Komatsu WA480-8 WHEEL LOADER Shop Manual CEBM032900 – PDF DOWNLOAD

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Komatsu WA480-8 WHEEL LOADER Shop Manual CEBM032900 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA480-8 WHEEL LOADER Shop Manual CEBM032900 – PDF DOWNLOAD

Language : English
Pages :3683
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA480-8 WHEEL LOADER Shop Manual CEBM032900 – PDF DOWNLOAD

SERIAL NUMBERS WA480-8 A48001 – A48164
ENGINE 6D125E-7

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu WA480-8 WHEEL LOADER Shop Manual CEBM032900 – PDF DOWNLOAD

SERIAL NUMBERS WA480-8 A48001 – A48164
ENGINE 6D125E-7

SHOP MANUAL, WA480-8 WHEEL LOADER 0
00 INDEX AND FOREWORD 2
INDEX 3
ABBREVIATION LIST 24
FOREWORD, SAFETY, BASIC INFORMATION 30
HOW TO READ THE SHOP MANUAL 30
SAFETY NOTICE FOR OPERATION 32
PRECAUTIONS TO PREVENT FIRE 40
ACTIONS IF FIRE OCCURS 42
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 43
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 44
PRECAUTIONS FOR DEF 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 45
THE OTHER PRECAUTIONS 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS 96
CONTENTS 97
ABBREVIATION LIST 98
SPECIFICATIONS 104
SPECIFICATION DRAWING 104
SPECIFICATION DRAWING: WA480-8 104
SPECIFICATIONS 106
SPECIFICATIONS: WA480-8 106
WEIGHT TABLE 111
WEIGHT TABLE:WA480-8 111
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 113
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 113
115
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 115
10 STRUCTURE AND FUNCTION 118
CONTENTS 119
ABBREVIATION LIST 124
UREA SCR SYSTEM 130
LAYOUT DRAWING OF UREA SCR SYSTEM 130
UREA SCR SYSTEM DIAGRAM 132
FUNCTION OF UREA SCR SYSTEM 133
FUNCTION OF AdBlue/DEF SYSTEM 133
INDUCEMENT STRATEGY 135
COMPONENT PARTS OF UREA SCR SYSTEM 142
AdBlue/DEF MIXING TUBE 142
SCR ASSEMBLY 142
AdBlue/DEF TANK 145
AdBlue/DEF PUMP 147
AdBlue/DEF INJECTOR 148
AdBlue/DEF HOSE 149
AdBlue/DEF TANK HEATING VALVE 150
BOOT-UP SYSTEM 151
LAYOUT DRAWING OF BOOT-UP SYSTEM 151
SYSTEM OPERATING LAMP SYSTEM 153
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 153
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 153
BATTERY DISCONNECT SWITCH 154
FUNCTION OF BATTERY DISCONNECT SWITCH 154
PREHEATING SYSTEM 155
PREHEATING SYSTEM DIAGRAM 155
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 155
OPERATION OF AUTOMATIC PREHEATING SYSTEM 155
FUNCTION OF MANUAL PREHEATING SYSTEM 156
OPERATION OF MANUAL PREHEATING SYSTEM 156
ENGINE SYSTEM 157
LAYOUT DRAWING OF ENGINE SYSTEM 157
FUNCTION OF ENGINE SYSTEM 158
ENGINE CONTROL SYSTEM 159
ENGINE CONTROL SYSTEM DIAGRAM 159
FUNCTION OF ENGINE CONTROL SYSTEM 160
OPERATION OF ENGINE CONTROL SYSTEM 163
ENGINE POWER MODE SELECTOR SYSTEM 165
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 165
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 165
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM 166
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 166
COMPONENT PARTS OF ENGINE SYSTEM 167
VGT 167
EGR SYSTEM 170
EGR VALVE 172
EGR COOLER 174
KCCV SYSTEM 175
KCCV VENTILATOR 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
COOLING FAN CONTROL SYSTEM 186
COOLING FAN CONTROL SYSTEM DIAGRAM 186
FUNCTION OF COOLING FAN CONTROL SYSTEM 186
COMPONENT PARTS OF COOLING SYSTEM 191
BRAKE AND COOLING FAN PUMP 191
COOLING FAN MOTOR 198
CONTROL SYSTEM 204
LAYOUT DRAWING OF CONTROL SYSTEM 204
MACHINE MONITOR SYSTEM 206
MACHINE MONITOR SYSTEM DIAGRAM 206
FUNCTION OF MACHINE MONITOR SYSTEM 206
REARVIEW MONITOR SYSTEM 208
REARVIEW MONITOR SYSTEM DIAGRAM 208
FUNCTION OF REARVIEW MONITOR SYSTEM 208
KOMTRAX SYSTEM 209
KOMTRAX SYSTEM DIAGRAM 209
FUNCTION OF KOMTRAX SYSTEM 209
LOAD METER SYSTEM 210
LOAD METER SYSTEM DIAGRAM 210
FUNCTION OF LOAD METER SYSTEM 210
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
SWITCH PANEL 236
REARVIEW MONITOR 237
REARVIEW CAMERA 238
KOMTRAX TERMINAL 239
TRANSMISSION CONTROLLER 241
WORK EQUIPMENT CONTROLLER 245
MONITOR CONTROLLER 249
CAN TERMINATING RESISTOR 253
ENGINE CONTROLLER 254
ACCELERATOR PEDAL 260
HYDRAULIC SYSTEM 262
LAYOUT DRAWING OF HYDRAULIC SYSTEM 262
CLSS 263
STRUCTURE OF CLSS 263
FUNCTION OF CLSS 264
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 266
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 266
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 266
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 266
COMPONENT PARTS OF HYDRAULIC SYSTEM 267
HYDRAULIC TANK 267
WORK EQUIPMENT PUMP 270
STEERING PUMP 288
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 299
CONTROL VALVE 300
POWER TRAIN SYSTEM 334
LAYOUT DRAWING OF POWER TRAIN SYSTEM 334
OPERATION OF POWER TRAIN SYSTEM 337
TRANSMISSION CONTROL SYSTEM 338
TRANSMISSION CONTROL SYSTEM DIAGRAM 338
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 340
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 340
ELECTRIC MODULATION FUNCTION 341
DISPLAY FUNCTION OF GEAR SHIFT 341
AUTOMATIC GEAR SHIFT FUNCTION 341
SHIFT HOLD FUNCTION 342
KICKDOWN FUNCTION 342
AUTOMATIC KICKDOWN FUNCTION 343
TORQUE CONVERTER LOCKUP FUNCTION 343
HUNTING PREVENTION FUNCTION 344
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 344
SHIFT POINT CHANGING FUNCTION 344
4TH GEAR SPEED LIMITATION FUNCTION 344
TRANSMISSION PROTECTION FUNCTION 346
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 346
SHIFT DOWN PROTECTION FUNCTION 346
ENGINE OVERRUN PREVENTION FUNCTION 347
MAXIMUM SPEED LIMITATION FUNCTION 347
NEUTRALIZER FUNCTION 347
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 349
TRANSMISSION CUT-OFF FUNCTION 351
COMPONENT PARTS OF POWER TRAIN SYSTEM 353
DRIVE SHAFT 353
TORQUE CONVERTER 355
LOCKUP CLUTCH ECMV 357
TRANSMISSION 361
TRANSMISSION CONTROL VALVE 378
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 380
3RD AND 4TH CLUTCH ECMV 385
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 391
AXLE 393
CONVENTIONAL DIFFERENTIAL 395
LIMITED SLIP DIFFERENTIAL 397
FINAL DRIVE 402
AJSS KNOB 403
COMBINATION SWITCH 405
SHIFT HOLD SWITCH 408
KICKDOWN SWITCH 409
WORK EQUIPMENT SYSTEM 410
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 410
WORK EQUIPMENT SYSTEM DIAGRAM 412
WORK EQUIPMENT CONTROL SYSTEM 414
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 414
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 414
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 415
WORK EQUIPMENT LEVER OPERATION FUNCTION 416
BUCKET PRIORITY CONTROL FUNCTION 416
BOOM STOP MODULATION FUNCTION 416
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 418
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 418
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 418
REMOTE POSITIONER SYSTEM 420
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 420
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 420
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 421
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 421
BUCKET POSITIONER AND BOOM POSITIONER 425
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 425
AUTO-DIGGING SYSTEM 426
AUTO-DIGGING SYSTEM DIAGRAM 426
FUNCTION OF AUTO-DIGGING SYSTEM 426
ECSS 428
ECSS DIAGRAM 428
FUNCTION OF ECSS 428
OPERATION OF ECSS 428
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 430
WORK EQUIPMENT LOCK SOLENOID VALVE 430
PILOT CIRCUIT ACCUMULATOR 431
ECSS CIRCUIT ACCUMULATOR 432
WORK EQUIPMENT ELECTRIC LEVER 434
MULTIFUNCTION MONO-LEVER 436
STEERING SYSTEM 438
LAYOUT DRAWING OF STEERING SYSTEM 438
SECONDARY STEERING SYSTEM 441
SECONDARY STEERING SYSTEM DIAGRAM 441
FUNCTION OF SECONDARY STEERING SYSTEM 441
AJSS 443
LAYOUT DRAWING OF AJSS 443
AJSS DIAGRAM 444
FUNCTION OF AJSS 445
NEUTRALIZER FUNCTION OF AJSS 446
