
H-26 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2501
H-27 HYDRAULIC DRIFT OF BUCKET IS LARGE 2503
H-28 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) .2504
H-29 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (2-LEVER TYPE OR 3-LEVER TYPE) 2505
H-30 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE) 2506
H-31 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2507
H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2508
H-33 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2510
H-34 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2511
H-35 BUCKET DOES NOT STOP AT THE POSITION WHICH IS SET WITH REMOTE BUCKET POSITIONER .2512
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2513
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2515
TROUBLESHOOTING OF ENGINE (S-MODE) .2516
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2516
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .2517
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .2518
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .2519
S-4 ENGINE STARTABILITY IS POOR 2521
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .2523
S-6 ENGINE STOPS DURING OPERATION 2525
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .2527
S-8 ENGINE LACKS POWER .2528
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2530
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .2532
S-11 OIL BECOMES CONTAMINATED QUICKLY 2533
S-12 FUEL CONSUMPTION IS EXCESSIVE .2534
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2535
S-14 OIL PRESSURE DROPS 2536
S-15 FUEL MIXES INTO ENGINE OIL 2538
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .2539
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2540
S-18 UNUSUAL NOISE IS HEARD 2541
S-19 VIBRATION IS EXCESSIVE 2542
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2543
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2544
S-22 ACTIVE REGENERATION TAKES TIME 2546
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2547
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE .2548
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2550
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM .2551
OUTLINE OF FAILURE DISPLAY .2551
TROUBLESHOOTING FOR FCS 2552
TROUBLESHOOTING FOR AUTO-GREASING PUMP .2553
REPLACEMENT OF PUMP ELEMENT 2556
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM .2557
REPLACEMENT OF AUTO-GREASING CONTROLLER 2559
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2560
TROUBLESHOOTING FOR RDS LOAD METER SYSTEM 2561
OUTLINE OF FAILURE DISPLAY .2561
METHOD FOR DISPLAYING DIAGNOSTICS SCREEN .2562
TROUBLESHOOTING FOR RDS LOAD METER .2563
50 DISASSEMBLY AND ASSEMBLY 2567
CONTENTS .2568
ABBREVIATION LIST 2573
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2579
HOW TO READ THIS MANUAL 2579
COATING MATERIALS LIST .2581
SPECIAL TOOLS LIST .2585
SKETCHES OF SPECIAL TOOLS 2605
ENGINE AND COOLING SYSTEM 2613
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2613
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2613
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2616
REMOVE AND INSTALL INJECTOR ASSEMBLY .2619
METHOD FOR REMOVING INJECTOR ASSEMBLY 2619
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2625
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2634
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2635
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2646
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2662
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2662
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2663
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2665
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2665
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2667
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2671
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2671
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2672
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .2674
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2674
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2675
REMOVE AND INSTALL ALTERNATOR BELT .2677
METHOD FOR REMOVING ALTERNATOR BELT 2677
METHOD FOR INSTALLING ALTERNATOR BELT 2678
REMOVE AND INSTALL AUTOMATIC TENSIONER .2680
METHOD FOR REMOVING AUTOMATIC TENSIONER 2680
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2680
REMOVE AND INSTALL RADIATOR CORE .2681
METHOD FOR REMOVING RADIATOR CORE 2681
METHOD FOR INSTALLING RADIATOR CORE 2688
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2695
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2695
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2698
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2701
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2701
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2703
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2705
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2705
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2709
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY .2714
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2714
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2717
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2721
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2722
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2736
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2751
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2751
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2752
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2753
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2753
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2754
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2756
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2756
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2757
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2761
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2761
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2765
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2769
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2769
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2771
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2774
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2774
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2779
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2783
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2783
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2783
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2785
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2785
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2786
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2792
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2792
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2792
REMOVE AND INSTALL KDPF ASSEMBLY .2793
METHOD FOR REMOVING KDPF ASSEMBLY 2794
METHOD FOR INSTALLING KDPF ASSEMBLY 2803
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2816
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2816
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2820
REMOVE AND INSTALL SCR ASSEMBLY 2825
METHOD FOR REMOVING SCR ASSEMBLY .2826
METHOD FOR INSTALLING SCR ASSEMBLY .2834
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2846
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2846
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2854
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2864
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2864
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2870
REMOVE AND INSTALL KCCV ASSEMBLY .2878
METHOD FOR REMOVING KCCV ASSEMBLY 2878
METHOD FOR INSTALLING KCCV ASSEMBLY 2879
REMOVE AND INSTALL VGT ASSEMBLY 2881
METHOD FOR REMOVING VGT ASSEMBLY .2881
METHOD FOR INSTALLING VGT ASSEMBLY .2884
