Komatsu WA470-8E0 Wheel Loader Shop Manual SEN06753-00 PDF

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Komatsu WA470-8E0 Wheel Loader Shop Manual SEN06753-00 –  PDF DOWNLOAD

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Komatsu WA470-8E0 Wheel Loader Shop Manual SEN06753-00 –  PDF DOWNLOAD

Language : English
Pages : 3666
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA470-8E0 Wheel Loader Shop Manual SEN06753-00 –  PDF DOWNLOAD

• SERIAL NUMBERS 100439 and up

COVER . 1
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: WA470-8E0 . 105
SPECIFICATIONS . 107
SPECIFICATIONS: WA470-8E0 107
WEIGHT TABLE . 112
WEIGHT TABLE:WA470-8E0 . 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 Ad Blue/DEF SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM . 151
Ad Blue/DEF MIXING TUBE . 151
SCR ASSEMBLY . 152
Ad Blue/DEF TANK 154
Ad Blue/DEF PUMP 156
Ad Blue/DEF INJECTOR 157
Ad Blue/DEF HOSE 158
Ad Blue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM . 160
LAYOUT DRAWING OF BOOT-UP SYSTEM . 160
SYSTEM OPERATING LAMP SYSTEM . 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 162
BATTERY DISCONNECT SWITCH 163
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 163
FUNCTION OF BATTERY DISCONNECT SWITCH 163
PREHEATING SYSTEM 165
PREHEATING SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 165
OPERATION OF AUTOMATIC PREHEATING SYSTEM . 165
FUNCTION OF MANUAL PREHEATING SYSTEM . 166
OPERATION OF MANUAL PREHEATING SYSTEM 166
ENGINE SYSTEM 167
LAYOUT DRAWING OF ENGINE SYSTEM 167
FUNCTION OF ENGINE SYSTEM 169
ENGINE CONTROL SYSTEM 170
ENGINE CONTROL SYSTEM DIAGRAM 170
FUNCTION OF ENGINE CONTROL SYSTEM 171
OPERATION OF ENGINE CONTROL SYSTEM . 174
ENGINE POWER MODE SELECTOR SYSTEM 176
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 176
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 176
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM . 176
AUTOMATIC IDLE STOP SYSTEM . 178
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 178
COMPONENT PARTS OF ENGINE SYSTEM . 179
VGT 179
EGR SYSTEM . 182
EGR VALVE 184
EGR COOLER . 186
KCCV SYSTEM 187
KCCV VENTILATOR 189
KDPF . 191
COOLING SYSTEM . 196
LAYOUT DRAWING OF COOLING SYSTEM . 196
SPECIFICATIONS OF COOLING SYSTEM . 197
COOLING FAN CONTROL SYSTEM . 199
COOLING FAN CONTROL SYSTEM DIAGRAM . 199
FUNCTION OF COOLING FAN CONTROL SYSTEM . 199
COMPONENT PARTS OF COOLING SYSTEM 204
BRAKE AND COOLING FAN PUMP . 204
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 . 311
CONTROL VALVE 312
POWER TRAIN SYSTEM . 346
LAYOUT DRAWING OF POWER TRAIN SYSTEM . 346
OPERATION OF POWER TRAIN SYSTEM 349
TRANSMISSION CONTROL SYSTEM 350
TRANSMISSION CONTROL SYSTEM DIAGRAM 350
TRANSMISSION GEAR SHIFT CONTROL SYSTEM . 352
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 352
ELECTRIC MODULATION FUNCTION . 353
DISPLAY FUNCTION OF GEAR SHIFT . 353
AUTOMATIC GEAR SHIFT FUNCTION 353
SHIFT HOLD FUNCTION 354
KICKDOWN FUNCTION 354
AUTOMATIC KICKDOWN FUNCTION 355
TORQUE CONVERTER LOCKUP FUNCTION . 355
HUNTING PREVENTION FUNCTION 356
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT . 356
SHIFT POINT CHANGING FUNCTION 356
4TH GEAR SPEED LIMITATION FUNCTION . 356
TRANSMISSION PROTECTION FUNCTION . 358
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED . 358
SHIFT DOWN PROTECTION FUNCTION . 358
ENGINE OVERRUN PREVENTION FUNCTION . 359
MAXIMUM SPEED LIMITATION FUNCTION 359
NEUTRALIZER FUNCTION . 359
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION . 361
TRANSMISSION CUT-OFF FUNCTION 363
COMPONENT PARTS OF POWER TRAIN SYSTEM 365
DRIVE SHAFT 365
TORQUE CONVERTER . 367
LOCKUP CLUTCH ECMV . 369
TRANSMISSION . 373
TRANSMISSION CONTROL VALVE . 390
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV . 392
3RD AND 4TH CLUTCH ECMV 397
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 403
AXLE . 405
CONVENTIONAL DIFFERENTIAL 407
LIMITED SLIP DIFFERENTIAL 409
FINAL DRIVE 414
COMBINATION SWITCH . 416
SHIFT HOLD SWITCH 419
KICKDOWN SWITCH 420
WORK EQUIPMENT SYSTEM 421
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 421
WORK EQUIPMENT SYSTEM DIAGRAM 423
WORK EQUIPMENT CONTROL SYSTEM 425
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE . 425
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION . 425
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM . 426
WORK EQUIPMENT LEVER OPERATION FUNCTION 427
BUCKET PRIORITY CONTROL FUNCTION . 427
BOOM STOP MODULATION FUNCTION 427
WORK EQUIPMENT NEUTRAL LOCK SYSTEM . 429
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM . 429
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM . 429
REMOTE POSITIONER SYSTEM . 431
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 431
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 431
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 432
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 432
BUCKET POSITIONER AND BOOM POSITIONER 436
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER . 436
AUTO-DIGGING SYSTEM 437
AUTO-DIGGING SYSTEM DIAGRAM 437
FUNCTION OF AUTO-DIGGING SYSTEM 437
SEMI AUTO-DIGGING SYSTEM . 439
SEMI AUTO-DIGGING SYSTEM DIAGRAM . 439
FUNCTION OF SEMI AUTO-DIGGING SYSTEM . 439
ECSS . 441
ECSS DIAGRAM . 441
FUNCTION OF ECSS . 441
OPERATION OF ECSS 441
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 443
WORK EQUIPMENT LOCK SOLENOID VALVE . 443
PILOT CIRCUIT ACCUMULATOR 444
ECSS CIRCUIT ACCUMULATOR . 445
WORK EQUIPMENT ELECTRIC LEVER 447
MULTIFUNCTION MONO-LEVER . 450
STEERING SYSTEM 451
LAYOUT DRAWING OF STEERING SYSTEM 451
SECONDARY STEERING SYSTEM 452
SECONDARY STEERING SYSTEM DIAGRAM 452
FUNCTION OF SECONDARY STEERING SYSTEM 452
JOYSTICK STEERING SYSTEM . 454
FUNCTION OF JOYSTICK STEERING SYSTEM . 454
JOYSTICK CONTROL FUNCTION 454
JOYSTICK NEUTRAL SAFETY FUNCTION . 457
JOYSTICK NEUTRAL INTERLOCK FUNCTION 457
JOYSTICK SPEED SENSING STEERING FUNCTION . 457
JOYSTICK Hi/Lo SELECTOR FUNCTION . 458
STEERING COLUMN 459
STRUCTURE OF STEERING COLUMN . 459
COMPONENT PARTS OF STEERING SYSTEM . 460
ORBITROL VALVE . 460
STOP VALVE . 464
STEERING VALVE . 465
SECONDARY STEERING PUMP 478
SECONDARY STEERING MOTOR . 479
JOYSTICK KNOB 480
BRAKE SYSTEM . 481
LAYOUT DRAWING OF BRAKE SYSTEM . 481
LAYOUT DRAWING OF BRAKE COOLING SYSTEM . 482
PARKING BRAKE CONTROL SYSTEM . 485
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 485
OPERATION OF PARKING BRAKE CONTROL SYSTEM 485
BRAKE COOLING CONTROL SYSTEM . 487
BRAKE COOLING CONTROL SYSTEM DIAGRAM . 487
FUNCTION OF BRAKE COOLING CONTROL SYSTEM . 488
COMPONENT PARTS OF BRAKE SYSTEM 489
CHARGE VALVE . 489
PARKING BRAKE SOLENOID VALVE . 494
PARKING BRAKE EMERGENCY RELEASE VALVE 496
BRAKE CIRCUIT ACCUMULATOR 497
BRAKE VALVE 498
SLACK ADJUSTER . 502
BRAKE 504
PARKING BRAKE 507
FLOW PRIORITY VALVE 509
BRAKE COOLING MOTOR 511
BRAKE COOLING PUMP . 513
BRAKE COOLING OIL COOLER . 514
AUTO-GREASING SYSTEM . 515
LAYOUT DRAWING OF AUTO-GREASING SYSTEM . 515
SPECIFICATIONS OF AUTO-GREASING SYSTEM . 517
FUNCTION OF AUTO-GREASING SYSTEM . 519
COMPONENT PARTS OF AUTO-GREASING SYSTEM 520
AUTO-GREASING PUMP . 520
UNDERCARRIAGE AND FRAME 521
FRAME, AXLE MOUNT AND CENTER HINGE PIN . 521
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 521
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN . 521
TIRE . 523
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE . 523
STRUCTURE OF RADIAL TIRE . 523
FUNCTION OF RADIAL TIRE 523
STRUCTURE OF BIAS TIRE . 524
FUNCTION OF BIAS TIRE 524
WORK EQUIPMENT . 525
STRUCTURE OF WORK EQUIPMENT 525
STRUCTURE OF BUCKET 526
CAB AND ITS ATTACHMENTS 527
ROPS CAB . 527
STRUCTURE OF ROPS CAB 527
FUNCTION OF ROPS CAB . 527
20 STANDARD VALUE TABLE 529
CONTENTS . 530
ABBREVIATION LIST 531
STANDARD VALUE TABLE FOR ENGINE 537
STANDARD VALUE TABLE FOR ENGINE: WA470-8E0 . 537