NEUTRAL INTERLOCK FUNCTION OF AJSS 446
SPEED SENSING STEERING FUNCTION OF AJSS 447
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS 448
STEERING COLUMN 449
STRUCTURE OF STEERING COLUMN 449
COMPONENT PARTS OF STEERING SYSTEM 450
AJSS EPC VALVE 450
STEERING LOCK VALVE 450
ROTARY VALVE 452
ORBITROL VALVE 455
STOP VALVE 459
STEERING VALVE 459
SECONDARY STEERING PUMP 471
SECONDARY STEERING MOTOR 472
BRAKE SYSTEM 474
LAYOUT DRAWING OF BRAKE SYSTEM 474
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 475
PARKING BRAKE CONTROL SYSTEM 477
PARKING BRAKE CONTROL SYSTEM DIAGRAM 477
OPERATION OF PARKING BRAKE CONTROL SYSTEM 477
BRAKE COOLING CONTROL SYSTEM 479
BRAKE COOLING CONTROL SYSTEM DIAGRAM 479
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 479
COMPONENT PARTS OF BRAKE SYSTEM 480
CHARGE VALVE 480
PARKING BRAKE SOLENOID VALVE 485
PARKING BRAKE EMERGENCY RELEASE VALVE 487
BRAKE CIRCUIT ACCUMULATOR 488
BRAKE VALVE 489
SLACK ADJUSTER 493
BRAKE 495
PARKING BRAKE 498
FLOW PRIORITY VALVE 499
BRAKE COOLING MOTOR 501
BRAKE COOLING PUMP 502
BRAKE COOLING OIL COOLER 503
AUTO-GREASING SYSTEM 505
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 505
SPECIFICATIONS OF AUTO-GREASING SYSTEM 506
FUNCTION OF AUTO-GREASING SYSTEM 508
COMPONENT PARTS OF AUTO-GREASING SYSTEM 509
AUTO-GREASING PUMP 509
UNDERCARRIAGE AND FRAME 510
FRAME, AXLE MOUNT AND CENTER HINGE PIN 510
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 510
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 510
TIRE 512
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 512
STRUCTURE OF RADIAL TIRE 512
FUNCTION OF RADIAL TIRE 512
STRUCTURE OF BIAS TIRE 513
FUNCTION OF BIAS TIRE 513
WORK EQUIPMENT 514
STRUCTURE OF WORK EQUIPMENT 514
STRUCTURE OF BUCKET 515
CAB AND ITS ATTACHMENTS 516
ROPS CAB 516
STRUCTURE OF ROPS CAB 516
FUNCTION OF ROPS CAB 516
20 STANDARD VALUE TABLE 518
CONTENTS 519
ABBREVIATION LIST 520
STANDARD VALUE TABLE FOR ENGINE 526
STANDARD VALUE TABLE FOR ENGINE: WA480-8 526
STANDARD VALUE TABLE FOR MACHINE 530
STANDARD VALUE TABLE FOR MACHINE: WA480-8 530
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 553
30 TESTING AND ADJUSTING 558
CONTENTS 559
ABBREVIATION LIST 563
RELATED INFORMATION ON TESTING AND ADJUSTING 569
TOOLS FOR TESTING AND ADJUSTING 569
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 578
ENGINE AND COOLING SYSTEM 580
TEST ENGINE SPEED 580
METHOD FOR TESTING ENGINE SPEED 580
TEST BOOST PRESSURE 585
METHOD FOR TESTING BOOST PRESSURE 585
TESTING EXHAUST GAS TEMPERATURE 588
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 588
TEST EXHAUST GAS COLOR 590
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 590
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 591
TEST AND ADJUST VALVE CLEARANCE 592
METHOD FOR TESTING VALVE CLEARANCE 592
METHOD FOR ADJUSTING VALVE CLEARANCE 594
TEST COMPRESSION PRESSURE 595
METHOD FOR TESTING COMPRESSION PRESSURE 595
TEST BLOWBY PRESSURE 599
METHOD FOR TESTING BLOWBY PRESSURE 599
TEST ENGINE OIL PRESSURE 602
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 602
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 602
TEST EGR VALVE AND VGT OIL PRESSURE 604
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 604
TEST FUEL PRESSURE 605
METHOD FOR TESTING FUEL PRESSURE 605
TEST FUEL RETURN RATE AND LEAKAGE 607
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 608
BLEEDING AIR FROM FUEL SYSTEM 611
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 612
TEST FUEL CIRCUIT FOR LEAKAGE 613
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 613
HANDLE CYLINDER CUT-OUT MODE OPERATION 615
HANDLE NO-INJECTION CRANKING OPERATION 616
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 617
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 617
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 618
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 618
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 619
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 619
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 620
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 620
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 620
TEST ALTERNATOR BELT 622
METHOD FOR TESTING ALTERNATOR BELT 622
TEST AUTOMATIC TENSIONER 624
METHOD FOR TESTING AUTOMATIC TENSIONER 624
CLEAN FUEL DOSER 627
METHOD FOR CLEANING FUEL DOSER 627
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 629
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 629
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 636
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 636
TEST SCR RELATED FUNCTIONS 637
TEST AdBlue/DEF PUMP RAISED PRESSURE 640
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 643
TEST AdBlue/DEF LINE HEATER RELAY 1 648
TEST AdBlue/DEF LINE HEATER RELAY 2 651
TEST AdBlue/DEF PUMP HEATER RELAY 654
TEST AdBlue/DEF TANK HEATER VALVE 658
TEST SCR NOx REMOVAL EFFICIENCY 661
CLEAN AdBlue/DEF TANK 666
METHOD FOR CLEANING AdBlue/DEF TANK 666
POWER TRAIN 670
TEST AND ADJUST POWER TRAIN OIL PRESSURE 670
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 672
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 690
ADJUST TRANSMISSION INPUT SPEED SENSOR 692
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 692
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 694
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 694
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 695
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 695
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 698
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 699
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 702
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 702
STEERING SYSTEM 703
TEST STEERING WHEEL 703
METHOD FOR TESTING STEERING WHEEL 703
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 705
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 705
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 709
BLEED AIR FROM STEERING CYLINDER CIRCUIT 711
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 711
TEST AND ADJUST STEERING STOP VALVE 713
METHOD FOR TESTING STEERING STOP VALVE 713
METHOD FOR ADJUSTING STEERING STOP VALVE 713
BRAKE SYSTEM 714
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 714
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 714
TEST WHEEL BRAKE OIL PRESSURE 715
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 715
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 717
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE 717
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE 718
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 719
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 719
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 721
BLEED AIR FROM BRAKE CIRCUIT 724
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 724
TEST BRAKING PERFORMANCE 728
METHOD FOR TESTING BRAKING PERFORMANCE 728
TEST BRAKE PEDAL 729
METHOD FOR TESTING BRAKE PEDAL 729
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 730
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 730
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 730
TEST LOWERING OF WHEEL BRAKE PRESSURE 731
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 732
TEST WEAR OF WHEEL BRAKE DISC 734
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 734
TEST PARKING BRAKE OIL PRESSURE 736
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 736
TEST PARKING BRAKE PERFORMANCE 738
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 738
RELEASE PARKING BRAKE MANUALLY 739
METHOD FOR RELEASING PARKING BRAKE MANUALLY 739
TEST WEAR AMOUNT OF PARKING BRAKE DISC 742
