Komatsu WA470-8 Wheel Loader Shop Manual VENBM49500 – PDF DOWNLOAD

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Komatsu WA470-8 Wheel Loader Shop Manual VENBM49500 – PDF DOWNLOAD

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Komatsu WA470-8 Wheel Loader Shop Manual VENBM49500 – PDF DOWNLOAD

Language : English
Pages : 3690
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA470-8 Wheel Loader Shop Manual VENBM49500 – PDF DOWNLOAD

• 100001 and up
• H55051 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: WA470-8 . 105
SPECIFICATIONS . 107
SPECIFICATIONS: WA470-8 107
WEIGHT TABLE . 112
WEIGHT TABLE:WA470-8 . 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 136
COMPONENT PARTS OF UREA SCR SYSTEM . 150
AdBlue/DEF MIXING TUBE . 150
SCR ASSEMBLY . 151
AdBlue/DEF TANK 153
AdBlue/DEF PUMP 155
AdBlue/DEF INJECTOR 156
AdBlue/DEF HOSE 157
AdBlue/DEF TANK HEATING VALVE 158
BOOT-UP SYSTEM . 159
LAYOUT DRAWING OF BOOT-UP SYSTEM . 159
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 168
ENGINE CONTROL SYSTEM 169
ENGINE CONTROL SYSTEM DIAGRAM 169
FUNCTION OF ENGINE CONTROL SYSTEM 170
OPERATION OF ENGINE CONTROL SYSTEM . 173
ENGINE POWER MODE SELECTOR SYSTEM 175
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 175
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 175
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM . 175
AUTOMATIC IDLE STOP SYSTEM . 177
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 177
COMPONENT PARTS OF ENGINE SYSTEM . 178
VGT 178
EGR SYSTEM . 182
EGR VALVE 184
EGR COOLER . 186
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 300
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP . 312
CONTROL VALVE 313
POWER TRAIN SYSTEM . 347
LAYOUT DRAWING OF POWER TRAIN SYSTEM . 347
OPERATION OF POWER TRAIN SYSTEM 350
TRANSMISSION CONTROL SYSTEM 351
TRANSMISSION CONTROL SYSTEM DIAGRAM 351
TRANSMISSION GEAR SHIFT CONTROL SYSTEM . 353
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 353
ELECTRIC MODULATION FUNCTION . 354
DISPLAY FUNCTION OF GEAR SHIFT . 354
AUTOMATIC GEAR SHIFT FUNCTION 354
SHIFT HOLD FUNCTION 355
KICKDOWN FUNCTION 355
AUTOMATIC KICKDOWN FUNCTION 356
TORQUE CONVERTER LOCKUP FUNCTION . 356
HUNTING PREVENTION FUNCTION 357
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT . 357
SHIFT POINT CHANGING FUNCTION 357
4TH GEAR SPEED LIMITATION FUNCTION . 357
TRANSMISSION PROTECTION FUNCTION . 359
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED . 359
SHIFT DOWN PROTECTION FUNCTION . 359
ENGINE OVERRUN PREVENTION FUNCTION . 360
MAXIMUM SPEED LIMITATION FUNCTION 360
NEUTRALIZER FUNCTION . 360
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION . 362
TRANSMISSION CUT-OFF FUNCTION 364
COMPONENT PARTS OF POWER TRAIN SYSTEM 366
DRIVE SHAFT 366
TORQUE CONVERTER . 368
LOCKUP CLUTCH ECMV . 371
TRANSMISSION . 374
TRANSMISSION CONTROL VALVE . 391
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV . 394
3RD AND 4TH CLUTCH ECMV 399
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 404
AXLE . 406
CONVENTIONAL DIFFERENTIAL 408
LIMITED SLIP DIFFERENTIAL 411
FINAL DRIVE 416
COMBINATION SWITCH . 418
SHIFT HOLD SWITCH 422
KICKDOWN SWITCH 423
WORK EQUIPMENT SYSTEM 424
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 424
WORK EQUIPMENT SYSTEM DIAGRAM 426
WORK EQUIPMENT CONTROL SYSTEM 428
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE . 428
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
JOYSTICK STEERING SYSTEM . 457
FUNCTION OF JOYSTICK STEERING SYSTEM . 457
JOYSTICK CONTROL FUNCTION 457
JOYSTICK NEUTRAL SAFETY FUNCTION . 460
JOYSTICK NEUTRAL INTERLOCK FUNCTION 460
JOYSTICK SPEED SENSING STEERING FUNCTION . 460
JOYSTICK Hi/Lo SELECTOR FUNCTION . 461
STEERING COLUMN 462
STRUCTURE OF STEERING COLUMN . 462
COMPONENT PARTS OF STEERING SYSTEM . 463
ORBITROL VALVE . 464
STOP VALVE . 468
STEERING VALVE . 469
SECONDARY STEERING PUMP 482
SECONDARY STEERING MOTOR . 483
JOYSTICK KNOB 484
BRAKE SYSTEM . 485
LAYOUT DRAWING OF BRAKE SYSTEM . 485
LAYOUT DRAWING OF BRAKE COOLING SYSTEM . 486
PARKING BRAKE CONTROL SYSTEM . 489
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 489
OPERATION OF PARKING BRAKE CONTROL SYSTEM 489
BRAKE COOLING CONTROL SYSTEM . 491
BRAKE COOLING CONTROL SYSTEM DIAGRAM . 491
FUNCTION OF BRAKE COOLING CONTROL SYSTEM . 492
COMPONENT PARTS OF BRAKE SYSTEM 493
CHARGE VALVE . 493
PARKING BRAKE SOLENOID VALVE . 499
PARKING BRAKE EMERGENCY RELEASE VALVE 501
BRAKE CIRCUIT ACCUMULATOR 502
BRAKE VALVE 504
SLACK ADJUSTER . 508
BRAKE 510
PARKING BRAKE 513
FLOW PRIORITY VALVE 515
BRAKE COOLING MOTOR 517
BRAKE COOLING PUMP . 520
BRAKE COOLING OIL COOLER . 521
AUTO-GREASING SYSTEM . 522
LAYOUT DRAWING OF AUTO-GREASING SYSTEM . 522
SPECIFICATIONS OF AUTO-GREASING SYSTEM . 524
FUNCTION OF AUTO-GREASING SYSTEM . 526
COMPONENT PARTS OF AUTO-GREASING SYSTEM 527
AUTO-GREASING PUMP . 527
UNDERCARRIAGE AND FRAME 528
FRAME, AXLE MOUNT AND CENTER HINGE PIN . 528
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN . 528
TIRE . 530
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE . 530
STRUCTURE OF RADIAL TIRE . 530
FUNCTION OF RADIAL TIRE 530
STRUCTURE OF BIAS TIRE . 531
FUNCTION OF BIAS TIRE 531
WORK EQUIPMENT . 532
STRUCTURE OF WORK EQUIPMENT 532
STRUCTURE OF BUCKET 533
CAB AND ITS ATTACHMENTS 534
ROPS CAB . 534
STRUCTURE OF ROPS CAB 534
FUNCTION OF ROPS CAB . 534
20 STANDARD VALUE TABLE 535
CONTENTS . 536
ABBREVIATION LIST 537
STANDARD VALUE TABLE FOR ENGINE 543
STANDARD VALUE TABLE FOR ENGINE: WA470-8 . 543
STANDARD VALUE TABLE FOR MACHINE . 547
STANDARD VALUE TABLE FOR MACHINE: WA470-8 547
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 566
STANDARD VALUE TABLE FOR ELECTRICAL 569
STANDARD VALUE TABLE FOR ELECTRICITY . 569
30 TESTING AND ADJUSTING . 589
CONTENTS . 590
ABBREVIATION LIST 594
RELATED INFORMATION ON TESTING AND ADJUSTING . 600
TOOLS FOR TESTING AND ADJUSTING 600
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 609
ENGINE AND COOLING SYSTEM 611
TEST ENGINE SPEED 611
METHOD FOR TESTING ENGINE SPEED 611
TEST BOOST PRESSURE 617
METHOD FOR TESTING BOOST PRESSURE 617
TESTING EXHAUST GAS TEMPERATURE 620
METHOD FOR TESTING EXHAUST GAS TEMPERATURE . 620
TEST EXHAUST GAS COLOR . 622
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 622
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 624
TEST AND ADJUST VALVE CLEARANCE 625
METHOD FOR TESTING VALVE CLEARANCE . 625
METHOD FOR ADJUSTING VALVE CLEARANCE . 627
TEST COMPRESSION PRESSURE 628
METHOD FOR TESTING COMPRESSION PRESSURE 628
TEST BLOWBY PRESSURE . 632
METHOD FOR TESTING BLOWBY PRESSURE . 632
TEST ENGINE OIL PRESSURE . 635
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 635
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL . 636
TEST EGR VALVE AND VGT OIL PRESSURE 637
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 637
TEST FUEL PRESSURE . 639
METHOD FOR TESTING FUEL PRESSURE . 639
TEST FUEL RETURN RATE AND LEAKAGE 641
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 642
BLEEDING AIR FROM FUEL SYSTEM 645
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 646
TEST FUEL CIRCUIT FOR LEAKAGE 647
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 647
HANDLE CYLINDER CUT-OUT MODE OPERATION . 649
HANDLE NO-INJECTION CRANKING OPERATION . 650
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 651
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 651
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 652
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 652