STANDARD VALUE TABLE FOR MACHINE . 541
STANDARD VALUE TABLE FOR MACHINE: WA470-8E0 541
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 560
STANDARD VALUE TABLE FOR ELECTRICAL 563
STANDARD VALUE TABLE FOR ELECTRICITY . 563
30 TESTING AND ADJUSTING . 583
CONTENTS . 584
ABBREVIATION LIST 588
RELATED INFORMATION ON TESTING AND ADJUSTING . 594
TOOLS FOR TESTING AND ADJUSTING 594
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 603
ENGINE AND COOLING SYSTEM 605
TEST ENGINE SPEED 605
METHOD FOR TESTING ENGINE SPEED 605
TEST BOOST PRESSURE 611
METHOD FOR TESTING BOOST PRESSURE 611
TESTING EXHAUST GAS TEMPERATURE 614
METHOD FOR TESTING EXHAUST GAS TEMPERATURE . 614
TEST EXHAUST GAS COLOR . 616
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 616
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 617
TEST AND ADJUST VALVE CLEARANCE 618
METHOD FOR TESTING VALVE CLEARANCE . 618
METHOD FOR ADJUSTING VALVE CLEARANCE . 620
TEST COMPRESSION PRESSURE 621
METHOD FOR TESTING COMPRESSION PRESSURE 621
TEST BLOWBY PRESSURE . 625
METHOD FOR TESTING BLOWBY PRESSURE . 625
TEST ENGINE OIL PRESSURE . 628
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 628
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL . 628
TEST EGR VALVE AND VGT OIL PRESSURE 630
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 630
TEST FUEL PRESSURE . 632
METHOD FOR TESTING FUEL PRESSURE . 632
TEST FUEL RETURN RATE AND LEAKAGE 634
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 635
BLEEDING AIR FROM FUEL SYSTEM 638
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 639
TEST FUEL CIRCUIT FOR LEAKAGE 640
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 640
HANDLE CYLINDER CUT-OUT MODE OPERATION . 642
HANDLE NO-INJECTION CRANKING OPERATION . 643
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 644
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 644
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 645
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 645
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 646
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 646
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 647
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION . 647
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION . 647
TEST ALTERNATOR BELT . 649
METHOD FOR TESTING ALTERNATOR BELT . 649
TEST AUTOMATIC TENSIONER . 651
METHOD FOR TESTING AUTOMATIC TENSIONER . 651
CLEAN FUEL DOSER . 654
METHOD FOR CLEANING FUEL DOSER . 654
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER . 656
METHOD FOR WRITING INJECTOR COMPENSATION VALUE . 656
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 663
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 663
TEST SCR RELATED FUNCTIONS . 664
TEST AdBlue/DEF PUMP RAISED PRESSURE . 668
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 671
TEST AdBlue/DEF LINE HEATER RELAY 1 676
TEST AdBlue/DEF LINE HEATER RELAY 2 680
TEST AdBlue/DEF PUMP HEATER RELAY 684
TEST AdBlue/DEF TANK HEATER VALVE 688
TEST SCR NOx REMOVAL EFFICIENCY 692
CLEAN AdBlue/DEF TANK 696
METHOD FOR CLEANING AdBlue/DEF TANK 696
POWER TRAIN 700
TEST AND ADJUST POWER TRAIN OIL PRESSURE . 700
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 702
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 719
ADJUST TRANSMISSION INPUT SPEED SENSOR . 721
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR . 721
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 723
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 723
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 724
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 724
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 727
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE . 728
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 731
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 731
STEERING SYSTEM 732
TEST STEERING WHEEL 732
METHOD FOR TESTING STEERING WHEEL 732
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 734
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE . 734
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE . 737
BLEED AIR FROM STEERING CYLINDER CIRCUIT . 738
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT . 738
TEST AND ADJUST STEERING STOP VALVE 740
METHOD FOR TESTING STEERING STOP VALVE . 740
METHOD FOR ADJUSTING STEERING STOP VALVE . 740
BRAKE SYSTEM . 741
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 741
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT . 741
TEST WHEEL BRAKE OIL PRESSURE 742
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 742
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 745
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE . 745
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE . 746
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 747
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE . 747
Japanese Only 749
BLEED AIR FROM BRAKE CIRCUIT . 752
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT . 752
TEST BRAKING PERFORMANCE . 755
METHOD FOR TESTING BRAKING PERFORMANCE . 755
TEST BRAKE PEDAL . 756
METHOD FOR TESTING BRAKE PEDAL . 756
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 757
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE . 757
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE . 757
TEST LOWERING OF WHEEL BRAKE PRESSURE 758
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 759
TEST WEAR OF WHEEL BRAKE DISC 761
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 761
TEST PARKING BRAKE OIL PRESSURE 763
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 763
TEST PARKING BRAKE PERFORMANCE . 765
METHOD FOR TESTING PARKING BRAKE PERFORMANCE . 765
RELEASE PARKING BRAKE MANUALLY . 766
METHOD FOR RELEASING PARKING BRAKE MANUALLY 766
TEST WEAR AMOUNT OF PARKING BRAKE DISC . 768
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC . 768
HYDRAULIC SYSTEM . 770
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 770
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 770
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 772
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE . 772
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE . 777
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 778
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE . 778
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE . 781
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 783
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 783
TEST COOLING FAN SPEED . 784
METHOD FOR TESTING COOLING FAN SPEED . 784
TEST COOLING FAN CIRCUIT OIL PRESSURE 786
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 786
BLEED AIR FROM COOLING FAN CIRCUIT . 789
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT . 789
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS . 791
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 791
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS . 793
WORK EQUIPMENT . 797
TEST AND ADJUST BUCKET POTENTIOMETER LEVER . 797
METHOD FOR TESTING BUCKET POSITIONER DETECTION LEVER . 797
METHOD FOR ADJUSTING BUCKET POSITIONER DETECTION LEVER . 797
TEST AND ADJUST BOOM POTENTIOMETER LEVER . 799
METHOD FOR TESTING BOOM POSITION DETECTION LEVER . 799
METHOD FOR ADJUSTING BOOM POSITION DETECTION LEVER . 799
CAB AND ITS ATTACHMENTS 800
TEST DIRECTIONAL LEVER . 800
METHOD FOR TESTING DIRECTIONAL LEVER . 800
TEST WORK EQUIPMENT CONTROL LEVER 801
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 801
ADJUST RATTLING OPERATOR’S SEAT 804
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 804
ELECTRICAL SYSTEM 805
SET AND ADJUST EACH EQUIPMENT 805
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT . 807