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 742
HYDRAULIC SYSTEM 744
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 744
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 744
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 746
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 746
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 750
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 752
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 752
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 755
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 757
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 757
TEST COOLING FAN SPEED 758
METHOD FOR TESTING COOLING FAN SPEED 758
TEST COOLING FAN CIRCUIT OIL PRESSURE 759
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 759
BLEED AIR FROM COOLING FAN CIRCUIT 762
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 762
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 764
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 764
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 766
WORK EQUIPMENT 770
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 770
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 770
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 770
TEST AND ADJUST BOOM POTENTIOMETER LEVER 771
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 771
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 771
CAB AND ITS ATTACHMENTS 772
TEST DIRECTIONAL LEVER 772
METHOD FOR TESTING DIRECTIONAL LEVER 772
TEST WORK EQUIPMENT CONTROL LEVER 773
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 773
TEST AJSS LEVER (FOR AJSS SPEC) 776
METHOD FOR TESTING AJSS LEVER 776
TEST STEERING LOCK LEVER(FOR AJSS SPEC) 779
METHOD FOR TESTING OF STEERING LOCK LEVER 779
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC) 780
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR 780
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR 780
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) 782
METHOD FOR TESTING STEERING STOPPER VALVE 782
METHOD FOR ADJUSTING STEERING STOPPER VALVE 782
ADJUST RATTLING OPERATOR’S SEAT 784
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 784
ELECTRICAL SYSTEM 785
SET AND ADJUST EACH EQUIPMENT 785
PREPARATION FOR TRANSMISSION ECMV CURRENT ADJUSTMENT 788
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 789
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 792
SET AND OPERATE MACHINE MONITOR 797
OPERATOR MODE 800
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 801
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 801
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 802
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 803
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 803
SERVICE MODE 806
METHOD FOR OPERATING SERVICE MODE 806
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 810
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 823
ABNORMALITY RECORD MENU 839
METHOD FOR CONFIRMING MAINTENANCE RECORD 844
METHOD FOR OPERATING MAINTENANCE MODE SETTING 846
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 851
DEFAULT MENU 852
DIAGNOSTIC TESTS MENU 868
ADJUSTMENT MENU 879
METHOD FOR PERFORMING NO-INJECTION CRANKING 917
KOMTRAX SETTINGS MENU 919
METHOD FOR DISPLAYING SERVICE MESSAGE 922
METHOD FOR STARTING UP KOMTRAX TERMINAL 924
ADJUST REARVIEW CAMERA ANGLE 929
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 929
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 931
HANDLE BATTERY DISCONNECT SWITCH 932
TEST DIODES 933
METHOD FOR TESTING DIODE USING DIGITAL TESTER 933
METHOD FOR TESTING DIODE USING ANALOG TESTER 933
AUTO-GREASING DEVICE 934
BLEED THE AIR OF AUTO-GREASING SYSTEM 934
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 934
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 937
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 937
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 938
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 939
Pm CLINIC 941
Pm CLINIC SERVICE 941
Pm CLINIC CHECK SHEET: WA480-8 943
40 TROUBLESHOOTING 954
CONTENTS 955
ABBREVIATION LIST 968
RELATED INFORMATION ON TROUBLESHOOTING 974
GENERAL TROUBLESHOOTING POINTS 974
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 975
SEQUENCE OF EVENTS IN TROUBLESHOOTING 987
CHECKS BEFORE TROUBLESHOOTING 989
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 991
WALK-AROUND CHECK 991
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 993
CHECK FUEL LEVEL AND TYPE 993
CHECK IMPURE INGREDIENT IN FUEL 993
CHECK AdBule/DEF LEVEL AND TYPE 994
CHECK FUEL PREFILTER 994
CHECK MAIN FILTER 996
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 997
CHECK COOLANT LEVEL (RESERVOIR TANK) 997
CHECK CLOGGING OF AIR CLEANER 998
OUTER ELEMENT – CLEAN 999
REPLACE ELEMENT1001
CHECK HYDRAULIC OIL LEVEL1002
CHECK HYDRAULIC OIL STRAINER1003
CHECK HYDRAULIC FILTER1004
CHECK OIL LEVEL IN TRANSMISSION CASE1005
CHECK OIL LEVEL IN FRONT AXLE CASE1007
CHECK OIL LEVEL IN REAR AXLE CASE1008
BLEED AIR FROM FUEL SYSTEM1008
BLEED AIR FROM HYDRAULIC SYSTEM1008
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod1008
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION1014
PROCEDURE FOR TESTING AND TROUBLESHOOTING1026
SYMPTOM AND TROUBLESHOOTING NUMBERS1028
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE1033
CONNECTORS LIST AND LAYOUT1035
CONNECTOR CONTACT IDENTIFICATION1062
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1102
FUSE LOCATION TABLE1108
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1112
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR1116
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT1118
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1124
FAILURE CODES TABLE1126
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1150
FAILURE CODE [1500L0]1150
FAILURE CODE [15SAL1]1151
FAILURE CODE [15SALH]1153
FAILURE CODE [15SBL1]1155
FAILURE CODE [15SBLH]1157
FAILURE CODE [15SEL1]1159
FAILURE CODE [15SELH]1161
FAILURE CODE [15SFL1]1163
FAILURE CODE [15SFLH]1165
FAILURE CODE [15SGL1]1167
FAILURE CODE [15SGLH]1169
FAILURE CODE [15SHL1]1171
FAILURE CODE [15SHLH]1173
FAILURE CODE [2F00MA]1176
FAILURE CODE [2F00MB]1180
FAILURE CODE [2G42ZG]1183
FAILURE CODE [2G43ZG]1185
FAILURE CODE [879AKA]1187
FAILURE CODE [879AKB]1189
FAILURE CODE [879BKA]1191
FAILURE CODE [879BKB]1193
FAILURE CODE [879CKA]1195
FAILURE CODE [879CKB]1197
FAILURE CODE [879DKZ]1199
FAILURE CODE [879EMC]1201
FAILURE CODE [879FMC]1204
FAILURE CODE [989A00]1207
FAILURE CODE [989L00]1208
FAILURE CODE [989M00]1209
FAILURE CODE [989N00]1210
FAILURE CODE [A1U0N3]1211
FAILURE CODE [A1U0N4]1213
FAILURE CODE [AA10NX]1215
FAILURE CODE [AB00KE]1217
FAILURE CODE [AB00KY]1219
FAILURE CODE [AQ10N3]1221
FAILURE CODE [AS00N3]1223
FAILURE CODE [AS00R2]1225
FAILURE CODE [AS00R3]1226
FAILURE CODE [AS00R4]1227
FAILURE CODE [AS00R5]1228
FAILURE CODE [AS00R6]1229
FAILURE CODE [AS00ZK]1230
FAILURE CODE [AS10KM]1231
FAILURE CODE [AS10NR]1232
FAILURE CODE [AS10NT]1233
FAILURE CODE [B@BAZG]1234
FAILURE CODE [B@BAZK]1235
FAILURE CODE [B@BCNS]1237
FAILURE CODE [B@BCZK]1238
FAILURE CODE [B@C7NS]1240
FAILURE CODE [B@CENS]1242
FAILURE CODE [B@HANS]1243
FAILURE CODE [CA115]1244
FAILURE CODE [CA122]1245
FAILURE CODE [CA123]1247
FAILURE CODE [CA131]1249
FAILURE CODE [CA132]1251
FAILURE CODE [CA135]1254
FAILURE CODE [CA141]1256
FAILURE CODE [CA144]1258
FAILURE CODE [CA145]1260
FAILURE CODE [CA153]1262
FAILURE CODE [CA154]1265
FAILURE CODE [CA187]1268
FAILURE CODE [CA221]1270
FAILURE CODE [CA222]1272
FAILURE CODE [CA227]1274
FAILURE CODE [CA234]1275
FAILURE CODE [CA238]1276
FAILURE CODE [CA239]1278