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 653
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 653
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 654
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION . 654
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION . 654
TEST ALTERNATOR BELT . 656
METHOD FOR TESTING ALTERNATOR BELT . 656
TEST AUTOMATIC TENSIONER . 658
METHOD FOR TESTING AUTOMATIC TENSIONER . 658
CLEAN FUEL DOSER . 661
METHOD FOR CLEANING FUEL DOSER . 661
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER . 663
METHOD FOR WRITING INJECTOR COMPENSATION VALUE . 663
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
POWER TRAIN 707
TEST AND ADJUST POWER TRAIN OIL PRESSURE . 707
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 709
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 726
ADJUST TRANSMISSION INPUT SPEED SENSOR . 728
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR . 728
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 730
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 730
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 731
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 731
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 734
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE . 735
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 738
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 738
STEERING SYSTEM 739
TEST STEERING WHEEL 739
METHOD FOR TESTING STEERING WHEEL 739
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 741
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE . 741
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE . 744
BLEED AIR FROM STEERING CYLINDER CIRCUIT . 745
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT . 745
TEST AND ADJUST STEERING STOP VALVE 747
METHOD FOR TESTING STEERING STOP VALVE . 747
METHOD FOR ADJUSTING STEERING STOP VALVE . 747
BRAKE SYSTEM . 748
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 748
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT . 748
TEST WHEEL BRAKE OIL PRESSURE 749
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 749
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 752
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE . 752
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE . 753
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 754
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE . 754
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 756
BLEED AIR FROM BRAKE CIRCUIT . 759
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT . 759
TEST BRAKING PERFORMANCE . 762
METHOD FOR TESTING BRAKING PERFORMANCE . 762
TEST BRAKE PEDAL . 763
METHOD FOR TESTING BRAKE PEDAL . 763
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 764
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE . 764
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE . 764
TEST LOWERING OF WHEEL BRAKE PRESSURE 765
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 766
TEST WEAR OF WHEEL BRAKE DISC 768
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 768
TEST PARKING BRAKE OIL PRESSURE 770
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 770
TEST PARKING BRAKE PERFORMANCE . 772
METHOD FOR TESTING PARKING BRAKE PERFORMANCE . 772
RELEASE PARKING BRAKE MANUALLY . 773
METHOD FOR RELEASING PARKING BRAKE MANUALLY 773
TEST WEAR AMOUNT OF PARKING BRAKE DISC . 775
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC . 775
HYDRAULIC SYSTEM . 777
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 777
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 777
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 779
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE . 779
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE . 784
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 785
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE . 785
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE . 788
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 790
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 790
TEST COOLING FAN SPEED . 791
METHOD FOR TESTING COOLING FAN SPEED . 791
TEST COOLING FAN CIRCUIT OIL PRESSURE 793
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 793
BLEED AIR FROM COOLING FAN CIRCUIT . 796
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT . 796
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS . 798
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 798
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS . 800
WORK EQUIPMENT . 804
TEST AND ADJUST BUCKET POTENTIOMETER LEVER . 804
METHOD FOR TESTING BUCKET POSITIONER DETECTION LEVER . 804
METHOD FOR ADJUSTING BUCKET POSITIONER DETECTION LEVER . 804
TEST AND ADJUST BOOM POTENTIOMETER LEVER . 806
METHOD FOR TESTING BOOM POSITION DETECTION LEVER . 806
METHOD FOR ADJUSTING BOOM POSITION DETECTION LEVER . 806
CAB AND ITS ATTACHMENTS 807
TEST DIRECTIONAL LEVER . 807
METHOD FOR TESTING DIRECTIONAL LEVER . 807
TEST WORK EQUIPMENT CONTROL LEVER 808
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 808
ADJUST RATTLING OPERATOR’S SEAT 811
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 811
ELECTRICAL SYSTEM 812
SET AND ADJUST EACH EQUIPMENT 812
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT . 814
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT . 816
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING . 819
SET AND OPERATE MACHINE MONITOR 824
OPERATOR MODE 828
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 828
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 828
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 829
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 830
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 830
SERVICE MODE . 834
METHOD FOR OPERATING SERVICE MODE 834
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 837
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 844
ABNORMALITY RECORD MENU 860
METHOD FOR CONFIRMING MAINTENANCE RECORD . 865
METHOD FOR OPERATING MAINTENANCE MODE SETTING 867
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 872
DEFAULT MENU . 874
DIAGNOSTIC TESTS MENU 889
ADJUSTMENT MENU 901
METHOD FOR PERFORMING NO-INJECTION CRANKING 935
KOMTRAX SETTINGS MENU 938
METHOD FOR DISPLAYING SERVICE MESSAGE 940
METHOD FOR STARTING UP KOMTRAX TERMINAL 942
ADJUST REARVIEW CAMERA ANGLE . 947
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 947
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 949
HANDLE BATTERY DISCONNECT SWITCH . 950
TEST DIODES 951
METHOD FOR TESTING DIODE USING DIGITAL TESTER 951
METHOD FOR TESTING DIODE USING ANALOG TESTER . 951
AUTO-GREASING DEVICE . 952
BLEED THE AIR OF AUTO-GREASING SYSTEM 952
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 952
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 955
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE . 955
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 956
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 957
Pm CLINIC 959
Pm CLINIC SERVICE 959
Pm CLINIC CHECK SHEET 962
40 TROUBLESHOOTING . 973
CONTENTS . 974
ABBREVIATION LIST 987
RELATED INFORMATION ON TROUBLESHOOTING . 993
GENERAL TROUBLESHOOTING POINTS . 993
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 994
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1006
CHECKS BEFORE TROUBLESHOOTING 1008
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1010
WALK-AROUND CHECK 1010