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT . 809
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING . 812
SET AND OPERATE MACHINE MONITOR 817
OPERATOR MODE 821
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 821
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 821
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 822
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 823
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 823
SERVICE MODE . 827
METHOD FOR OPERATING SERVICE MODE 827
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 830
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 837
ABNORMALITY RECORD MENU 853
METHOD FOR CONFIRMING MAINTENANCE RECORD . 858
METHOD FOR OPERATING MAINTENANCE MODE SETTING 860
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 865
DEFAULT MENU . 867
DIAGNOSTIC TESTS MENU 882
ADJUSTMENT MENU 894
METHOD FOR PERFORMING NO-INJECTION CRANKING 928
KOMTRAX SETTINGS MENU 931
METHOD FOR DISPLAYING SERVICE MESSAGE 933
METHOD FOR STARTING UP KOMTRAX TERMINAL 935
ADJUST REARVIEW CAMERA ANGLE . 940
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 940
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 942
HANDLE BATTERY DISCONNECT SWITCH . 943
TEST DIODES 944
METHOD FOR TESTING DIODE USING DIGITAL TESTER 944
METHOD FOR TESTING DIODE USING ANALOG TESTER . 944
AUTO-GREASING DEVICE . 945
BLEED THE AIR OF AUTO-GREASING SYSTEM 945
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 945
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 948
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE . 948
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 949
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 950
Pm CLINIC 952
Pm CLINIC SERVICE 952
Pm CLINIC CHECK SHEET 954
40 TROUBLESHOOTING . 965
CONTENTS . 966
ABBREVIATION LIST 979
RELATED INFORMATION ON TROUBLESHOOTING . 985
GENERAL TROUBLESHOOTING POINTS . 985
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 986
SEQUENCE OF EVENTS IN TROUBLESHOOTING 998
CHECKS BEFORE TROUBLESHOOTING 1000
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1002
WALK-AROUND CHECK 1002
TESTING IN ACCORDANCE WITH TESTING PROCEDURE .1004
CHECK FUEL LEVEL AND TYPE 1004
CHECK IMPURE INGREDIENT IN FUEL 1004
CHECK AdBule/DEF LEVEL AND TYPE 1005
CHECK FUEL PREFILTER .1005
CHECK MAIN FILTER 1007
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1008
CHECK COOLANT LEVEL (RESERVOIR TANK) .1008
CHECK CLOGGING OF AIR CLEANER 1009
OUTER ELEMENT – CLEAN 1010
REPLACE ELEMENT 1012
CHECK HYDRAULIC OIL LEVEL 1013
CHECK HYDRAULIC OIL STRAINER .1014
CHECK HYDRAULIC FILTER .1015
CHECK OIL LEVEL IN TRANSMISSION CASE .1016
CHECK OIL LEVEL IN FRONT AXLE CASE .1018
CHECK OIL LEVEL IN REAR AXLE CASE 1019
BLEED AIR FROM FUEL SYSTEM .1019
BLEED AIR FROM HYDRAULIC SYSTEM 1019
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod .1019
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1025
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1037
SYMPTOM AND TROUBLESHOOTING NUMBERS 1039
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .1044
CONNECTORS LIST AND LAYOUT .1046
CONNECTOR CONTACT IDENTIFICATION .1066
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1106
FUSE LOCATION TABLE 1112
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1116
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR .1120
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1122
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1128
FAILURE CODES TABLE 1130
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1154
FAILURE CODE [1500L0] 1154
FAILURE CODE [15SAL1] 1155
FAILURE CODE [15SALH] 1157
FAILURE CODE [15SBL1] 1159
FAILURE CODE [15SBLH] 1161
FAILURE CODE [15SEL1] 1163
FAILURE CODE [15SELH] 1165
FAILURE CODE [15SFL1] 1167
FAILURE CODE [15SFLH] 1169
FAILURE CODE [15SGL1] 1171
FAILURE CODE [15SGLH] 1173
FAILURE CODE [15SHL1] 1175
FAILURE CODE [15SHLH] 1177
FAILURE CODE [2F00MA] 1180
FAILURE CODE [2F00MB] 1184
FAILURE CODE [2G42ZG] 1187
FAILURE CODE [2G43ZG] 1189
FAILURE CODE [879AKA] 1191
FAILURE CODE [879AKB] 1193
FAILURE CODE [879BKA] 1195
FAILURE CODE [879BKB] 1197
FAILURE CODE [879CKA] 1199
FAILURE CODE [879CKB] 1201
FAILURE CODE [879DKZ] 1203
FAILURE CODE [879EMC] 1205
FAILURE CODE [879FMC] 1208
FAILURE CODE [989A00] 1211
FAILURE CODE [989L00] 1212
FAILURE CODE [989M00] 1213
FAILURE CODE [989N00] 1214
FAILURE CODE [A1U0N3] 1215
FAILURE CODE [A1U0N4] 1217
FAILURE CODE [AA10NX] 1219
FAILURE CODE [AB00KE] 1221
FAILURE CODE [AB00KY] 1223
FAILURE CODE [AQ10N3] 1225
FAILURE CODE [AS00N3] 1227
FAILURE CODE [AS00R2] 1229
FAILURE CODE [AS00R3] 1230
FAILURE CODE [AS00R4] 1231
FAILURE CODE [AS00R5] 1232
FAILURE CODE [AS00R6] 1233
FAILURE CODE [AS00ZK] 1234
FAILURE CODE [AS10KM] 1235
FAILURE CODE [AS10NR] 1236
FAILURE CODE [AS10NT] 1237
FAILURE CODE [B@BAZG] 1238
FAILURE CODE [B@BAZK] 1239
FAILURE CODE [B@BCNS] 1241
FAILURE CODE [B@BCZK] 1242
FAILURE CODE [B@C7NS] 1244
FAILURE CODE [B@CENS] 1246
FAILURE CODE [B@HANS] 1247
FAILURE CODE [CA115] .1248
FAILURE CODE [CA122] .1249
FAILURE CODE [CA123] .1251
FAILURE CODE [CA131] .1253
FAILURE CODE [CA132] .1255
FAILURE CODE [CA135] .1258
FAILURE CODE [CA141] .1260
FAILURE CODE [CA144] .1262
FAILURE CODE [CA145] .1264
FAILURE CODE [CA153] .1266
FAILURE CODE [CA154] .1269
FAILURE CODE [CA187] .1272
FAILURE CODE [CA221] .1274
FAILURE CODE [CA222] .1276
FAILURE CODE [CA227] .1278
FAILURE CODE [CA234] .1279
FAILURE CODE [CA238] .1280
FAILURE CODE [CA239] .1282
FAILURE CODE [CA249] .1284
FAILURE CODE [CA256] .1286
FAILURE CODE [CA271] .1288
FAILURE CODE [CA272] .1290
FAILURE CODE [CA273] .1291
FAILURE CODE [CA274] .1293
FAILURE CODE [CA322] .1294
FAILURE CODE [CA323] .1296
FAILURE CODE [CA324] .1298
FAILURE CODE [CA325] .1300
FAILURE CODE [CA331] .1302
FAILURE CODE [CA332] .1304
FAILURE CODE [CA343] .1306
FAILURE CODE [CA351] .1307
FAILURE CODE [CA352] .1308
FAILURE CODE [CA356] .1311
FAILURE CODE [CA357] .1313
FAILURE CODE [CA386] .1315
FAILURE CODE [CA431] .1316
FAILURE CODE [CA432] .1319
FAILURE CODE [CA441] .1323
FAILURE CODE [CA442] .1325
FAILURE CODE [CA449] .1326
FAILURE CODE [CA451] .1327
FAILURE CODE [CA452] .1329
FAILURE CODE [CA515] .1331
FAILURE CODE [CA516] .1333
FAILURE CODE [CA553] .1335
FAILURE CODE [CA555] .1336
FAILURE CODE [CA556] .1337
FAILURE CODE [CA559] .1338
FAILURE CODE [CA595] .1343
FAILURE CODE [CA687] .1344
FAILURE CODE [CA689] .1346
FAILURE CODE [CA691] .1348
FAILURE CODE [CA692] .1350
FAILURE CODE [CA697] .1352
FAILURE CODE [CA698] .1353
FAILURE CODE [CA731] .1354
FAILURE CODE [CA778] .1355
FAILURE CODE [CA1117] 1358
FAILURE CODE [CA1664] 1359
FAILURE CODE [CA1669] 1362
FAILURE CODE [CA1673] 1363
FAILURE CODE [CA1677] 1364
FAILURE CODE [CA1678] 1365
FAILURE CODE [CA1682] 1366
FAILURE CODE [CA1683] 1370
FAILURE CODE [CA1684] 1372
FAILURE CODE [CA1686] 1374
FAILURE CODE [CA1691] 1375
FAILURE CODE [CA1694] 1378
FAILURE CODE [CA1695] 1380
FAILURE CODE [CA1696] 1381
FAILURE CODE [CA1712] 1383
FAILURE CODE [CA1713] 1386
FAILURE CODE [CA1714] 1388
FAILURE CODE [CA1715] 1389
FAILURE CODE [CA1776] 1390
FAILURE CODE [CA1777] 1393
FAILURE CODE [CA1843] 1396
FAILURE CODE [CA1844] 1398
FAILURE CODE [CA1879] 1401
FAILURE CODE [CA1881] 1404
FAILURE CODE [CA1883] 1406
FAILURE CODE [CA1885] 1410
FAILURE CODE [CA1887] 1412
FAILURE CODE [CA1921] 1414
FAILURE CODE [CA1922] 1417
FAILURE CODE [CA1923] 1422
FAILURE CODE [CA1924] 1424
FAILURE CODE [CA1925] 1426
FAILURE CODE [CA1927] 1428
FAILURE CODE [CA1928] 1430
FAILURE CODE [CA1942] 1432
FAILURE CODE [CA1963] 1433
FAILURE CODE [CA1977] 1437
FAILURE CODE [CA1993] 1440
FAILURE CODE [CA2185] 1443
FAILURE CODE [CA2186] 1445
FAILURE CODE [CA2249] 1447
FAILURE CODE [CA2265] 1448
FAILURE CODE [CA2266] 1450
FAILURE CODE [CA2271] 1453