FAILURE CODE [CA249]1280
FAILURE CODE [CA256]1282
FAILURE CODE [CA271]1284
FAILURE CODE [CA272]1286
FAILURE CODE [CA273]1287
FAILURE CODE [CA274]1289
FAILURE CODE [CA322]1290
FAILURE CODE [CA323]1292
FAILURE CODE [CA324]1294
FAILURE CODE [CA325]1296
FAILURE CODE [CA331]1298
FAILURE CODE [CA332]1300
FAILURE CODE [CA343]1302
FAILURE CODE [CA351]1303
FAILURE CODE [CA352]1304
FAILURE CODE [CA356]1307
FAILURE CODE [CA357]1309
FAILURE CODE [CA386]1311
FAILURE CODE [CA431]1312
FAILURE CODE [CA432]1315
FAILURE CODE [CA441]1319
FAILURE CODE [CA442]1321
FAILURE CODE [CA449]1322
FAILURE CODE [CA451]1323
FAILURE CODE [CA452]1325
FAILURE CODE [CA515]1327
FAILURE CODE [CA516]1329
FAILURE CODE [CA553]1331
FAILURE CODE [CA555]1332
FAILURE CODE [CA556]1333
FAILURE CODE [CA559]1334
FAILURE CODE [CA595]1339
FAILURE CODE [CA687]1340
FAILURE CODE [CA689]1342
FAILURE CODE [CA691]1344
FAILURE CODE [CA692]1346
FAILURE CODE [CA697]1348
FAILURE CODE [CA698]1349
FAILURE CODE [CA731]1350
FAILURE CODE [CA778]1351
FAILURE CODE [CA1117]1354
FAILURE CODE [CA1664]1355
FAILURE CODE [CA1669]1358
FAILURE CODE [CA1673]1359
FAILURE CODE [CA1677]1360
FAILURE CODE [CA1678]1361
FAILURE CODE [CA1682]1362
FAILURE CODE [CA1683]1366
FAILURE CODE [CA1684]1368
FAILURE CODE [CA1686]1370
FAILURE CODE [CA1691]1371
FAILURE CODE [CA1694]1374
FAILURE CODE [CA1695]1376
FAILURE CODE [CA1696]1377
FAILURE CODE [CA1712]1379
FAILURE CODE [CA1713]1382
FAILURE CODE [CA1714]1384
FAILURE CODE [CA1715]1385
FAILURE CODE [CA1776]1386
FAILURE CODE [CA1777]1389
FAILURE CODE [CA1843]1392
FAILURE CODE [CA1844]1394
FAILURE CODE [CA1879]1397
FAILURE CODE [CA1881]1400
FAILURE CODE [CA1883]1402
FAILURE CODE [CA1885]1406
FAILURE CODE [CA1887]1408
FAILURE CODE [CA1921]1410
FAILURE CODE [CA1922]1413
FAILURE CODE [CA1923]1418
FAILURE CODE [CA1924]1420
FAILURE CODE [CA1925]1422
FAILURE CODE [CA1927]1424
FAILURE CODE [CA1928]1426
FAILURE CODE [CA1942]1428
FAILURE CODE [CA1963]1429
FAILURE CODE [CA1977]1433
FAILURE CODE [CA1993]1436
FAILURE CODE [CA2185]1439
FAILURE CODE [CA2186]1441
FAILURE CODE [CA2249]1443
FAILURE CODE [CA2265]1444
FAILURE CODE [CA2266]1446
FAILURE CODE [CA2271]1449
FAILURE CODE [CA2272]1451
FAILURE CODE [CA2349]1453
FAILURE CODE [CA2353]1455
FAILURE CODE [CA2357]1457
FAILURE CODE [CA2381]1458
FAILURE CODE [CA2382]1460
FAILURE CODE [CA2383]1462
FAILURE CODE [CA2386]1464
FAILURE CODE [CA2387]1466
FAILURE CODE [CA2555]1467
FAILURE CODE [CA2556]1469
FAILURE CODE [CA2637]1471
FAILURE CODE [CA2639]1473
FAILURE CODE [CA2732]1476
FAILURE CODE [CA2733]1478
FAILURE CODE [CA2741]1480
FAILURE CODE [CA2765]1481
FAILURE CODE [CA2771]1482
FAILURE CODE [CA2777]1488
FAILURE CODE [CA2878]1491
FAILURE CODE [CA2881]1494
FAILURE CODE [CA2976]1497
FAILURE CODE [CA3133]1499
FAILURE CODE [CA3134]1501
FAILURE CODE [CA3135]1503
FAILURE CODE [CA3142]1507
FAILURE CODE [CA3143]1508
FAILURE CODE [CA3144]1509
FAILURE CODE [CA3146]1512
FAILURE CODE [CA3147]1513
FAILURE CODE [CA3148]1514
FAILURE CODE [CA3151]1516
FAILURE CODE [CA3165]1522
FAILURE CODE [CA3167]1524
FAILURE CODE [CA3229]1527
FAILURE CODE [CA3231]1529
FAILURE CODE [CA3232]1531
FAILURE CODE [CA3235]1535
FAILURE CODE [CA3239]1537
FAILURE CODE [CA3241]1540
FAILURE CODE [CA3242]1543
FAILURE CODE [CA3251]1546
FAILURE CODE [CA3253]1548
FAILURE CODE [CA3254]1551
FAILURE CODE [CA3255]1554
FAILURE CODE [CA3256]1558
FAILURE CODE [CA3311]1560
FAILURE CODE [CA3312]1562
FAILURE CODE [CA3313]1565
FAILURE CODE [CA3314]1566
FAILURE CODE [CA3315]1567
FAILURE CODE [CA3316]1570
FAILURE CODE [CA3317]1571
FAILURE CODE [CA3318]1572
FAILURE CODE [CA3319]1575
FAILURE CODE [CA3321]1576
FAILURE CODE [CA3322]1578
FAILURE CODE [CA3419]1581
FAILURE CODE [CA3421]1583
FAILURE CODE [CA3497]1585
FAILURE CODE [CA3498]1586
FAILURE CODE [CA3543]1587
FAILURE CODE [CA3545]1594
FAILURE CODE [CA3547]1596
FAILURE CODE [CA3558]1597
FAILURE CODE [CA3559]1599
FAILURE CODE [CA3562]1601
FAILURE CODE [CA3563]1603
FAILURE CODE [CA3567]1606
FAILURE CODE [CA3568]1609
FAILURE CODE [CA3571]1615
FAILURE CODE [CA3572]1617
FAILURE CODE [CA3574]1619
FAILURE CODE [CA3575]1621
FAILURE CODE [CA3577]1623
FAILURE CODE [CA3578]1625
FAILURE CODE [CA3582]1627
FAILURE CODE [CA3583]1635
FAILURE CODE [CA3596]1637
FAILURE CODE [CA3649]1640
FAILURE CODE [CA3681]1642
FAILURE CODE [CA3682]1647
FAILURE CODE [CA3713]1653
FAILURE CODE [CA3717]1656
FAILURE CODE [CA3718]1657
FAILURE CODE [CA3725]1658
FAILURE CODE [CA3748]1661
FAILURE CODE [CA3751]1664
FAILURE CODE [CA3755]1666
FAILURE CODE [CA3866]1668
FAILURE CODE [CA3867]1671
FAILURE CODE [CA3868]1674
FAILURE CODE [CA3899]1678
FAILURE CODE [CA3911]1680
FAILURE CODE [CA3912]1684
FAILURE CODE [CA3932]1686
FAILURE CODE [CA3933]1688
FAILURE CODE [CA3934]1690
FAILURE CODE [CA3935]1693
FAILURE CODE [CA3936]1695
FAILURE CODE [CA4151]1697
FAILURE CODE [CA4152]1701
FAILURE CODE [CA4155]1705
FAILURE CODE [CA4156]1707
FAILURE CODE [CA4157]1710
FAILURE CODE [CA4158]1712
FAILURE CODE [CA4159]1713
FAILURE CODE [CA4161]1714
FAILURE CODE [CA4162]1717
FAILURE CODE [CA4163]1720
FAILURE CODE [CA4164]1722
FAILURE CODE [CA4165]1724
FAILURE CODE [CA4166]1726
FAILURE CODE [CA4168]1728
FAILURE CODE [CA4169]1731
FAILURE CODE [CA4171]1733
FAILURE CODE [CA4249]1736
FAILURE CODE [CA4251]1738
FAILURE CODE [CA4259]1740
FAILURE CODE [CA4261]1743
FAILURE CODE [CA4277]1746
FAILURE CODE [CA4281]1749
FAILURE CODE [CA4459]1752
FAILURE CODE [CA4461]1755
FAILURE CODE [CA4658]1758
FAILURE CODE [CA4731]1762
FAILURE CODE [CA4732]1763
FAILURE CODE [CA4739]1764
FAILURE CODE [CA4768]1765
FAILURE CODE [CA4769]1767
FAILURE CODE [CA4842]1770
FAILURE CODE [CA4952]1773
FAILURE CODE [CA5115]1775
FAILURE CODE [CA5179]1778
FAILURE CODE [CA5181]1780
FAILURE CODE [CA5383]1782
FAILURE CODE [D150KA]1784
FAILURE CODE [D150KB]1786
FAILURE CODE [D150KY]1788
FAILURE CODE [D160KA]1790
FAILURE CODE [D160KB]1792
FAILURE CODE [D160KY]1794
FAILURE CODE [D191KA]1796
FAILURE CODE [D191KB]1799
FAILURE CODE [D191KY]1802
FAILURE CODE [D192KA]1804
FAILURE CODE [D192KB]1806
FAILURE CODE [D192KY]1808
FAILURE CODE [D19JKZ]1809
FAILURE CODE [D1E6KA]1811
FAILURE CODE [D1E6KB]1813
FAILURE CODE [D1E6KY]1815
FAILURE CODE [D5ZHKA]1817
FAILURE CODE [D5ZHKB]1819
FAILURE CODE [D5ZHKZ]1821
FAILURE CODE [D5ZHL6]1824
FAILURE CODE [D811MC]1826
FAILURE CODE [D862KA]1827
FAILURE CODE [D8ALKA]1828
FAILURE CODE [D8ALKB]1830
FAILURE CODE [D8AQK4]1832
FAILURE CODE [D8AQKR]1833
FAILURE CODE [DAF0KT]1835
FAILURE CODE [DAF0MB]1836
FAILURE CODE [DAF0MC]1837
FAILURE CODE [DAF3KK]1838
FAILURE CODE [DAF8KB]1840
FAILURE CODE [DAFDKB]1842
FAILURE CODE [DAFGMC]1844
FAILURE CODE [DAFLKA]1845
FAILURE CODE [DAFLKB]1847
FAILURE CODE [DAFQKR]1849
FAILURE CODE [DAQ0KK]1850
FAILURE CODE [DAQ0KT]1853
FAILURE CODE [DAQ0MC]1854
FAILURE CODE [DAQ1KA]1855
FAILURE CODE [DAQ2KK]1857
FAILURE CODE [DAQ4KB]1860
FAILURE CODE [DAQ9KQ]1862
FAILURE CODE [DAQLKA]1863
FAILURE CODE [DAQLKB]1865
FAILURE CODE [DAQQKR]1867
FAILURE CODE [DAQRKR]1868
FAILURE CODE [DAQRMA]1869
FAILURE CODE [DAZ9KQ]1870
FAILURE CODE [DAZQKR]1871
FAILURE CODE [DB2QKR]1872
FAILURE CODE [DB2RKR]1877
FAILURE CODE [DB90KK]1883
FAILURE CODE [DB90KT]1886
FAILURE CODE [DB90MC]1887
FAILURE CODE [DB91KA]1888
FAILURE CODE [DB92KK]1890
FAILURE CODE [DB95KX]1893
FAILURE CODE [DB96KX]1896
FAILURE CODE [DB99KQ]1898
FAILURE CODE [DB9LKA]1899
FAILURE CODE [DB9LKB]1901
FAILURE CODE [DB9QKR]1903
FAILURE CODE [DB9RKR]1904
FAILURE CODE [DB9RMA]1905
FAILURE CODE [DBE5KX]1906
FAILURE CODE [DBE6KX]1908
FAILURE CODE [DD1ALD]1910
FAILURE CODE [DDAAL6]1912
FAILURE CODE [DDB6L4]1914
FAILURE CODE [DDD1LD]1917
FAILURE CODE [DDK3KA]1919
FAILURE CODE [DDK3KB]1922
FAILURE CODE [DDK4KA]1925
FAILURE CODE [DDK4KB]1928
FAILURE CODE [DDK5L4]1930
FAILURE CODE [DDK6KA]1932