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2888
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2889
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2896
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2904
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2904
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2907
REMOVE AND INSTALL AdBlue/DEF PUMP .2910
METHOD FOR REMOVING AdBlue/DEF PUMP 2910
METHOD FOR INSTALLING AdBlue/DEF PUMP 2913
REMOVE AND INSTALL AdBlue/DEF HOSE .2916
METHOD FOR REMOVING AdBlue/DEF HOSE 2917
METHOD FOR INSTALLING AdBlue/DEF HOSE 2922
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2930
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2930
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2932
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2934
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2934
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2936
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2939
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2939
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2940
POWER TRAIN 2942
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY .2942
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY .2943
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 2946
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY .2952
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY .2953
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 2961
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 2973
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 2974
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY .2983
DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY 2995
METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY 2996
METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY .2998
REMOVE AND INSTALL FRONT AXLE ASSEMBLY .3006
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3006
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3007
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3010
METHOD FOR REMOVING REAR AXLE ASSEMBLY .3010
METHOD FOR INSTALLING REAR AXLE ASSEMBLY .3013
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY .3018
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY .3019
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3024
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY .3032
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY .3033
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3043
STEERING SYSTEM 3061
REMOVE AND INSTALL STEERING VALVE ASSEMBLY .3061
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3061
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3063
BRAKE SYSTEM .3066
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3066
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE .3066
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE .3069
UNDERCARRIAGE AND FRAME 3072
REMOVE AND INSTALL CENTER HINGE PIN 3072
METHOD FOR REMOVING CENTER HINGE PIN .3072
METHOD FOR INSTALLING CENTER HINGE PIN .3077
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3084
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY .3084
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY .3089
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY .3094
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3094
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3095
HYDRAULIC SYSTEM .3096
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .3096
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3096
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3099
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY .3103
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3103
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3105
REMOVE AND INSTALL STEERING PUMP AND COOLING FAN PUMP ASSEMBLY .3107
METHOD FOR REMOVING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3107
METHOD FOR INSTALLING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3109
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3111
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .3111
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .3115
WORK EQUIPMENT .3119
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .3119
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3119
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3123
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY .3129
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY .3130
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3133
CAB AND ITS ATTACHMENTS 3139
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .3139
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3139
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3143
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3149
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .3149
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .3150
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .3159
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3159
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3165
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3171
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY .3171
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY .3173
REMOVE AND INSTALL SEAT BELT .3175
METHOD FOR REMOVING SEAT BELT 3175
METHOD FOR INSTALLING SEAT BELT 3175
ELECTRICAL SYSTEM 3177
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3177
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .3177
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .3179
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3182
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY .3182
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY .3183
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3186
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY .3186
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY .3186
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY .3188
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3188
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3190
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3192
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .3192
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .3193
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3195
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .3195
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .3195
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3197
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .3197
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .3198
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR .3199
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3199
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3202
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR .3205
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3205
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3208
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3211
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .3211
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .3214
REMOVE AND INSTALL AMMONIA SENSOR 3217
METHOD FOR REMOVING AMMONIA SENSOR .3217
METHOD FOR INSTALLING AMMONIA SENSOR .3218
REMOVE AND INSTALL SCR OUTLET NOx SENSOR .3220
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3220
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3221
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .3223
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3223
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3224
60 MAINTENANCE STANDARD 3225
CONTENTS .3226
ABBREVIATION LIST 3228
ENGINE AND COOLING SYSTEM 3234
MAINTENANCE STANDARD OF ENGINE MOUNT .3234
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP .3235
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3237
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3238