FAILURE CODE [CA2272] 1455
FAILURE CODE [CA2349] 1457
FAILURE CODE [CA2353] 1459
FAILURE CODE [CA2357] 1461
FAILURE CODE [CA2381] 1462
FAILURE CODE [CA2382] 1464
FAILURE CODE [CA2383] 1466
FAILURE CODE [CA2386] 1468
FAILURE CODE [CA2387] 1470
FAILURE CODE [CA2555] 1472
FAILURE CODE [CA2556] 1474
FAILURE CODE [CA2637] 1476
FAILURE CODE [CA2639] 1478
FAILURE CODE [CA2732] 1481
FAILURE CODE [CA2733] 1483
FAILURE CODE [CA2741] 1485
FAILURE CODE [CA2765] 1486
FAILURE CODE [CA2771] 1487
FAILURE CODE [CA2777] 1493
FAILURE CODE [CA2878] 1496
FAILURE CODE [CA2881] 1499
FAILURE CODE [CA2976] 1502
FAILURE CODE [CA3133] 1504
FAILURE CODE [CA3134] 1506
FAILURE CODE [CA3135] 1508
FAILURE CODE [CA3142] 1512
FAILURE CODE [CA3143] 1513
FAILURE CODE [CA3144] 1514
FAILURE CODE [CA3146] 1517
FAILURE CODE [CA3147] 1518
FAILURE CODE [CA3148] 1519
FAILURE CODE [CA3151] 1521
FAILURE CODE [CA3165] 1527
FAILURE CODE [CA3167] 1529
FAILURE CODE [CA3229] 1532
FAILURE CODE [CA3231] 1534
FAILURE CODE [CA3232] 1536
FAILURE CODE [CA3235] 1540
FAILURE CODE [CA3239] 1542
FAILURE CODE [CA3241] 1545
FAILURE CODE [CA3242] 1548
FAILURE CODE [CA3251] 1551
FAILURE CODE [CA3253] 1553
FAILURE CODE [CA3254] 1556
FAILURE CODE [CA3255] 1559
FAILURE CODE [CA3256] 1563
FAILURE CODE [CA3311] 1565
FAILURE CODE [CA3312] 1567
FAILURE CODE [CA3313] 1570
FAILURE CODE [CA3314] 1571
FAILURE CODE [CA3315] 1572
FAILURE CODE [CA3316] 1575
FAILURE CODE [CA3317] 1576
FAILURE CODE [CA3318] 1577
FAILURE CODE [CA3319] 1580
FAILURE CODE [CA3321] 1581
FAILURE CODE [CA3322] 1583
FAILURE CODE [CA3419] 1586
FAILURE CODE [CA3421] 1588
FAILURE CODE [CA3497] 1590
FAILURE CODE [CA3498] 1591
FAILURE CODE [CA3543] 1592
FAILURE CODE [CA3545] 1599
FAILURE CODE [CA3547] 1601
FAILURE CODE [CA3558] 1602
FAILURE CODE [CA3559] 1604
FAILURE CODE [CA3562] 1606
FAILURE CODE [CA3563] 1608
FAILURE CODE [CA3567] 1611
FAILURE CODE [CA3568] 1614
FAILURE CODE [CA3571] 1620
FAILURE CODE [CA3572] 1622
FAILURE CODE [CA3574] 1624
FAILURE CODE [CA3575] 1626
FAILURE CODE [CA3577] 1628
FAILURE CODE [CA3578] 1630
FAILURE CODE [CA3582] 1632
FAILURE CODE [CA3583] 1640
FAILURE CODE [CA3596] 1642
FAILURE CODE [CA3649] 1645
FAILURE CODE [CA3681] 1647
FAILURE CODE [CA3682] 1652
FAILURE CODE [CA3713] 1658
FAILURE CODE [CA3717] 1661
FAILURE CODE [CA3718] 1662
FAILURE CODE [CA3725] 1663
FAILURE CODE [CA3748] 1666
FAILURE CODE [CA3751] 1669
FAILURE CODE [CA3755] 1671
FAILURE CODE [CA3866] 1673
FAILURE CODE [CA3867] 1677
FAILURE CODE [CA3868] 1680
FAILURE CODE [CA3899] 1684
FAILURE CODE [CA3911] 1686
FAILURE CODE [CA3912] 1690
FAILURE CODE [CA3932] 1692
FAILURE CODE [CA3933] 1694
FAILURE CODE [CA3934] 1696
FAILURE CODE [CA3935] 1699
FAILURE CODE [CA3936] 1701
FAILURE CODE [CA4151] 1703
FAILURE CODE [CA4152] 1707
FAILURE CODE [CA4155] 1711
FAILURE CODE [CA4156] 1713
FAILURE CODE [CA4157] 1716
FAILURE CODE [CA4158] 1718
FAILURE CODE [CA4159] 1719
FAILURE CODE [CA4161] 1720
FAILURE CODE [CA4162] 1723
FAILURE CODE [CA4163] 1726
FAILURE CODE [CA4164] 1728
FAILURE CODE [CA4165] 1730
FAILURE CODE [CA4166] 1732
FAILURE CODE [CA4168] 1734
FAILURE CODE [CA4169] 1737
FAILURE CODE [CA4171] 1739
FAILURE CODE [CA4249] 1742
FAILURE CODE [CA4251] 1744
FAILURE CODE [CA4259] 1746
FAILURE CODE [CA4261] 1749
FAILURE CODE [CA4277] 1752
FAILURE CODE [CA4281] 1756
FAILURE CODE [CA4459] 1759
FAILURE CODE [CA4461] 1762
FAILURE CODE [CA4658] 1765
FAILURE CODE [CA4731] 1769
FAILURE CODE [CA4732] 1770
FAILURE CODE [CA4739] 1771
FAILURE CODE [CA4768] 1772
FAILURE CODE [CA4769] 1774
FAILURE CODE [CA4842] 1777
FAILURE CODE [CA4952] 1781
FAILURE CODE [CA5115] 1783
FAILURE CODE [CA5179] 1786
FAILURE CODE [CA5181] 1788
FAILURE CODE [CA5383] 1790
FAILURE CODE [D150KA] 1792
FAILURE CODE [D150KB] 1794
FAILURE CODE [D150KY] 1796
FAILURE CODE [D160KA] 1798
FAILURE CODE [D160KB] 1800
FAILURE CODE [D160KY] 1802
FAILURE CODE [D191KA] 1804
FAILURE CODE [D191KB] 1807
FAILURE CODE [D191KY] 1810
FAILURE CODE [D192KA] 1812
FAILURE CODE [D192KB] 1814
FAILURE CODE [D192KY] 1816
FAILURE CODE [D193KA] 1817
FAILURE CODE [D193KB] 1819
FAILURE CODE [D193KY] 1821
FAILURE CODE [D193MC] 1823
FAILURE CODE [D19JKZ] 1825
FAILURE CODE [D1E6KA] 1827
FAILURE CODE [D1E6KB] 1829
FAILURE CODE [D1E6KY] 1831
FAILURE CODE [D5ZHKA] 1833
FAILURE CODE [D5ZHKB] 1835
FAILURE CODE [D5ZHKZ] 1837
FAILURE CODE [D5ZHL6] 1840
FAILURE CODE [D811MC] 1842
FAILURE CODE [D862KA] 1843
FAILURE CODE [D8ALKA] 1844
FAILURE CODE [D8ALKB] 1846
FAILURE CODE [D8AQK4] 1848
FAILURE CODE [D8AQKR] 1849
FAILURE CODE [DAF0KT] 1851
FAILURE CODE [DAF0MB] 1852
FAILURE CODE [DAF0MC] 1853
FAILURE CODE [DAF3KK] 1854
FAILURE CODE [DAF8KB] 1856
FAILURE CODE [DAFDKB] 1858
FAILURE CODE [DAFGMC] 1860
FAILURE CODE [DAFLKA] 1861
FAILURE CODE [DAFLKB] 1863
FAILURE CODE [DAFQKR] 1865
FAILURE CODE [DAQ0KK] 1866
FAILURE CODE [DAQ0KT] 1869
FAILURE CODE [DAQ0MC] 1870
FAILURE CODE [DAQ1KA] 1871
FAILURE CODE [DAQ2KK] 1873
FAILURE CODE [DAQ4KB] 1876
FAILURE CODE [DAQ9KQ] 1878
FAILURE CODE [DAQLKA] 1879
FAILURE CODE [DAQLKB] 1881
FAILURE CODE [DAQQKR] 1883
FAILURE CODE [DAQRKR] 1884
FAILURE CODE [DAQRMA] 1885
FAILURE CODE [DAZ9KQ] 1886
FAILURE CODE [DAZQKR] 1887
FAILURE CODE [DB2QKR] 1888
FAILURE CODE [DB2RKR] 1893
FAILURE CODE [DB90KK] 1899
FAILURE CODE [DB90KT] 1902
FAILURE CODE [DB90MC] 1903
FAILURE CODE [DB91KA] 1904
FAILURE CODE [DB92KK] 1906
FAILURE CODE [DB95KX] 1909
FAILURE CODE [DB96KX] 1913
FAILURE CODE [DB99KQ] 1915
FAILURE CODE [DB9LKA] 1916
FAILURE CODE [DB9LKB] 1918
FAILURE CODE [DB9QKR] 1920
FAILURE CODE [DB9RKR] 1921
FAILURE CODE [DB9RMA] 1922
FAILURE CODE [DBE5KX] 1923
FAILURE CODE [DBE6KX] 1925
FAILURE CODE [DD1ALD] 1927
FAILURE CODE [DDAAL6] 1929
FAILURE CODE [DDB6L4] 1931
FAILURE CODE [DDD1LD] 1934
FAILURE CODE [DDK3KA] 1936
FAILURE CODE [DDK3KB] 1939
FAILURE CODE [DDK6KA] 1942
FAILURE CODE [DDK6KB] 1945
FAILURE CODE [DDKLKA] 1948
FAILURE CODE [DDKLKB] 1951
FAILURE CODE [DDNRKY] 1953
FAILURE CODE [DDT0L4] 1955
FAILURE CODE [DDT4LD] 1957
FAILURE CODE [DDT9LD] 1959
FAILURE CODE [DDTALD] 1961
FAILURE CODE [DDW9LD] 1963
FAILURE CODE [DDWLLD] 1965
FAILURE CODE [DF10KA] 1967
FAILURE CODE [DF10KB] 1970
FAILURE CODE [DGF1KA] 1973
FAILURE CODE [DGF1KB] 1975
FAILURE CODE [DGH2KX] 1977
FAILURE CODE [DGR2KB] 1979
FAILURE CODE [DGR2KZ] 1981
FAILURE CODE [DGT1KA] 1983
FAILURE CODE [DGT1KB] 1985
FAILURE CODE [DH21KA] 1987
FAILURE CODE [DH21KB] 1990
FAILURE CODE [DHA4KA] 1992
FAILURE CODE [DHAAMA] 1994
FAILURE CODE [DHACMA] 1996
FAILURE CODE [DHPCKX] 1998
FAILURE CODE [DHPDKX] 2001
FAILURE CODE [DHT1KX] 2004
FAILURE CODE [DHT5KX] 2007
FAILURE CODE [DHT7KX] 2010
FAILURE CODE [DHT8KA] 2013
FAILURE CODE [DHT8KB] 2016
FAILURE CODE [DHT8ZG] 2018
FAILURE CODE [DHUDKA] 2019
FAILURE CODE [DHUDKB] 2022
FAILURE CODE [DJF1KA] 2024
FAILURE CODE [DK55KA] 2026
FAILURE CODE [DK55KY] 2029
FAILURE CODE [DK55L5] 2031
FAILURE CODE [DK59KA] 2032
FAILURE CODE [DK59KY] 2036
FAILURE CODE [DK59L8] 2040
FAILURE CODE [DK5AKA] 2045
FAILURE CODE [DK5AKY] 2049
FAILURE CODE [DK5BKA] 2053
FAILURE CODE [DK5BKY] 2057
FAILURE CODE [DK5BL8] 2061
FAILURE CODE [DK5CKA] 2066
FAILURE CODE [DK5CKY] 2070
FAILURE CODE [DK5DKA] 2074
FAILURE CODE [DK5DKY] 2077
FAILURE CODE [DK5DL8] 2080
FAILURE CODE [DK5EKA] 2084
FAILURE CODE [DK5EKY] 2087
FAILURE CODE [DK5FKA] 2090
FAILURE CODE [DK5FKY] 2093
FAILURE CODE [DK5FL8] 2096
FAILURE CODE [DK5GKA] 2100
FAILURE CODE [DK5GKY] 2103
FAILURE CODE [DKA0KA] 2106
FAILURE CODE [DKA0KY] 2109
FAILURE CODE [DKA0L0] 2112
FAILURE CODE [DKA1KA] 2115
FAILURE CODE [DKA1KY] 2118
FAILURE CODE [DLF1KA] 2121
FAILURE CODE [DLF1LC] 2123
FAILURE CODE [DLM3KA] 2125
FAILURE CODE [DLM3LC] 2127
FAILURE CODE [DLT3KA] 2129
FAILURE CODE [DLT3LC] 2131
FAILURE CODE [DPQ1KR] 2133
FAILURE CODE [DPQ2KR] 2136
FAILURE CODE [DPQ3KR] 2139
FAILURE CODE [DSJ0KR] 2142