FAILURE CODE [DDK6KB]1935
FAILURE CODE [DDKLKA]1938
FAILURE CODE [DDKLKB]1941
FAILURE CODE [DDNRKY]1943
FAILURE CODE [DDP5KA]1945
FAILURE CODE [DDT0L4]1947
FAILURE CODE [DDT4LD]1949
FAILURE CODE [DDT9LD]1951
FAILURE CODE [DDTALD]1953
FAILURE CODE [DDW9LD]1955
FAILURE CODE [DDWLLD]1957
FAILURE CODE [DF10KA]1959
FAILURE CODE [DF10KB]1962
FAILURE CODE [DGF1KA]1965
FAILURE CODE [DGF1KB]1967
FAILURE CODE [DGH2KX]1969
FAILURE CODE [DGR2KB]1971
FAILURE CODE [DGR2KZ]1973
FAILURE CODE [DGT1KA]1975
FAILURE CODE [DGT1KB]1977
FAILURE CODE [DH21KA]1979
FAILURE CODE [DH21KB]1982
FAILURE CODE [DHA4KA]1984
FAILURE CODE [DHAAMA]1986
FAILURE CODE [DHACMA]1988
FAILURE CODE [DHPCKX]1990
FAILURE CODE [DHPDKX]1993
FAILURE CODE [DHT1KX]1996
FAILURE CODE [DHT5KX]1999
FAILURE CODE [DHT7KX]2002
FAILURE CODE [DHT8KA]2005
FAILURE CODE [DHT8KB]2008
FAILURE CODE [DHT8ZG]2010
FAILURE CODE [DHUDKA]2011
FAILURE CODE [DHUDKB]2014
FAILURE CODE [DJF1KA]2016
FAILURE CODE [DK30KA]2018
FAILURE CODE [DK30KY]2020
FAILURE CODE [DK55KA]2022
FAILURE CODE [DK55KY]2025
FAILURE CODE [DK55L5]2027
FAILURE CODE [DK59KA]2028
FAILURE CODE [DK59KY]2032
FAILURE CODE [DK59L8]2036
FAILURE CODE [DK5AKA]2041
FAILURE CODE [DK5AKY]2045
FAILURE CODE [DK5BKA]2049
FAILURE CODE [DK5BKY]2053
FAILURE CODE [DK5BL8]2057
FAILURE CODE [DK5CKA]2062
FAILURE CODE [DK5CKY]2066
FAILURE CODE [DK5DKA]2070
FAILURE CODE [DK5DKY]2073
FAILURE CODE [DK5DL8]2076
FAILURE CODE [DK5EKA]2080
FAILURE CODE [DK5EKY]2083
FAILURE CODE [DKA0KA]2086
FAILURE CODE [DKA0KY]2089
FAILURE CODE [DKA0L0]2092
FAILURE CODE [DKA1KA]2095
FAILURE CODE [DKA1KY]2098
FAILURE CODE [DKD0KA]2101
FAILURE CODE [DKD0KY]2103
FAILURE CODE [DKD0L8]2105
FAILURE CODE [DLF1KA]2106
FAILURE CODE [DLF1LC]2108
FAILURE CODE [DLM3KA]2110
FAILURE CODE [DLM3LC]2112
FAILURE CODE [DLT3KA]2114
FAILURE CODE [DLT3LC]2116
FAILURE CODE [DPQ1KR]2118
FAILURE CODE [DPQ2KR]2121
FAILURE CODE [DPQ3KR]2124
FAILURE CODE [DSJ0KR]2127
FAILURE CODE [DT20KB]2130
FAILURE CODE [DT22KB]2132
FAILURE CODE [DT23KB]2134
FAILURE CODE [DV00KB]2136
FAILURE CODE [DW4PKA]2138
FAILURE CODE [DW4PKB]2140
FAILURE CODE [DW4PKY]2142
FAILURE CODE [DW4QKA]2144
FAILURE CODE [DW4QKB]2146
FAILURE CODE [DW4QKY]2148
FAILURE CODE [DW4RKA]2150
FAILURE CODE [DW4RKB]2152
FAILURE CODE [DW4RKY]2154
FAILURE CODE [DW4SKA]2156
FAILURE CODE [DW4SKB]2158
FAILURE CODE [DW4SKY]2160
FAILURE CODE [DW7BKA]2162
FAILURE CODE [DW7BKB]2164
FAILURE CODE [DW7BKY]2166
FAILURE CODE [DWM1KA]2168
FAILURE CODE [DWM1KB]2170
FAILURE CODE [DWM1KY]2172
FAILURE CODE [DWN6KA]2174
FAILURE CODE [DWN6KB]2176
FAILURE CODE [DWN6KY]2178
FAILURE CODE [DWN8KA]2180
FAILURE CODE [DWN8KB]2182
FAILURE CODE [DWN8KY]2184
FAILURE CODE [DX16KA]2186
FAILURE CODE [DX16KB]2188
FAILURE CODE [DX16KY]2190
FAILURE CODE [DXA1KA]2192
FAILURE CODE [DXA1KB]2194
FAILURE CODE [DXA1KY]2196
FAILURE CODE [DXANKA]2198
FAILURE CODE [DXANKB]2200
FAILURE CODE [DXANKY]2202
FAILURE CODE [DXF0KA]2204
FAILURE CODE [DXF0KB]2206
FAILURE CODE [DXF0KY]2208
FAILURE CODE [DXH1KA]2210
FAILURE CODE [DXH1KB]2212
FAILURE CODE [DXH1KY]2214
FAILURE CODE [DXH4KA]2216
FAILURE CODE [DXH4KB]2218
FAILURE CODE [DXH4KY]2220
FAILURE CODE [DXH5KA]2222
FAILURE CODE [DXH5KB]2224
FAILURE CODE [DXH5KY]2226
FAILURE CODE [DXH6KA]2228
FAILURE CODE [DXH6KB]2230
FAILURE CODE [DXH6KY]2232
FAILURE CODE [DXH7KA]2234
FAILURE CODE [DXH7KB]2236
FAILURE CODE [DXH7KY]2238
FAILURE CODE [DXH8KA]2240
FAILURE CODE [DXH8KB]2242
FAILURE CODE [DXH8KY]2244
FAILURE CODE [DXHHKA]2246
FAILURE CODE [DXHHKB]2248
FAILURE CODE [DXHHKY]2250
FAILURE CODE [DXHJKA]2252
FAILURE CODE [DXHJKB]2254
FAILURE CODE [DXHJKY]2256
FAILURE CODE [DXHKKA]2258
FAILURE CODE [DXHKKB]2260
FAILURE CODE [DXHKKY]2262
FAILURE CODE [DY30MA]2264
FAILURE CODE [DY30MC]2268
FAILURE CODE [DY30ME]2273
FAILURE CODE [LA00L3]2275
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2276
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2276
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2285
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2288
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2291
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING2293
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING2296
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)2299
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY2302
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL2305
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL2308
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL2312
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY2314
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION2317
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL2320
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY2323
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY2324
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS2327
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY2330
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED2333
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL2337
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP2339
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP2341
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION2343
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP2347
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP2348
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL2349
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP2351
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT2352
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL2354
E-30 ALARM BUZZER DOES NOT SOUND2355
E-31 ALARM BUZZER DOES NOT STOP SOUNDING2357
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON2358
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED2360
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED2362
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED2366
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED2368
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED2370
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED2372
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE2374
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED2375
E-41 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC)2377
E-42 HORN DOES NOT SOUND2379
E-43 HORN DOES NOT SOUND (FOR AJSS SPEC)2382
E-44 HORN DOES NOT STOP SOUNDING2385
E-45 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2388
E-46 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC)2390
E-47 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT2392
E-48 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2396
E-49 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT2400
E-50 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2404
E-51 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2408
E-52 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2410
E-53 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2412
E-54 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2414
E-55 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT2416
E-56 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT2421
E-57 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT2425
E-58 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2428
E-59 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT2431
E-60 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC)2434
E-61 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT2438
E-62 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED2443
E-63 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT2447
E-64 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND2450
E-65 FRONT WIPER DOES NOT OPERATE2452