POWER TRAIN 3240
MAINTENANCE STANDARD OF DRIVE SHAFT 3240
MAINTENANCE STANDARD OF TORQUE CONVERTER .3241
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV .3243
MAINTENANCE STANDARD OF TRANSMISSION .3244
MAINTENANCE STANDARD OF F, R CLUTCH 3249
MAINTENANCE STANDARD OF 1ST, 4TH CLUTCH 3250
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH 3251
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE .3252
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV .3253
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3254
MAINTENANCE STANDARD OF FRONT AXLE .3255
MAINTENANCE STANDARD OF REAR AXLE 3256
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3257
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL .3258
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3259
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL .3261
MAINTENANCE STANDARD OF FINAL DRIVE 3263
STEERING SYSTEM 3265
MAINTENANCE STANDARD OF STEERING COLUMN 3265
MAINTENANCE STANDARD OF STEERING PUMP 3266
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP .3269
MAINTENANCE STANDARD OF STEERING VALVE .3270
MAINTENANCE STANDARD OF STEERING CYLINDER 3272
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3274
BRAKE SYSTEM .3275
MAINTENANCE STANDARD OF CHARGE VALVE .3275
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3277
MAINTENANCE STANDARD OF FRONT BRAKE 3278
MAINTENANCE STANDARD OF REAR BRAKE .3279
MAINTENANCE STANDARD OF PARKING BRAKE 3280
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE .3281
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3282
MAINTENANCE STANDARD OF BRAKE COOLING PUMP .3283
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER .3284
UNDERCARRIAGE AND FRAME 3285
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN .3285
HYDRAULIC SYSTEM .3290
MAINTENANCE STANDARD OF HYDRAULIC TANK .3290
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3291
MAINTENANCE STANDARD OF SERVO VALVEWORK OF EQUIPMENT PUMP 3294
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP .3296
MAINTENANCE STANDARD OF CONTROL VALVE 3297
MAINTENANCE STANDARD OF STABILIZER VALVE .3309
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE .3310
WORK EQUIPMENT .3311
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE .3311
MAINTENANCE STANDARD OF BUCKET .3314
MAINTENANCE STANDARD OF LIFT CYLINDER 3315
MAINTENANCE STANDARD OF BUCKET CYLINDER 3316
80 APPENDIX 3317
CONTENTS .3318
ABBREVIATION LIST 3320
AIR CONDITIONER SYSTEM .3326
PRECAUTIONS FOR REFRIGERANT 3326
AIR CONDITIONER COMPONENT 3327
SPECIFICATIONS OF AIR CONDITIONER 3329
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3330
OUTLINE OF REFRIGERATION CYCLE .3331
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3333
AIR CONDITIONER UNIT .3333
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3333
FUNCTION OF AIR CONDITIONER UNIT .3334
COMPONENT PARTS OF AIR CONDITIONER UNIT 3335
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .3335
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3335
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT .3336
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT .3336
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3336
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3336
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3336
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3337
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3337
FUNCTION OF DUAL PRESSURE SWITCH .3337
AIR CONDITIONER CONTROLLER .3338
STRUCTURE OF AIR CONDITIONER CONTROLLER 3338
COMPRESSOR .3339
STRUCTURE OF COMPRESSOR 3339
SPECIFICATIONS OF COMPRESSOR .3339
FUNCTION OF COMPRESSOR .3339
CONDENSER 3340
STRUCTURE OF CONDENSER .3340
SPECIFICATIONS OF CONDENSER 3340
FUNCTION OF CONDENSER 3340
RECEIVER DRIER .3341
STRUCTURE OF RECEIVER DRIER 3341
SPECIFICATIONS OF RECEIVER DRIER .3341
FUNCTION OF RECEIVER DRIER .3341
SENSORS FOR AIR CONDITIONER SYSTEM .3342
FUNCTION OF SUNLIGHT SENSOR 3342
FUNCTION OF AMBIENT TEMPERATURE SENSOR .3342
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3343
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3345
AIR CONDITIONER SYSTEM DIAGRAM .3348
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .3349
FUNCTION OF AIR CONDITIONER CONTROLLER .3350
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3351
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3357
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .3358
CHECK TEMPERATURE CONTROL FUNCTION .3359
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION .3359
TEST VENT (MODE) CHANGEOVER 3361
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3361
TESTING FRESH/RECIRC AIR CHANGEOVER 3363
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .3363
TEST EVAPORATOR TEMPERATURE SENSOR .3365
TEST RELAYS 3367
METHOD FOR TESTING RELAYS 3367
AIR CONDITIONER TROUBLESHOOTING CHART 1 3369
AIR CONDITIONER TROUBLESHOOTING CHART 2 3370
FAILURE CODE [879AKA] 3373
FAILURE CODE [879AKB] 3375
FAILURE CODE [879BKA] 3377
FAILURE CODE [879BKB] 3379
FAILURE CODE [879CKA] 3381
FAILURE CODE [879CKB] 3383
FAILURE CODE [879DKZ] 3385
FAILURE CODE [879EMC] 3387
FAILURE CODE [879FMC] 3390
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) .3393
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3396
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .3399
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3403
TROUBLESHOOTING USING GAUGE PRESSURE .3405
CONNECTION OF SERVICE TOOL .3408
METHOD FOR CONNECTING SERVICE TOOL .3409
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3410
HANDLE COMPRESSOR OIL 3412
90 CIRCUIT DIAGRAMS 3415
CONTENTS .3416
ABBREVIATION LIST 3417
HYDRAULIC CIRCUIT DIAGRAM 3423
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3423
HYDRAULIC CIRCUIT DIAGRAM 3427
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3429
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM .3431
HYDRAULIC AUTO-GREASING DIAGRAM 3433
ELECTRICAL CIRCUIT DIAGRAM .3435
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .3435
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10) .3439
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10) .3441
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10) .3443
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10) .3445
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10) .3447
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10) .3449
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10) .3451
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10) .3453
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10) .3455
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10) 3457
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8) 3459
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8) 3461
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8) 3463
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8) 3465
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8) 3467
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8) 3469
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8) 3471
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8) 3473
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) .3475
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) .3477
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) .3479
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) .3481
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) .3483
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) .3485
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) .3487
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) .3489
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) .3491
RDS LOAD METER SYSTEM ELECTRICAL CIRCUIT DIAGRAM .3493
INDEX .3495

DESCRIPTION:

Komatsu WA380-8 Wheel Loader Shop Manual VENBM48500  – PDF DOWNLOAD

• 15001 and up
• H65051 and up

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

G.B 28/12/24