FAILURE CODE [DT20KB] 2145
FAILURE CODE [DT22KB] 2147
FAILURE CODE [DT23KB] 2149
FAILURE CODE [DV00KB] 2151
FAILURE CODE [DW4PKA] 2153
FAILURE CODE [DW4PKB] 2155
FAILURE CODE [DW4PKY] 2157
FAILURE CODE [DW4QKA] 2159
FAILURE CODE [DW4QKB] 2161
FAILURE CODE [DW4QKY] 2163
FAILURE CODE [DW4RKA] 2165
FAILURE CODE [DW4RKB] 2167
FAILURE CODE [DW4RKY] 2169
FAILURE CODE [DW4SKA] 2171
FAILURE CODE [DW4SKB] 2173
FAILURE CODE [DW4SKY] 2175
FAILURE CODE [DW7BKA] 2177
FAILURE CODE [DW7BKB] 2179
FAILURE CODE [DW7BKY] 2181
FAILURE CODE [DWM1KA] 2183
FAILURE CODE [DWM1KB] 2185
FAILURE CODE [DWM1KY] 2187
FAILURE CODE [DWN6KA] 2189
FAILURE CODE [DWN6KB] 2191
FAILURE CODE [DWN6KY] 2193
FAILURE CODE [DWN8KA] 2195
FAILURE CODE [DWN8KB] 2197
FAILURE CODE [DWN8KY] 2199
FAILURE CODE [DX16KA] 2201
FAILURE CODE [DX16KB] 2203
FAILURE CODE [DX16KY] 2205
FAILURE CODE [DXA1KA] 2207
FAILURE CODE [DXA1KB] 2209
FAILURE CODE [DXA1KY] 2211
FAILURE CODE [DXANKA] 2213
FAILURE CODE [DXANKB] 2215
FAILURE CODE [DXANKY] 2217
FAILURE CODE [DXH1KA] 2219
FAILURE CODE [DXH1KB] 2221
FAILURE CODE [DXH1KY] 2223
FAILURE CODE [DXH4KA] 2225
FAILURE CODE [DXH4KB] 2227
FAILURE CODE [DXH4KY] 2229
FAILURE CODE [DXH5KA] 2231
FAILURE CODE [DXH5KB] 2233
FAILURE CODE [DXH5KY] 2235
FAILURE CODE [DXH6KA] 2237
FAILURE CODE [DXH6KB] 2239
FAILURE CODE [DXH6KY] 2241
FAILURE CODE [DXH7KA] 2243
FAILURE CODE [DXH7KB] 2245
FAILURE CODE [DXH7KY] 2247
FAILURE CODE [DXH8KA] 2249
FAILURE CODE [DXH8KB] 2251
FAILURE CODE [DXH8KY] 2253
FAILURE CODE [DXHHKA] 2255
FAILURE CODE [DXHHKB] 2257
FAILURE CODE [DXHHKY] 2259
FAILURE CODE [DXHJKA] 2261
FAILURE CODE [DXHJKB] 2263
FAILURE CODE [DXHJKY] 2265
FAILURE CODE [DXHKKA] 2267
FAILURE CODE [DXHKKB] 2269
FAILURE CODE [DXHKKY] 2271
FAILURE CODE [DXHLKA] 2273
FAILURE CODE [DXHLKB] 2275
FAILURE CODE [DXHLKY] 2277
FAILURE CODE [DXHMKA] 2279
FAILURE CODE [DXHMKB] 2281
FAILURE CODE [DXHMKY] 2283
FAILURE CODE [DY30MA] 2285
FAILURE CODE [DY30MC] 2289
FAILURE CODE [DY30ME] 2294
FAILURE CODE [LA00L3] 2296
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2297
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2297
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .2304
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2307
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2310
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING .2312
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING .2315
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) .2318
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY .2321
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2324
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2327
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2331
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2333
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION .2336
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2339
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2342
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2343
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2346
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY .2349
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2352
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL .2356
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP .2358
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP .2360
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2362
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2366
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .2367
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2368
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2370
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT .2371
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL .2373
E-30 ALARM BUZZER DOES NOT SOUND .2374
E-31 ALARM BUZZER DOES NOT STOP SOUNDING .2376
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2377
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2379
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED .2381
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED .2385
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED .2387
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2389
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2391
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE .2393
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2394
E-41 HORN DOES NOT SOUND .2396
E-42 HORN DOES NOT SOUND (JOYSTICKSTEERING SPECIFICATION) 2399
E-43 HORN DOES NOT STOP SOUNDING .2402
E-44 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2405
E-45 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2407
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT .2411
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2415
E-48 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT .2417
E-49 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2419
E-50 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) .2424
E-51 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT .2429
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2433
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT .2438
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT .2441
E-55 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT .2444
E-56 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2448
E-57 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2452
E-58 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2455
E-59 FRONT WIPER DOES NOT OPERATE 2457
E-60 REAR WIPER DOES NOT OPERATE .2461
E-61 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY .2464
E-62 FAN DOES NOT ROTATE IN REVERSE 2467
E-63 FAN REMAINS ROTATED IN REVERSE 2468
E-64 WINDOW WASHER DOES NOT OPERATE 2469
E-65 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2472
E-66 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2473
E-67 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2475
E-68 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP .2476
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2478
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2478
FAILURE MODE AND CAUSE TABLE .2479
H-1 MACHINE DOES NOT START .2495
H-2 LOCKUP IS NOT RELEASED .2499
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE .2500
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2501
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2505
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED .2508
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2511
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2514
H-9 MACHINE DOES NOT TURN (JOYSTICKSTEERING SPECIFICATION) .2516
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2518
H-11 TURNING RESPONSE IS POOR (JOYSTICKSTEERING SPECIFICATION) .2520
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2522
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2523
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (JOYSTICKSTEERING SPECIFICATION) .2525
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS .2527
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2528
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG .2530
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK .2531
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS 2532
H-20 BOOM DOES NOT RISE 2534
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE .2536
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2538
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2539
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE 2541
H-25 BOOM MOVES UP AND DOWN DURING OPERATION .2542
H-26 BUCKET DOES NOT TILT BACK .2543
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2545
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION .2547