TESTING IN ACCORDANCE WITH TESTING PROCEDURE .1012
CHECK FUEL LEVEL AND TYPE 1012
CHECK IMPURE INGREDIENT IN FUEL 1012
CHECK AdBule/DEF LEVEL AND TYPE 1013
CHECK FUEL PREFILTER .1013
CHECK MAIN FILTER 1015
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1016
CHECK COOLANT LEVEL (RESERVOIR TANK) .1016
CHECK CLOGGING OF AIR CLEANER 1017
OUTER ELEMENT – CLEAN 1018
REPLACE ELEMENT 1020
CHECK HYDRAULIC OIL LEVEL 1021
CHECK HYDRAULIC OIL STRAINER .1022
CHECK HYDRAULIC FILTER .1023
CHECK OIL LEVEL IN TRANSMISSION CASE .1024
CHECK OIL LEVEL IN FRONT AXLE CASE .1026
CHECK OIL LEVEL IN REAR AXLE CASE 1027
BLEED AIR FROM FUEL SYSTEM .1027
BLEED AIR FROM HYDRAULIC SYSTEM 1027
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod .1027
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1033
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1045
SYMPTOM AND TROUBLESHOOTING NUMBERS 1047
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .1052
CONNECTORS LIST AND LAYOUT .1054
CONNECTOR CONTACT IDENTIFICATION .1074
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1114
FUSE LOCATION TABLE 1120
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1124
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR .1128
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1130
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1136
FAILURE CODES TABLE 1138
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1162
FAILURE CODE [1500L0] 1162
FAILURE CODE [15SAL1] 1163
FAILURE CODE [15SALH] 1165
FAILURE CODE [15SBL1] 1167
FAILURE CODE [15SBLH] 1169
FAILURE CODE [15SEL1] 1171
FAILURE CODE [15SELH] 1173
FAILURE CODE [15SFL1] 1175
FAILURE CODE [15SFLH] 1177
FAILURE CODE [15SGL1] 1179
FAILURE CODE [15SGLH] 1181
FAILURE CODE [15SHL1] 1183
FAILURE CODE [15SHLH] 1185
FAILURE CODE [2F00MA] 1188
FAILURE CODE [2F00MB] 1192
FAILURE CODE [2G42ZG] 1195
FAILURE CODE [2G43ZG] 1197
FAILURE CODE [879AKA] 1199
FAILURE CODE [879AKB] 1201
FAILURE CODE [879BKA] 1203
FAILURE CODE [879BKB] 1205
FAILURE CODE [879CKA] 1207
FAILURE CODE [879CKB] 1209
FAILURE CODE [879DKZ] 1211
FAILURE CODE [879EMC] 1213
FAILURE CODE [879FMC] 1216
FAILURE CODE [989A00] 1219
FAILURE CODE [989L00] 1220
FAILURE CODE [989M00] 1221
FAILURE CODE [989N00] 1222
FAILURE CODE [A1U0N3] 1223
FAILURE CODE [A1U0N4] 1225
FAILURE CODE [AA10NX] 1227
FAILURE CODE [AB00KE] 1229
FAILURE CODE [AB00KY] 1231
FAILURE CODE [AQ10N3] 1233
FAILURE CODE [AS00N3] 1235
FAILURE CODE [AS00R2] 1237
FAILURE CODE [AS00R3] 1238
FAILURE CODE [AS00R4] 1239
FAILURE CODE [AS00R5] 1240
FAILURE CODE [AS00R6] 1241
FAILURE CODE [AS00ZK] 1242
FAILURE CODE [AS10KM] 1243
FAILURE CODE [AS10NR] 1244
FAILURE CODE [AS10NT] 1245
FAILURE CODE [B@BAZG] 1246
FAILURE CODE [B@BAZK] 1247
FAILURE CODE [B@BCNS] 1249
FAILURE CODE [B@BCZK] 1250
FAILURE CODE [B@C7NS] 1252
FAILURE CODE [B@CENS] 1254
FAILURE CODE [B@HANS] 1255
FAILURE CODE [CA115] .1256
FAILURE CODE [CA122] .1257
FAILURE CODE [CA123] .1259
FAILURE CODE [CA131] .1261
FAILURE CODE [CA132] .1263
FAILURE CODE [CA135] .1266
FAILURE CODE [CA141] .1268
FAILURE CODE [CA144] .1270
FAILURE CODE [CA145] .1272
FAILURE CODE [CA153] .1274
FAILURE CODE [CA154] .1277
FAILURE CODE [CA187] .1280
FAILURE CODE [CA221] .1282
FAILURE CODE [CA222] .1284
FAILURE CODE [CA227] .1286
FAILURE CODE [CA234] .1287
FAILURE CODE [CA238] .1288
FAILURE CODE [CA239] .1290
FAILURE CODE [CA249] .1292
FAILURE CODE [CA256] .1294
FAILURE CODE [CA271] .1296
FAILURE CODE [CA272] .1298
FAILURE CODE [CA273] .1299
FAILURE CODE [CA274] .1301
FAILURE CODE [CA322] .1302
FAILURE CODE [CA323] .1304
FAILURE CODE [CA324] .1306
FAILURE CODE [CA325] .1308
FAILURE CODE [CA331] .1310
FAILURE CODE [CA332] .1312
FAILURE CODE [CA343] .1314
FAILURE CODE [CA351] .1315
FAILURE CODE [CA352] .1316
FAILURE CODE [CA356] .1319
FAILURE CODE [CA357] .1321
FAILURE CODE [CA386] .1323
FAILURE CODE [CA431] .1324
FAILURE CODE [CA432] .1327
FAILURE CODE [CA441] .1331
FAILURE CODE [CA442] .1333
FAILURE CODE [CA449] .1334
FAILURE CODE [CA451] .1335
FAILURE CODE [CA452] .1337
FAILURE CODE [CA515] .1339
FAILURE CODE [CA516] .1341
FAILURE CODE [CA553] .1343
FAILURE CODE [CA555] .1344
FAILURE CODE [CA556] .1345
FAILURE CODE [CA559] .1346
FAILURE CODE [CA595] .1351
FAILURE CODE [CA687] .1352
FAILURE CODE [CA689] .1354
FAILURE CODE [CA691] .1356
FAILURE CODE [CA692] .1358
FAILURE CODE [CA697] .1360
FAILURE CODE [CA698] .1361
FAILURE CODE [CA731] .1362
FAILURE CODE [CA778] .1363
FAILURE CODE [CA1117] 1366
FAILURE CODE [CA1664] 1367
FAILURE CODE [CA1669] 1370
FAILURE CODE [CA1673] 1371
FAILURE CODE [CA1677] 1372
FAILURE CODE [CA1678] 1373
FAILURE CODE [CA1682] 1374
FAILURE CODE [CA1683] 1378
FAILURE CODE [CA1684] 1380
FAILURE CODE [CA1686] 1382
FAILURE CODE [CA1691] 1383
FAILURE CODE [CA1694] 1386
FAILURE CODE [CA1695] 1388
FAILURE CODE [CA1696] 1389
FAILURE CODE [CA1712] 1391
FAILURE CODE [CA1713] 1394
FAILURE CODE [CA1714] 1396
FAILURE CODE [CA1715] 1397
FAILURE CODE [CA1776] 1398
FAILURE CODE [CA1777] 1401
FAILURE CODE [CA1843] 1404
FAILURE CODE [CA1844] 1406
FAILURE CODE [CA1879] 1409
FAILURE CODE [CA1881] 1412
FAILURE CODE [CA1883] 1414
FAILURE CODE [CA1885] 1418
FAILURE CODE [CA1887] 1420
FAILURE CODE [CA1921] 1422
FAILURE CODE [CA1922] 1425
FAILURE CODE [CA1923] 1430
FAILURE CODE [CA1924] 1432
FAILURE CODE [CA1925] 1434
FAILURE CODE [CA1927] 1436
FAILURE CODE [CA1928] 1438
FAILURE CODE [CA1942] 1440
FAILURE CODE [CA1963] 1441
FAILURE CODE [CA1977] 1445
FAILURE CODE [CA1993] 1448
FAILURE CODE [CA2185] 1451
FAILURE CODE [CA2186] 1453
FAILURE CODE [CA2249] 1455
FAILURE CODE [CA2265] 1456
FAILURE CODE [CA2266] 1458
FAILURE CODE [CA2271] 1461
FAILURE CODE [CA2272] 1463
FAILURE CODE [CA2349] 1465
FAILURE CODE [CA2353] 1467
FAILURE CODE [CA2357] 1469
FAILURE CODE [CA2381] 1470
FAILURE CODE [CA2382] 1472
FAILURE CODE [CA2383] 1474
FAILURE CODE [CA2386] 1476
FAILURE CODE [CA2387] 1478
FAILURE CODE [CA2555] 1479
FAILURE CODE [CA2556] 1481
FAILURE CODE [CA2637] 1483
FAILURE CODE [CA2639] 1485
FAILURE CODE [CA2732] 1488
FAILURE CODE [CA2733] 1490
FAILURE CODE [CA2741] 1492
FAILURE CODE [CA2765] 1493
FAILURE CODE [CA2771] 1494
FAILURE CODE [CA2777] 1500
FAILURE CODE [CA2878] 1503
FAILURE CODE [CA2881] 1506
FAILURE CODE [CA2976] 1509
FAILURE CODE [CA3133] 1511
FAILURE CODE [CA3134] 1513
FAILURE CODE [CA3135] 1515
FAILURE CODE [CA3142] 1519
FAILURE CODE [CA3143] 1520
FAILURE CODE [CA3144] 1521
FAILURE CODE [CA3146] 1524
FAILURE CODE [CA3147] 1525
FAILURE CODE [CA3148] 1526
FAILURE CODE [CA3151] 1528
FAILURE CODE [CA3165] 1534
FAILURE CODE [CA3167] 1536
FAILURE CODE [CA3229] 1539
FAILURE CODE [CA3231] 1541
FAILURE CODE [CA3232] 1543
FAILURE CODE [CA3235] 1547
FAILURE CODE [CA3239] 1549
FAILURE CODE [CA3241] 1552
FAILURE CODE [CA3242] 1555
FAILURE CODE [CA3251] 1558
FAILURE CODE [CA3253] 1560
FAILURE CODE [CA3254] 1563
FAILURE CODE [CA3255] 1566
FAILURE CODE [CA3256] 1570
FAILURE CODE [CA3311] 1572
FAILURE CODE [CA3312] 1574
FAILURE CODE [CA3313] 1577
FAILURE CODE [CA3314] 1578
FAILURE CODE [CA3315] 1579
FAILURE CODE [CA3316] 1582
FAILURE CODE [CA3317] 1583
FAILURE CODE [CA3318] 1584
FAILURE CODE [CA3319] 1587
FAILURE CODE [CA3321] 1588
FAILURE CODE [CA3322] 1590
FAILURE CODE [CA3419] 1593
FAILURE CODE [CA3421] 1595
FAILURE CODE [CA3497] 1597
FAILURE CODE [CA3498] 1598
FAILURE CODE [CA3543] 1599
FAILURE CODE [CA3545] 1606
FAILURE CODE [CA3547] 1608
FAILURE CODE [CA3558] 1609
FAILURE CODE [CA3559] 1611
FAILURE CODE [CA3562] 1613
FAILURE CODE [CA3563] 1615
FAILURE CODE [CA3567] 1618