E-66 FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC)2456
E-67 REAR WIPER DOES NOT OPERATE2460
E-68 REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC)2463
E-69 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY2466
E-70 FAN DOES NOT ROTATE IN REVERSE2469
E-71 FAN REMAINS ROTATED IN REVERSE2470
E-72 WINDOW WASHER DOES NOT OPERATE2471
E-73 WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC)2474
E-74 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2477
E-75 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2478
E-76 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2480
E-77 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP2481
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2483
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2483
FAILURE MODE AND CAUSE TABLE2484
H-1 MACHINE DOES NOT START2504
H-2 LOCKUP IS NOT RELEASED2508
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE2509
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT2510
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED2514
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED2517
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH2520
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC)2523
H-9 MACHINE DOES NOT TURN (AJSS SPECIFICATION)2525
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC)2527
H-11 TURNING RESPONSE IS POOR (AJSS SPECIFICATION)2529
H-12 STEERING WHEEL IS HEAVY TO OPERATE2531
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC)2532
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION)2534
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS2536
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK2537
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG2539
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK2540
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS2541
H-20 BOOM DOES NOT RISE2543
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE2545
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT2547
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND2548
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE2550
H-25 BOOM MOVES UP AND DOWN DURING OPERATION2551
H-26 BUCKET DOES NOT TILT BACK2552
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE2554
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION2556
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND2557
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE2559
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)2560
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE2561
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2562
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS2563
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2566
H-36 ECSS (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES2567
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2568
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN2570
TROUBLESHOOTING OF ENGINE (S-MODE)2571
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2571
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2572
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2573
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2574
S-4 ENGINE STARTABILITY IS POOR2575
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2577
S-6 ENGINE STOPS DURING OPERATION2579
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2581
S-8 ENGINE LACKS POWER2582
S-9 KDPF GETS CLOGGED IN A SHORT TIME2584
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2586
S-11 OIL BECOMES CONTAMINATED QUICKLY2587
S-12 FUEL CONSUMPTION IS EXCESSIVE2588
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2589
S-14 OIL PRESSURE DROPS2590
S-15 FUEL MIXES INTO ENGINE OIL2592
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2593
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2594
S-18 UNUSUAL NOISE IS HEARD2595
S-19 VIBRATION IS EXCESSIVE2596
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2597
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2598
S-22 ACTIVE REGENERATION TAKES TIME2600
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2602
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2603
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2605
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2606
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM2607
OUTLINE OF FAILURE DISPLAY2607
TROUBLESHOOTING FOR FCS2608
TROUBLESHOOTING FOR AUTO-GREASING PUMP2609
REPLACEMENT OF PUMP ELEMENT2612
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM2613
REPLACEMENT OF AUTO-GREASING CONTROLLER2615
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING2616
50 DISASSEMBLY AND ASSEMBLY2618
CONTENTS2619
ABBREVIATION LIST2624
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2630
HOW TO READ THIS MANUAL2630
COATING MATERIALS LIST2632
SPECIAL TOOLS LIST2636
SKETCHES OF SPECIAL TOOLS2657
ENGINE AND COOLING SYSTEM2663
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2663
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2663
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2667
REMOVE AND INSTALL INJECTOR ASSEMBLY2673
METHOD FOR REMOVING INJECTOR ASSEMBLY2673
METHOD FOR INSTALLING INJECTOR ASSEMBLY2677
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2685
METHOD FOR REMOVING FUEL DOSER ASSEMBLY2685
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY2686
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2689
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2689
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2700
REMOVE AND INSTALL EGR VALVE ASSEMBLY2717
METHOD FOR REMOVING EGR VALVE ASSEMBLY2717
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2717
REMOVE AND INSTALL EGR COOLER ASSEMBLY2719
METHOD FOR REMOVING EGR COOLER ASSEMBLY2719
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2721
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2724
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2724
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2725
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2727
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2727
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2729
REMOVE AND INSTALL ALTERNATOR BELT2732
METHOD FOR REMOVING ALTERNATOR BELT2732
METHOD FOR INSTALLING ALTERNATOR BELT2733
REMOVE AND INSTALL AUTOMATIC TENSIONER2735
METHOD FOR REMOVING AUTOMATIC TENSIONER2735
METHOD FOR INSTALLING AUTOMATIC TENSIONER2735
REMOVE AND INSTALL RADIATOR ASSEMBLY2736
METHOD FOR REMOVING RADIATOR ASSEMBLY2736
METHOD FOR INSTALLING RADIATOR ASSEMBLY2741
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2746
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2746
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2749
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2751
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2751
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2753
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2755
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2755
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2759
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY2763
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY2763
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY2768
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2774
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2775
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2792
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2809
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2809
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY2810
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2812
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2812