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2548
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE 2550
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) .2551
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE .2552
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2553
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2554
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2557
H-36 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2558
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2559
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2561
TROUBLESHOOTING OF ENGINE (S-MODE) .2562
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2562
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .2563
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .2564
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .2565
S-4 ENGINE STARTABILITY IS POOR 2566
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .2568
S-6 ENGINE STOPS DURING OPERATION 2570
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .2572
S-8 ENGINE LACKS POWER .2573
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2575
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .2577
S-11 OIL BECOMES CONTAMINATED QUICKLY 2578
S-12 FUEL CONSUMPTION IS EXCESSIVE .2579
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2580
S-14 OIL PRESSURE DROPS 2581
S-15 FUEL MIXES INTO ENGINE OIL 2583
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .2584
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2585
S-18 UNUSUAL NOISE IS HEARD 2586
S-19 VIBRATION IS EXCESSIVE 2587
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2588
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2589
S-22 ACTIVE REGENERATION TAKES TIME 2591
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2593
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE .2594
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2596
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2597
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM .2598
OUTLINE OF FAILURE DISPLAY .2598
TROUBLESHOOTING FOR FCS 2599
TROUBLESHOOTING FOR AUTO-GREASING PUMP .2600
REPLACEMENT OF PUMP ELEMENT 2603
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM .2604
REPLACEMENT OF AUTO-GREASING CONTROLLER 2606
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2607
TROUBLESHOOTING FOR RDS LOAD METER SYSTEM 2608
OUTLINE OF FAILURE DISPLAY .2608
METHOD FOR DISPLAYING DIAGNOSTICS SCREEN .2609
TROUBLESHOOTING FOR RDS LOAD METER .2610
50 DISASSEMBLY AND ASSEMBLY 2613
CONTENTS .2614
ABBREVIATION LIST 2619
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2625
HOW TO READ THIS MANUAL 2625
COATING MATERIALS LIST .2627
SPECIAL TOOLS LIST .2631
SKETCHES OF SPECIAL TOOLS 2652
ENGINE AND COOLING SYSTEM 2675
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2675
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2675
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2679
REMOVE AND INSTALL INJECTOR ASSEMBLY .2685
METHOD FOR REMOVING INJECTOR ASSEMBLY 2685
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2689
REMOVE AND INSTALL FUEL DOSER ASSEMBLY .2697
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2697
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2698
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2701
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2701
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2712
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2729
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2729
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2729
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2731
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2731
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2733
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2736
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2736
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2737
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .2739
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2739
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2741
REMOVE AND INSTALL ALTERNATOR BELT .2744
METHOD FOR REMOVING ALTERNATOR BELT 2744
METHOD FOR INSTALLING ALTERNATOR BELT 2745
REMOVE AND INSTALL AUTOMATIC TENSIONER .2747
METHOD FOR REMOVING AUTOMATIC TENSIONER 2747
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2747
REMOVE AND INSTALL RADIATOR ASSEMBLY .2748
METHOD FOR REMOVING RADIATOR ASSEMBLY 2748
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2753
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2758
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2758
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2761
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2763
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2763
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2765
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2767
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2767
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2771
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY .2775
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2775
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2780
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2786
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2787
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2802
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2817
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2817
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .2818
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2820
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2820
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2821
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2824
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2824
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2825
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2832
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2832
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2838
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2845
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2845
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2848
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2853
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2853
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2857
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2861
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2861
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2866
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2870
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2870
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2871
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2877
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2877
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2877
REMOVE AND INSTALL KDPF ASSEMBLY .2878
METHOD FOR REMOVING KDPF ASSEMBLY 2879
METHOD FOR INSTALLING KDPF ASSEMBLY 2891
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2904
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2904
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2908
REMOVE AND INSTALL SCR ASSEMBLY 2913
METHOD FOR REMOVING SCR ASSEMBLY .2914
METHOD FOR INSTALLING SCR ASSEMBLY .2923
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2935
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2936
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2945
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY .2955
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2955
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2960