FAILURE CODE [CA3568] 1621
FAILURE CODE [CA3571] 1627
FAILURE CODE [CA3572] 1629
FAILURE CODE [CA3574] 1631
FAILURE CODE [CA3575] 1633
FAILURE CODE [CA3577] 1635
FAILURE CODE [CA3578] 1637
FAILURE CODE [CA3582] 1639
FAILURE CODE [CA3583] 1647
FAILURE CODE [CA3596] 1649
FAILURE CODE [CA3649] 1652
FAILURE CODE [CA3681] 1654
FAILURE CODE [CA3682] 1659
FAILURE CODE [CA3713] 1665
FAILURE CODE [CA3717] 1668
FAILURE CODE [CA3718] 1669
FAILURE CODE [CA3725] 1670
FAILURE CODE [CA3748] 1673
FAILURE CODE [CA3751] 1676
FAILURE CODE [CA3755] 1678
FAILURE CODE [CA3866] 1680
FAILURE CODE [CA3867] 1684
FAILURE CODE [CA3868] 1687
FAILURE CODE [CA3899] 1691
FAILURE CODE [CA3911] 1693
FAILURE CODE [CA3912] 1697
FAILURE CODE [CA3932] 1699
FAILURE CODE [CA3933] 1701
FAILURE CODE [CA3934] 1703
FAILURE CODE [CA3935] 1706
FAILURE CODE [CA3936] 1708
FAILURE CODE [CA4151] 1710
FAILURE CODE [CA4152] 1714
FAILURE CODE [CA4155] 1718
FAILURE CODE [CA4156] 1720
FAILURE CODE [CA4157] 1723
FAILURE CODE [CA4158] 1725
FAILURE CODE [CA4159] 1726
FAILURE CODE [CA4161] 1727
FAILURE CODE [CA4162] 1730
FAILURE CODE [CA4163] 1733
FAILURE CODE [CA4164] 1735
FAILURE CODE [CA4165] 1737
FAILURE CODE [CA4166] 1739
FAILURE CODE [CA4168] 1741
FAILURE CODE [CA4169] 1744
FAILURE CODE [CA4171] 1746
FAILURE CODE [CA4249] 1749
FAILURE CODE [CA4251] 1751
FAILURE CODE [CA4259] 1753
FAILURE CODE [CA4261] 1756
FAILURE CODE [CA4277] 1759
FAILURE CODE [CA4281] 1763
FAILURE CODE [CA4459] 1766
FAILURE CODE [CA4461] 1769
FAILURE CODE [CA4658] 1772
FAILURE CODE [CA4731] 1776
FAILURE CODE [CA4732] 1777
FAILURE CODE [CA4739] 1778
FAILURE CODE [CA4768] 1779
FAILURE CODE [CA4769] 1781
FAILURE CODE [CA4842] 1784
FAILURE CODE [CA4952] 1788
FAILURE CODE [CA5115] 1790
FAILURE CODE [CA5179] 1793
FAILURE CODE [CA5181] 1795
FAILURE CODE [CA5383] 1797
FAILURE CODE [D150KA] 1799
FAILURE CODE [D150KB] 1801
FAILURE CODE [D150KY] 1803
FAILURE CODE [D160KA] 1805
FAILURE CODE [D160KB] 1807
FAILURE CODE [D160KY] 1809
FAILURE CODE [D191KA] 1811
FAILURE CODE [D191KB] 1814
FAILURE CODE [D191KY] 1817
FAILURE CODE [D192KA] 1819
FAILURE CODE [D192KB] 1821
FAILURE CODE [D192KY] 1823
FAILURE CODE [D193KA] 1824
FAILURE CODE [D193KB] 1826
FAILURE CODE [D193KY] 1828
FAILURE CODE [D193MC] 1830
FAILURE CODE [D19JKZ] 1832
FAILURE CODE [D1E6KA] 1834
FAILURE CODE [D1E6KB] 1836
FAILURE CODE [D1E6KY] 1838
FAILURE CODE [D5ZHKA] 1840
FAILURE CODE [D5ZHKB] 1842
FAILURE CODE [D5ZHKZ] 1844
FAILURE CODE [D5ZHL6] 1847
FAILURE CODE [D811MC] 1849
FAILURE CODE [D862KA] 1850
FAILURE CODE [D8ALKA] 1851
FAILURE CODE [D8ALKB] 1853
FAILURE CODE [D8AQK4] 1855
FAILURE CODE [D8AQKR] 1856
FAILURE CODE [DAF0KT] 1858
FAILURE CODE [DAF0MB] 1859
FAILURE CODE [DAF0MC] 1860
FAILURE CODE [DAF3KK] 1861
FAILURE CODE [DAF8KB] 1863
FAILURE CODE [DAFDKB] 1865
FAILURE CODE [DAFGMC] 1867
FAILURE CODE [DAFLKA] 1868
FAILURE CODE [DAFLKB] 1870
FAILURE CODE [DAFQKR] 1872
FAILURE CODE [DAQ0KK] 1873
FAILURE CODE [DAQ0KT] 1876
FAILURE CODE [DAQ0MC] 1877
FAILURE CODE [DAQ1KA] 1878
FAILURE CODE [DAQ2KK] 1880
FAILURE CODE [DAQ4KB] 1883
FAILURE CODE [DAQ9KQ] 1885
FAILURE CODE [DAQLKA] 1886
FAILURE CODE [DAQLKB] 1888
FAILURE CODE [DAQQKR] 1890
FAILURE CODE [DAQRKR] 1891
FAILURE CODE [DAQRMA] 1892
FAILURE CODE [DAZ9KQ] 1893
FAILURE CODE [DAZQKR] 1894
FAILURE CODE [DB2QKR] 1895
FAILURE CODE [DB2RKR] 1900
FAILURE CODE [DB90KK] 1906
FAILURE CODE [DB90KT] 1909
FAILURE CODE [DB90MC] 1910
FAILURE CODE [DB91KA] 1911
FAILURE CODE [DB92KK] 1913
FAILURE CODE [DB95KX] 1916
FAILURE CODE [DB96KX] 1920
FAILURE CODE [DB99KQ] 1922
FAILURE CODE [DB9LKA] 1923
FAILURE CODE [DB9LKB] 1925
FAILURE CODE [DB9QKR] 1927
FAILURE CODE [DB9RKR] 1928
FAILURE CODE [DB9RMA] 1929
FAILURE CODE [DBE5KX] 1930
FAILURE CODE [DBE6KX] 1932
FAILURE CODE [DD1ALD] 1934
FAILURE CODE [DDAAL6] 1936
FAILURE CODE [DDB6L4] 1938
FAILURE CODE [DDD1LD] 1941
FAILURE CODE [DDK3KA] 1943
FAILURE CODE [DDK3KB] 1946
FAILURE CODE [DDK6KA] 1949
FAILURE CODE [DDK6KB] 1952
FAILURE CODE [DDKLKA] 1955
FAILURE CODE [DDKLKB] 1958
FAILURE CODE [DDNRKY] 1960
FAILURE CODE [DDT0L4] 1962
FAILURE CODE [DDT4LD] 1964
FAILURE CODE [DDT9LD] 1966
FAILURE CODE [DDTALD] 1968
FAILURE CODE [DDW9LD] 1970
FAILURE CODE [DDWLLD] 1972
FAILURE CODE [DF10KA] 1974
FAILURE CODE [DF10KB] 1977
FAILURE CODE [DGF1KA] 1980
FAILURE CODE [DGF1KB] 1982
FAILURE CODE [DGH2KX] 1984
FAILURE CODE [DGR2KB] 1986
FAILURE CODE [DGR2KZ] 1988
FAILURE CODE [DGT1KA] 1990
FAILURE CODE [DGT1KB] 1992
FAILURE CODE [DH21KA] 1994
FAILURE CODE [DH21KB] 1997
FAILURE CODE [DHA4KA] 1999
FAILURE CODE [DHAAMA] 2001
FAILURE CODE [DHACMA] 2003
FAILURE CODE [DHPCKX] 2005
FAILURE CODE [DHPDKX] 2008
FAILURE CODE [DHT1KX] 2011
FAILURE CODE [DHT5KX] 2014
FAILURE CODE [DHT7KX] 2017
FAILURE CODE [DHT8KA] 2020
FAILURE CODE [DHT8KB] 2023
FAILURE CODE [DHT8ZG] 2025
FAILURE CODE [DHUDKA] 2026
FAILURE CODE [DHUDKB] 2029
FAILURE CODE [DJF1KA] 2031
FAILURE CODE [DK55KA] 2033
FAILURE CODE [DK55KY] 2036
FAILURE CODE [DK55L5] 2038
FAILURE CODE [DK59KA] 2039
FAILURE CODE [DK59KY] 2043
FAILURE CODE [DK59L8] 2047
FAILURE CODE [DK5AKA] 2052
FAILURE CODE [DK5AKY] 2056
FAILURE CODE [DK5BKA] 2060
FAILURE CODE [DK5BKY] 2064
FAILURE CODE [DK5BL8] 2068
FAILURE CODE [DK5CKA] 2073
FAILURE CODE [DK5CKY] 2077
FAILURE CODE [DK5DKA] 2081
FAILURE CODE [DK5DKY] 2084
FAILURE CODE [DK5DL8] 2087
FAILURE CODE [DK5EKA] 2091
FAILURE CODE [DK5EKY] 2094
FAILURE CODE [DK5FKA] 2097
FAILURE CODE [DK5FKY] 2100
FAILURE CODE [DK5FL8] 2103
FAILURE CODE [DK5GKA] 2107
FAILURE CODE [DK5GKY] 2110
FAILURE CODE [DKA0KA] 2113
FAILURE CODE [DKA0KY] 2116
FAILURE CODE [DKA0L0] 2119
FAILURE CODE [DKA1KA] 2122
FAILURE CODE [DKA1KY] 2125
FAILURE CODE [DLF1KA] 2128
FAILURE CODE [DLF1LC] 2130
FAILURE CODE [DLM3KA] 2132
FAILURE CODE [DLM3LC] 2134
FAILURE CODE [DLT3KA] 2136
FAILURE CODE [DLT3LC] 2138
FAILURE CODE [DPQ1KR] 2140
FAILURE CODE [DPQ2KR] 2143
FAILURE CODE [DPQ3KR] 2146
FAILURE CODE [DSJ0KR] 2149
FAILURE CODE [DT20KB] 2152
FAILURE CODE [DT22KB] 2154
FAILURE CODE [DT23KB] 2156
FAILURE CODE [DV00KB] 2158
FAILURE CODE [DW4PKA] 2160
FAILURE CODE [DW4PKB] 2162
FAILURE CODE [DW4PKY] 2164
FAILURE CODE [DW4QKA] 2166
FAILURE CODE [DW4QKB] 2168
FAILURE CODE [DW4QKY] 2170
FAILURE CODE [DW4RKA] 2172
FAILURE CODE [DW4RKB] 2174
FAILURE CODE [DW4RKY] 2176
FAILURE CODE [DW4SKA] 2178
FAILURE CODE [DW4SKB] 2180
FAILURE CODE [DW4SKY] 2182
FAILURE CODE [DW7BKA] 2184
FAILURE CODE [DW7BKB] 2186
FAILURE CODE [DW7BKY] 2188
FAILURE CODE [DWM1KA] 2190
FAILURE CODE [DWM1KB] 2192
FAILURE CODE [DWM1KY] 2194
FAILURE CODE [DWN6KA] 2196
FAILURE CODE [DWN6KB] 2198
FAILURE CODE [DWN6KY] 2200
FAILURE CODE [DWN8KA] 2202
FAILURE CODE [DWN8KB] 2204
FAILURE CODE [DWN8KY] 2206
FAILURE CODE [DX16KA] 2208
FAILURE CODE [DX16KB] 2210
FAILURE CODE [DX16KY] 2212
FAILURE CODE [DXA1KA] 2214
FAILURE CODE [DXA1KB] 2216
FAILURE CODE [DXA1KY] 2218
FAILURE CODE [DXANKA] 2220
FAILURE CODE [DXANKB] 2222
FAILURE CODE [DXANKY] 2224
FAILURE CODE [DXH1KA] 2226
FAILURE CODE [DXH1KB] 2228
FAILURE CODE [DXH1KY] 2230
FAILURE CODE [DXH4KA] 2232
FAILURE CODE [DXH4KB] 2234
FAILURE CODE [DXH4KY] 2236
FAILURE CODE [DXH5KA] 2238
FAILURE CODE [DXH5KB] 2240
FAILURE CODE [DXH5KY] 2242
FAILURE CODE [DXH6KA] 2244
FAILURE CODE [DXH6KB] 2246
FAILURE CODE [DXH6KY] 2248
FAILURE CODE [DXH7KA] 2250
FAILURE CODE [DXH7KB] 2252
FAILURE CODE [DXH7KY] 2254
FAILURE CODE [DXH8KA] 2256
FAILURE CODE [DXH8KB] 2258
FAILURE CODE [DXH8KY] 2260
FAILURE CODE [DXHHKA] 2262
FAILURE CODE [DXHHKB] 2264
FAILURE CODE [DXHHKY] 2266
FAILURE CODE [DXHJKA] 2268