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2813
REMOVE AND INSTALL ENGINE REAR OIL SEAL2816
METHOD FOR REMOVING ENGINE REAR OIL SEAL2816
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2817
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2824
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2824
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2830
REMOVE AND INSTALL FUEL TANK ASSEMBLY2837
METHOD FOR REMOVING FUEL TANK ASSEMBLY2837
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2840
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2845
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2845
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2849
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2853
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2853
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2858
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2862
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2862
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2862
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2864
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2864
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2864
REMOVE AND INSTALL KDPF ASSEMBLY2865
METHOD FOR REMOVING KDPF ASSEMBLY2866
METHOD FOR INSTALLING KDPF ASSEMBLY2879
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2894
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2894
METHOD FOR ASSEMBLING KDPF ASSEMBLY2898
REMOVE AND INSTALL SCR ASSEMBLY2904
METHOD FOR REMOVING SCR ASSEMBLY2905
METHOD FOR INSTALLING SCR ASSEMBLY2915
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2929
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2930
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2941
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2952
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2952
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2957
REMOVE AND INSTALL KCCV ASSEMBLY2965
METHOD FOR REMOVING KCCV ASSEMBLY2965
METHOD FOR INSTALLING KCCV ASSEMBLY2965
REMOVE AND INSTALL VGT ASSEMBLY2967
METHOD FOR REMOVING VGT ASSEMBLY2967
METHOD FOR INSTALLING VGT ASSEMBLY2973
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2979
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2980
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2986
REMOVE AND INSTALL AdBlue/DEF INJECTOR2996
METHOD FOR REMOVING AdBlue/DEF INJECTOR2996
METHOD FOR INSTALLING AdBlue/DEF INJECTOR3000
REMOVE AND INSTALL AdBlue/DEF PUMP3004
METHOD FOR REMOVING AdBlue/DEF PUMP3004
METHOD FOR INSTALLING AdBlue/DEF PUMP3007
REMOVE AND INSTALL AdBlue/DEF HOSE3010
METHOD FOR REMOVING AdBlue/DEF HOSE3011
METHOD FOR INSTALLING AdBlue/DEF HOSE3020
REMOVE AND INSTALL AIR CLEANER ASSEMBLY3031
METHOD FOR REMOVING AIR CLEANER ASSEMBLY3031
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY3032
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY3034
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY3034
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY3035
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY3037
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY3037
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY3038
POWER TRAIN3040
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY3040
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY3040
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY3044
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY3052
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY3054
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY3072
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3099
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3100
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY3116
REMOVE AND INSTALL FRONT AXLE ASSEMBLY3136
METHOD FOR REMOVING FRONT AXLE ASSEMBLY3136
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY3138
REMOVE AND INSTALL REAR AXLE ASSEMBLY3140
METHOD FOR REMOVING REAR AXLE ASSEMBLY3140
METHOD FOR INSTALLING REAR AXLE ASSEMBLY3147
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY3155
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY3156
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY3161
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY3169
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY3170
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY3179
STEERING SYSTEM3198
REMOVE AND INSTALL STEERING VALVE ASSEMBLY3198
METHOD FOR REMOVING STEERING VALVE ASSEMBLY3198
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY3200
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC)3203
METHOD FOR REMOVING ROTARY VALVE ASSEMBLY3203
METHOD FOR INSTALLING ROTARY VALVE ASSEMBLY3208
BRAKE SYSTEM3217
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE3217
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE3217
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE3220
UNDERCARRIAGE AND FRAME3223
REMOVE AND INSTALL CENTER HINGE PIN3223
METHOD FOR REMOVING CENTER HINGE PIN3223
METHOD FOR INSTALLING CENTER HINGE PIN3229
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY3236
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY3236
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY3238
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY3242
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY3242
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY3243
HYDRAULIC SYSTEM3244
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY3244
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY3244
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY3248
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3252
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3252
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY3253
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3255
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3255
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY3256
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY3259
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY3259
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY3262
WORK EQUIPMENT3266
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY3266
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY3266
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY3270
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY3275
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY3276
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY3279
CAB AND ITS ATTACHMENTS3285
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY3285
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY3285
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY3291
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)3298
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)3298
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)3299
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY3308
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY3308
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY3314
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY3319
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY3319
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY3321
REMOVE AND INSTALL SEAT BELT3323
METHOD FOR REMOVING SEAT BELT3323
METHOD FOR INSTALLING SEAT BELT3323
ELECTRICAL SYSTEM3325
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3325
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY3325
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY3327
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY3330
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY3330