REMOVE AND INSTALL KCCV ASSEMBLY .2968
METHOD FOR REMOVING KCCV ASSEMBLY 2968
METHOD FOR INSTALLING KCCV ASSEMBLY 2968
REMOVE AND INSTALL VGT ASSEMBLY 2970
METHOD FOR REMOVING VGT ASSEMBLY .2970
METHOD FOR INSTALLING VGT ASSEMBLY .2976
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2982
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2983
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2989
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2998
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2998
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3002
REMOVE AND INSTALL AdBlue/DEF PUMP .3006
METHOD FOR REMOVING AdBlue/DEF PUMP 3006
METHOD FOR INSTALLING AdBlue/DEF PUMP 3009
REMOVE AND INSTALL AdBlue/DEF HOSE .3012
METHOD FOR REMOVING AdBlue/DEF HOSE 3013
METHOD FOR INSTALLING AdBlue/DEF HOSE 3022
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3033
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .3033
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .3034
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .3036
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3036
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3037
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3039
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .3039
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .3040
POWER TRAIN 3042
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY .3042
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY .3042
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3046
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY .3054
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY .3056
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY .3074
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3101
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3102
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY .3118
REMOVE AND INSTALL FRONT AXLE ASSEMBLY .3138
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3138
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3140
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3142
METHOD FOR REMOVING REAR AXLE ASSEMBLY .3142
METHOD FOR INSTALLING REAR AXLE ASSEMBLY .3149
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY .3157
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY .3158
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3163
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY .3171
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY .3172
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3181
STEERING SYSTEM 3200
REMOVE AND INSTALL STEERING VALVE ASSEMBLY .3200
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3200
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3202
BRAKE SYSTEM .3205
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3205
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE .3205
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE .3208
UNDERCARRIAGE AND FRAME 3211
REMOVE AND INSTALL CENTER HINGE PIN 3211
METHOD FOR REMOVING CENTER HINGE PIN .3211
METHOD FOR INSTALLING CENTER HINGE PIN .3217
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3224
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY .3224
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY .3226
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY .3230
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3230
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3231
HYDRAULIC SYSTEM .3232
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .3232
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3232
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3236
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY .3240
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3240
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3241
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY .3243
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3243
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3244
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3247
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .3247
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .3250
WORK EQUIPMENT .3254
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .3254
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3254
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3258
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY .3263
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY .3264
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3267
CAB AND ITS ATTACHMENTS 3273
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY .3273
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3273
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3278
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3283
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .3283
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .3284
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .3293
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3293
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3299
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3304
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY .3304
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY .3306
REMOVE AND INSTALL SEAT BELT .3308
METHOD FOR REMOVING SEAT BELT 3308
METHOD FOR INSTALLING SEAT BELT 3308
ELECTRICAL SYSTEM 3310
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3310
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .3310
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .3312
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3315
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY .3315
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY .3316
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3319
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY .3319
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY .3319
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY .3321
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3321
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3323
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3325
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .3325
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .3326
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3328
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .3328
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .3329
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3330
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .3330
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .3331
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR .3332
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3332
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3337
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR .3342
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3342
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3347
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3351
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .3351
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .3355
REMOVE AND INSTALL AMMONIA SENSOR 3360
METHOD FOR REMOVING AMMONIA SENSOR .3360
METHOD FOR INSTALLING AMMONIA SENSOR .3364
REMOVE AND INSTALL SCR OUTLET NOx SENSOR .3369
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3369
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3373
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .3378
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3378
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3379
60 MAINTENANCE STANDARD 3381
CONTENTS .3382
ABBREVIATION LIST 3384