FAILURE CODE [DXHJKB] 2270
FAILURE CODE [DXHJKY] 2272
FAILURE CODE [DXHKKA] 2274
FAILURE CODE [DXHKKB] 2276
FAILURE CODE [DXHKKY] 2278
FAILURE CODE [DXHLKA] 2280
FAILURE CODE [DXHLKB] 2282
FAILURE CODE [DXHLKY] 2284
FAILURE CODE [DXHMKA] 2286
FAILURE CODE [DXHMKB] 2288
FAILURE CODE [DXHMKY] 2290
FAILURE CODE [DY30MA] 2292
FAILURE CODE [DY30MC] 2296
FAILURE CODE [DY30ME] 2301
FAILURE CODE [LA00L3] 2303
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2304
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2304
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .2311
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2314
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2317
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING .2319
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING .2322
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) .2325
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY .2328
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2331
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2334
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2338
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2340
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION .2343
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2346
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2349
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2350
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2353
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY .2356
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2359
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL .2363
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP .2365
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP .2367
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2369
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2373
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .2374
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2375
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2377
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT .2378
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL .2380
E-30 ALARM BUZZER DOES NOT SOUND .2381
E-31 ALARM BUZZER DOES NOT STOP SOUNDING .2383
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2384
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2386
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED .2388
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED .2392
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED .2394
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2396
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2398
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE .2400
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2401
E-41 HORN DOES NOT SOUND .2403
E-42 HORN DOES NOT SOUND (JOYSTICKSTEERING SPECIFICATION) 2406
E-43 HORN DOES NOT STOP SOUNDING .2409
E-44 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2412
E-45 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2414
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT .2418
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2422
E-48 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT .2424
E-49 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2426
E-50 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) .2431
E-51 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT .2436
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2440
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT .2445
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT .2448
E-55 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT .2451
E-56 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2455
E-57 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2459
E-58 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2462
E-59 FRONT WIPER DOES NOT OPERATE 2464
E-60 REAR WIPER DOES NOT OPERATE .2468
E-61 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY .2471
E-62 FAN DOES NOT ROTATE IN REVERSE 2474
E-63 FAN REMAINS ROTATED IN REVERSE 2475
E-64 WINDOW WASHER DOES NOT OPERATE 2476
E-65 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2479
E-66 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2480
E-67 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2482
E-68 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP .2483
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2485
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2485
FAILURE MODE AND CAUSE TABLE .2486
H-1 MACHINE DOES NOT START .2502
H-2 LOCKUP IS NOT RELEASED .2506
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE .2507
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2508
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2512
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED .2515
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2518
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2521
H-9 MACHINE DOES NOT TURN (JOYSTICKSTEERING SPECIFICATION) .2523
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2525
H-11 TURNING RESPONSE IS POOR (JOYSTICKSTEERING SPECIFICATION) .2527
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2529
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2530
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (JOYSTICKSTEERING SPECIFICATION) .2532
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS .2534
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2535
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG .2537
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK .2538
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS 2539
H-20 BOOM DOES NOT RISE 2541
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE .2543
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2545
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2546
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE 2548
H-25 BOOM MOVES UP AND DOWN DURING OPERATION .2549
H-26 BUCKET DOES NOT TILT BACK .2550
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2552
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION .2554
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2555
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE 2557
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) .2558
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE .2559
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2560
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2561
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2564
H-36 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2565
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2566
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2568
TROUBLESHOOTING OF ENGINE (S-MODE) .2569
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2569
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .2570
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .2571
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .2572
S-4 ENGINE STARTABILITY IS POOR 2573
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .2575
S-6 ENGINE STOPS DURING OPERATION 2577
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .2579
S-8 ENGINE LACKS POWER .2580
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2582
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .2584
S-11 OIL BECOMES CONTAMINATED QUICKLY 2585
S-12 FUEL CONSUMPTION IS EXCESSIVE .2586