ENGINE AND COOLING SYSTEM 3390
MAINTENANCE STANDARD OF ENGINE MOUNT .3390
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP .3391
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3393
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3394
POWER TRAIN 3396
MAINTENANCE STANDARD OF DRIVE SHAFT 3396
MAINTENANCE STANDARD OF TORQUE CONVERTER .3397
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV .3399
MAINTENANCE STANDARD OF TRANSMISSION .3400
MAINTENANCE STANDARD OF F, 1ST CLUTCH 3406
MAINTENANCE STANDARD OF R, 2ND CLUTCH 3408
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH 3410
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE .3412
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV .3414
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV .3415
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3416
MAINTENANCE STANDARD OF FRONT AXLE .3417
MAINTENANCE STANDARD OF REAR AXLE 3418
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3419
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL .3422
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3425
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL .3427
MAINTENANCE STANDARD OF FINAL DRIVE 3429
STEERING SYSTEM 3432
MAINTENANCE STANDARD OF STEERING COLUMN 3432
MAINTENANCE STANDARD OF STEERING PUMP 3433
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP .3436
MAINTENANCE STANDARD OF STEERING VALVE .3437
MAINTENANCE STANDARD OF STEERING CYLINDER 3439
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3441
BRAKE SYSTEM .3442
MAINTENANCE STANDARD OF CHARGE VALVE .3442
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3444
MAINTENANCE STANDARD OF SLACK ADJUSTER .3445
MAINTENANCE STANDARD OF FRONT BRAKE 3446
MAINTENANCE STANDARD OF REAR BRAKE .3447
MAINTENANCE STANDARD OF PARKING BRAKE 3448
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE .3450
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3451
MAINTENANCE STANDARD OF BRAKE COOLING PUMP .3452
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER .3453
UNDERCARRIAGE AND FRAME 3454
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN .3454
HYDRAULIC SYSTEM .3459
MAINTENANCE STANDARD OF HYDRAULIC TANK .3459
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3461
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP .3463
MAINTENANCE STANDARD OF CONTROL VALVE 3464
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE .3473
WORK EQUIPMENT .3474
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE .3474
MAINTENANCE STANDARD OF BUCKET .3478
MAINTENANCE STANDARD OF LIFT CYLINDER 3479
MAINTENANCE STANDARD OF BUCKET CYLINDER 3480
80 APPENDIX 3481
CONTENTS .3482
ABBREVIATION LIST 3484
AIR CONDITIONER SYSTEM .3490
PRECAUTIONS FOR REFRIGERANT 3490
AIR CONDITIONER COMPONENT 3491
SPECIFICATIONS OF AIR CONDITIONER 3493
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3494
OUTLINE OF REFRIGERATION CYCLE .3495
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3497
AIR CONDITIONER UNIT .3497
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3497
FUNCTION OF AIR CONDITIONER UNIT .3498
COMPONENT PARTS OF AIR CONDITIONER UNIT 3499
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .3499
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3499
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT .3500
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT .3500
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3500
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3500
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3500
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3500
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3501
FUNCTION OF DUAL PRESSURE SWITCH .3501
AIR CONDITIONER CONTROLLER .3502
STRUCTURE OF AIR CONDITIONER CONTROLLER 3502
COMPRESSOR .3503
STRUCTURE OF COMPRESSOR 3503
SPECIFICATIONS OF COMPRESSOR .3503
FUNCTION OF COMPRESSOR .3503
CONDENSER 3504
STRUCTURE OF CONDENSER .3504
SPECIFICATIONS OF CONDENSER 3504
FUNCTION OF CONDENSER 3504
RECEIVER DRIER .3505
STRUCTURE OF RECEIVER DRIER 3505
SPECIFICATIONS OF RECEIVER DRIER .3505
FUNCTION OF RECEIVER DRIER .3505
SENSORS FOR AIR CONDITIONER SYSTEM .3506
FUNCTION OF SUNLIGHT SENSOR 3506
FUNCTION OF AMBIENT TEMPERATURE SENSOR .3506
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3507
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3509
AIR CONDITIONER SYSTEM DIAGRAM .3512
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .3513
FUNCTION OF AIR CONDITIONER CONTROLLER .3514
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3515
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3521
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .3522
CHECK TEMPERATURE CONTROL FUNCTION .3523
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION .3523
TEST VENT (MODE) CHANGEOVER 3525
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3525
TESTING FRESH/RECIRC AIR CHANGEOVER 3527
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .3527
TEST EVAPORATOR TEMPERATURE SENSOR .3529
TEST RELAYS 3531
METHOD FOR TESTING RELAYS 3531
AIR CONDITIONER TROUBLESHOOTING CHART 1 3533
AIR CONDITIONER TROUBLESHOOTING CHART 2 3534
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .3537
FAILURE CODE [879AKA] 3539
FAILURE CODE [879AKB] 3541
FAILURE CODE [879BKA] 3543
FAILURE CODE [879BKB] 3545
FAILURE CODE [879CKA] 3547
FAILURE CODE [879CKB] 3549
FAILURE CODE [879DKZ] 3551
FAILURE CODE [879EMC] 3553
FAILURE CODE [879FMC] 3556
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) .3559
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3562
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .3565
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3569
TROUBLESHOOTING USING GAUGE PRESSURE .3571
CONNECTION OF SERVICE TOOL .3574
METHOD FOR CONNECTING SERVICE TOOL .3575
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3576
HANDLE COMPRESSOR OIL 3578
90 CIRCUIT DIAGRAMS 3581
CONTENTS .3582
ABBREVIATION LIST 3583
HYDRAULIC CIRCUIT DIAGRAM 3589
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3589
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC) 3593
HYDRAULIC CIRCUIT DIAGRAM (FOR JOYSTICK STEERING SPEC) .3595
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3597
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM .3599
HYDRAULIC AUTO-GREASING DIAGRAM 3601
ELECTRICAL CIRCUIT DIAGRAM .3603
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .3603
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/9) 3607
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/9) 3609
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/9) 3611
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/9) 3613
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/9) 3615
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/9) 3617
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/9) 3619
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/9) 3621
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/9) 3623
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) .3625
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) .3627
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) .3629
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) .3631
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) .3633
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) .3635
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) .3637
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) .3639
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) .3641
RDS LOAD METER SYSTEM ELECTRICAL CIRCUIT DIAGRAM .3643
INDEX .3645

DESCRIPTION:

Komatsu WA470-8E0 Wheel Loader Shop Manual SEN06753-00 –  PDF DOWNLOAD

• SERIAL NUMBERS 100439 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