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2587
S-14 OIL PRESSURE DROPS 2588
S-15 FUEL MIXES INTO ENGINE OIL 2590
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .2591
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2592
S-18 UNUSUAL NOISE IS HEARD 2593
S-19 VIBRATION IS EXCESSIVE 2594
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2595
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2596
S-22 ACTIVE REGENERATION TAKES TIME 2598
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2600
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE .2601
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2603
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2604
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM .2605
OUTLINE OF FAILURE DISPLAY .2605
TROUBLESHOOTING FOR FCS 2606
TROUBLESHOOTING FOR AUTO-GREASING PUMP .2607
REPLACEMENT OF PUMP ELEMENT 2610
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM .2611
REPLACEMENT OF AUTO-GREASING CONTROLLER 2613
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2614
TROUBLESHOOTING FOR RDS LOAD METER SYSTEM 2615
OUTLINE OF FAILURE DISPLAY .2615
METHOD FOR DISPLAYING DIAGNOSTICS SCREEN .2616
TROUBLESHOOTING FOR RDS LOAD METER .2617
50 DISASSEMBLY AND ASSEMBLY 2621
CONTENTS .2622
ABBREVIATION LIST 2627
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2633
HOW TO READ THIS MANUAL 2633
COATING MATERIALS LIST .2635
SPECIAL TOOLS LIST .2639
SKETCHES OF SPECIAL TOOLS 2660
ENGINE AND COOLING SYSTEM 2683
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2683
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2683
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2687
REMOVE AND INSTALL INJECTOR ASSEMBLY .2693
METHOD FOR REMOVING INJECTOR ASSEMBLY 2693
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2697
REMOVE AND INSTALL FUEL DOSER ASSEMBLY .2705
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2705
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2706
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2709
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2709
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2720
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2737
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2737
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2737
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2739
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2739
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2741
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2744
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2744
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2745
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .2747
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2747
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2749
REMOVE AND INSTALL ALTERNATOR BELT .2752
METHOD FOR REMOVING ALTERNATOR BELT 2752
METHOD FOR INSTALLING ALTERNATOR BELT 2753
REMOVE AND INSTALL AUTOMATIC TENSIONER .2755
METHOD FOR REMOVING AUTOMATIC TENSIONER 2755
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2755
REMOVE AND INSTALL RADIATOR ASSEMBLY .2756
METHOD FOR REMOVING RADIATOR ASSEMBLY 2756
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2761
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2766
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2766
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2769
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2771
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2771
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2773
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2775
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2775
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2779
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY .2783
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2783
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2788
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2794
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2795
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2810
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2825
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2825
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2826
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2828
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2828
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2829
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2832
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2832
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2833
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2840
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2840
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2846
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2853
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2853
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2856
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2861
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2861
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2865
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2869
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2869
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2874
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2878
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2878
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2879
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2885
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2885
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2885
REMOVE AND INSTALL KDPF ASSEMBLY .2886
METHOD FOR REMOVING KDPF ASSEMBLY 2887
METHOD FOR INSTALLING KDPF ASSEMBLY 2899
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2912
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2912
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2916
REMOVE AND INSTALL SCR ASSEMBLY 2921
METHOD FOR REMOVING SCR ASSEMBLY .2922
METHOD FOR INSTALLING SCR ASSEMBLY .2931
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2943
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2944
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2953
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2963
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2963
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2968
REMOVE AND INSTALL KCCV ASSEMBLY .2976
METHOD FOR REMOVING KCCV ASSEMBLY 2976
METHOD FOR INSTALLING KCCV ASSEMBLY 2976
REMOVE AND INSTALL VGT ASSEMBLY 2978
METHOD FOR REMOVING VGT ASSEMBLY .2978
METHOD FOR INSTALLING VGT ASSEMBLY .2984
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2990
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2991
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2997
REMOVE AND INSTALL AdBlue/DEF INJECTOR .3006
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3006
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3010
REMOVE AND INSTALL AdBlue/DEF PUMP .3014
METHOD FOR REMOVING AdBlue/DEF PUMP 3014
METHOD FOR INSTALLING AdBlue/DEF PUMP 3017
REMOVE AND INSTALL AdBlue/DEF HOSE .3020
METHOD FOR REMOVING AdBlue/DEF HOSE 3021
METHOD FOR INSTALLING AdBlue/DEF HOSE 3030
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3041
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .3041
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .3042
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .3044
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3044
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3045
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3047
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .3047
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .3048
POWER TRAIN 3050
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY .3050
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY .3050
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3054
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY .3062
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY .3064
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY .3082
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3109
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3110
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY .3126
REMOVE AND INSTALL FRONT AXLE ASSEMBLY .3146
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3146
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3148
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3150
METHOD FOR REMOVING REAR AXLE ASSEMBLY .3150
METHOD FOR INSTALLING REAR AXLE ASSEMBLY .3157
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY .3165
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY .3166
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3171
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY .3179
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY .3180
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3189
STEERING SYSTEM 3208
REMOVE AND INSTALL STEERING VALVE ASSEMBLY .3208
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3208
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3210
BRAKE SYSTEM .3213
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3213
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE .3213
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE .3216
UNDERCARRIAGE AND FRAME 3219
REMOVE AND INSTALL CENTER HINGE PIN 3219
METHOD FOR REMOVING CENTER HINGE PIN .3219
METHOD FOR INSTALLING CENTER HINGE PIN .3225
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3232
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY .3232
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY .3234
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY .3238
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3238
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3239
HYDRAULIC SYSTEM .3240
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .3240
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3240
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3244
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY .3248
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3248
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3249
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY .3251
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3251
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3252
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3255
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .3255
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .3258
WORK EQUIPMENT .3262
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .3262
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3262
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3266
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY .3271
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY .3272
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3275
CAB AND ITS ATTACHMENTS 3281
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .3281
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3281
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3286
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3291
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .3291
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .3292
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .3301
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3301
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3307
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3312
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY .3312
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY .3314
REMOVE AND INSTALL SEAT BELT .3316
METHOD FOR REMOVING SEAT BELT 3316
METHOD FOR INSTALLING SEAT BELT 3316
ELECTRICAL SYSTEM 3318
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3318
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .3318
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .3320
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3323
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY .3323
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY .3324
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3327
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY .3327
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY .3327
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY .3329
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3329
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3331
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3333
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .3333
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .3334
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3336
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .3336
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .3337
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3338
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .3338
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .3339
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR .3340
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3340
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3345
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR .3350
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3350
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3355
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3359
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .3359
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .3363
REMOVE AND INSTALL AMMONIA SENSOR 3368
METHOD FOR REMOVING AMMONIA SENSOR .3368
METHOD FOR INSTALLING AMMONIA SENSOR .3372
REMOVE AND INSTALL SCR OUTLET NOx SENSOR .3377
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3377
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3381
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .3386
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3386
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3387
60 MAINTENANCE STANDARD 3389
CONTENTS .3390
ABBREVIATION LIST 3392
ENGINE AND COOLING SYSTEM 3398
MAINTENANCE STANDARD OF ENGINE MOUNT .3398
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP .3399
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3401
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3402
POWER TRAIN 3404
MAINTENANCE STANDARD OF DRIVE SHAFT 3404
MAINTENANCE STANDARD OF TORQUE CONVERTER .3405
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV .3407
MAINTENANCE STANDARD OF TRANSMISSION .3408
MAINTENANCE STANDARD OF F, 1ST CLUTCH 3414
MAINTENANCE STANDARD OF R, 2ND CLUTCH 3416
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH 3418
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE .3420
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV .3422
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV .3423
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3424
MAINTENANCE STANDARD OF FRONT AXLE .3425
MAINTENANCE STANDARD OF REAR AXLE 3426
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3427
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL .3430
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3433
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL .3435
MAINTENANCE STANDARD OF FINAL DRIVE 3437
STEERING SYSTEM 3440
MAINTENANCE STANDARD OF STEERING COLUMN 3440
MAINTENANCE STANDARD OF STEERING PUMP 3441
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP .3444
MAINTENANCE STANDARD OF STEERING VALVE .3445
MAINTENANCE STANDARD OF STEERING CYLINDER 3447
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3449
BRAKE SYSTEM .3450
MAINTENANCE STANDARD OF CHARGE VALVE .3450
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3452
MAINTENANCE STANDARD OF SLACK ADJUSTER .3453
MAINTENANCE STANDARD OF FRONT BRAKE 3454
MAINTENANCE STANDARD OF REAR BRAKE .3455
MAINTENANCE STANDARD OF PARKING BRAKE 3456
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE .3458
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3459
MAINTENANCE STANDARD OF BRAKE COOLING PUMP .3460
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER .3461
UNDERCARRIAGE AND FRAME 3462
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN .3462
HYDRAULIC SYSTEM .3467
MAINTENANCE STANDARD OF HYDRAULIC TANK .3467
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3469
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP .3471
MAINTENANCE STANDARD OF CONTROL VALVE 3472
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE .3481
WORK EQUIPMENT .3482
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE .3482
MAINTENANCE STANDARD OF BUCKET .3486
MAINTENANCE STANDARD OF LIFT CYLINDER 3487
MAINTENANCE STANDARD OF BUCKET CYLINDER 3488
80 APPENDIX 3489
CONTENTS .3490
ABBREVIATION LIST 3492
AIR CONDITIONER SYSTEM .3498
PRECAUTIONS FOR REFRIGERANT 3498
AIR CONDITIONER COMPONENT 3499
SPECIFICATIONS OF AIR CONDITIONER 3501
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3502
OUTLINE OF REFRIGERATION CYCLE .3503
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3505
AIR CONDITIONER UNIT .3505
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3505
FUNCTION OF AIR CONDITIONER UNIT .3506
COMPONENT PARTS OF AIR CONDITIONER UNIT 3507
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .3507
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3507
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT .3508
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT .3508
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3508
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3508
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3508
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3508
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3509
FUNCTION OF DUAL PRESSURE SWITCH .3509
AIR CONDITIONER CONTROLLER .3510
STRUCTURE OF AIR CONDITIONER CONTROLLER 3510
COMPRESSOR .3511
STRUCTURE OF COMPRESSOR 3511
SPECIFICATIONS OF COMPRESSOR .3511
FUNCTION OF COMPRESSOR .3511
CONDENSER 3512
STRUCTURE OF CONDENSER .3512
SPECIFICATIONS OF CONDENSER 3512
FUNCTION OF CONDENSER 3512
RECEIVER DRIER .3513
STRUCTURE OF RECEIVER DRIER 3513
SPECIFICATIONS OF RECEIVER DRIER .3513
FUNCTION OF RECEIVER DRIER .3513
SENSORS FOR AIR CONDITIONER SYSTEM .3514
FUNCTION OF SUNLIGHT SENSOR 3514
FUNCTION OF AMBIENT TEMPERATURE SENSOR .3514
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3515
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3517
AIR CONDITIONER SYSTEM DIAGRAM .3520
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .3521
FUNCTION OF AIR CONDITIONER CONTROLLER .3522
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3523
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3529
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .3530
CHECK TEMPERATURE CONTROL FUNCTION .3531
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION .3531
TEST VENT (MODE) CHANGEOVER 3533
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3533
TESTING FRESH/RECIRC AIR CHANGEOVER 3535
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .3535
TEST EVAPORATOR TEMPERATURE SENSOR .3537
TEST RELAYS 3539
METHOD FOR TESTING RELAYS 3539
AIR CONDITIONER TROUBLESHOOTING CHART 1 3541
AIR CONDITIONER TROUBLESHOOTING CHART 2 3542
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .3545
FAILURE CODE [879AKA] 3547
FAILURE CODE [879AKB] 3549
FAILURE CODE [879BKA] 3551
FAILURE CODE [879BKB] 3553
FAILURE CODE [879CKA] 3555
FAILURE CODE [879CKB] 3557
FAILURE CODE [879DKZ] 3559
FAILURE CODE [879EMC] 3561
FAILURE CODE [879FMC] 3564
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) .3567
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3570
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .3573
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3577
TROUBLESHOOTING USING GAUGE PRESSURE .3579
CONNECTION OF SERVICE TOOL .3582
METHOD FOR CONNECTING SERVICE TOOL .3583
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3584
HANDLE COMPRESSOR OIL 3586
90 CIRCUIT DIAGRAMS 3589
CONTENTS .3590
ABBREVIATION LIST 3591
HYDRAULIC CIRCUIT DIAGRAM 3597
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3597
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC) 3601
HYDRAULIC CIRCUIT DIAGRAM (FOR JOYSTICK STEERING SPEC) .3603
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3605
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM .3607
HYDRAULIC AUTO-GREASING DIAGRAM 3609
ELECTRICAL CIRCUIT DIAGRAM .3611
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .3611
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/9) 3615
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/9) 3617
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/9) 3619
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/9) 3621
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/9) 3623
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/9) 3625
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/9) 3627
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/9) 3629
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/9) 3631
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8) 3633
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8) 3635
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8) 3637
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8) 3639
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8) 3641
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8) 3643
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8) 3645
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8) 3647
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) .3649
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) .3651
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) .3653
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) .3655
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) .3657
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) .3659
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) .3661
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) .3663
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) .3665
RDS LOAD METER SYSTEM ELECTRICAL CIRCUIT DIAGRAM .3667
INDEX .3669

DESCRIPTION:

Komatsu WA470-8 Wheel Loader Shop Manual VENBM49500 – PDF DOWNLOAD

• 100001 and up
• H55051 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 30/12/24