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY3331
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY3334
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY3334
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY3334
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY3336
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY3336
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY3338
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3340
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3340
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3341
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3343
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3343
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3344
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3345
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3345
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3346
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR3347
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR3347
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR3351
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR3356
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR3356
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR3360
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3364
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3364
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3368
REMOVE AND INSTALL AMMONIA SENSOR3372
METHOD FOR REMOVING AMMONIA SENSOR3372
METHOD FOR INSTALLING AMMONIA SENSOR3375
REMOVE AND INSTALL SCR OUTLET NOx SENSOR3379
METHOD FOR REMOVING SCR OUTLET NOx SENSOR3379
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR3382
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3387
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3387
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3388
60 MAINTENANCE STANDARD3390
CONTENTS3391
ABBREVIATION LIST3393
ENGINE AND COOLING SYSTEM3399
MAINTENANCE STANDARD OF ENGINE MOUNT3399
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP3400
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP3402
MAINTENANCE STANDARD OF COOLING FAN MOTOR3403
POWER TRAIN3405
MAINTENANCE STANDARD OF DRIVE SHAFT3405
MAINTENANCE STANDARD OF TORQUE CONVERTER3406
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV3408
MAINTENANCE STANDARD OF TRANSMISSION3409
MAINTENANCE STANDARD OF F, 1ST CLUTCH3415
MAINTENANCE STANDARD OF R, 2ND CLUTCH3417
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH3419
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE3421
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV3423
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV3424
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE3425
MAINTENANCE STANDARD OF FRONT AXLE3426
MAINTENANCE STANDARD OF REAR AXLE3427
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL3428
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL3431
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL3434
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL3436
MAINTENANCE STANDARD OF FINAL DRIVE3438
STEERING SYSTEM3441
MAINTENANCE STANDARD OF STEERING COLUMN3441
MAINTENANCE STANDARD OF STEERING PUMP3442
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP3445
MAINTENANCE STANDARD OF STEERING VALVE3446
MAINTENANCE STANDARD OF STEERING CYLINDER3448
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP3450
BRAKE SYSTEM3451
MAINTENANCE STANDARD OF CHARGE VALVE3451
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR3453
MAINTENANCE STANDARD OF SLACK ADJUSTER3454
MAINTENANCE STANDARD OF FRONT BRAKE3455
MAINTENANCE STANDARD OF REAR BRAKE3456
MAINTENANCE STANDARD OF PARKING BRAKE3457
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE3459
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE3460
MAINTENANCE STANDARD OF BRAKE COOLING PUMP3461
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER3462
UNDERCARRIAGE AND FRAME3463
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN3463
HYDRAULIC SYSTEM3468
MAINTENANCE STANDARD OF HYDRAULIC TANK3468
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP3470
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP3472
MAINTENANCE STANDARD OF CONTROL VALVE3473
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE3482
WORK EQUIPMENT3483
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3483
MAINTENANCE STANDARD OF BUCKET3487
MAINTENANCE STANDARD OF LIFT CYLINDER3488
MAINTENANCE STANDARD OF BUCKET CYLINDER3489
80 APPENDIX3490
CONTENTS3491
ABBREVIATION LIST3493
AIR CONDITIONER SYSTEM3499
PRECAUTIONS FOR REFRIGERANT3499
AIR CONDITIONER COMPONENT3500
SPECIFICATIONS OF AIR CONDITIONER3502
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3503
OUTLINE OF REFRIGERATION CYCLE3504
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3506
AIR CONDITIONER UNIT3506
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3506
FUNCTION OF AIR CONDITIONER UNIT3507
COMPONENT PARTS OF AIR CONDITIONER UNIT3508
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3508
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3508
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3509
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3510
FUNCTION OF DUAL PRESSURE SWITCH3510
AIR CONDITIONER CONTROLLER3511
STRUCTURE OF AIR CONDITIONER CONTROLLER3511
COMPRESSOR3512
STRUCTURE OF COMPRESSOR3512
SPECIFICATIONS OF COMPRESSOR3512
FUNCTION OF COMPRESSOR3512
CONDENSER3513
STRUCTURE OF CONDENSER3513
SPECIFICATIONS OF CONDENSER3513
FUNCTION OF CONDENSER3513
RECEIVER DRIER3514
STRUCTURE OF RECEIVER DRIER3514
SPECIFICATIONS OF RECEIVER DRIER3514
FUNCTION OF RECEIVER DRIER3514
SENSORS FOR AIR CONDITIONER SYSTEM3515
FUNCTION OF SUNLIGHT SENSOR3515
FUNCTION OF AMBIENT TEMPERATURE SENSOR3515
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3516
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3518
AIR CONDITIONER SYSTEM DIAGRAM3521
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3522
FUNCTION OF AIR CONDITIONER CONTROLLER3523
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3524
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3530
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3531
CHECK TEMPERATURE CONTROL FUNCTION3532
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION3532
TEST VENT (MODE) CHANGEOVER3534
METHOD FOR TESTING VENT (MODE) CHANGEOVER3534
TESTING FRESH/RECIRC AIR CHANGEOVER3536
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3536
TEST EVAPORATOR TEMPERATURE SENSOR3538
TEST RELAYS3540
METHOD FOR TESTING RELAYS3540
AIR CONDITIONER TROUBLESHOOTING CHART 13542
AIR CONDITIONER TROUBLESHOOTING CHART 23543
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3546
FAILURE CODE [879AKA]3548
FAILURE CODE [879AKB]3550
FAILURE CODE [879BKA]3552
FAILURE CODE [879BKB]3554
FAILURE CODE [879CKA]3556
FAILURE CODE [879CKB]3558
FAILURE CODE [879DKZ]3560
FAILURE CODE [879EMC]3562
FAILURE CODE [879FMC]3565
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3568
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3571
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3574
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3578
TROUBLESHOOTING USING GAUGE PRESSURE3580
CONNECTION OF SERVICE TOOL3583
METHOD FOR CONNECTING SERVICE TOOL3584
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3585
HANDLE COMPRESSOR OIL3587
90 CIRCUIT DIAGRAMS3590
CONTENTS3591
ABBREVIATION LIST3592
HYDRAULIC CIRCUIT DIAGRAM3598
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3598
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC)3602
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC)3604
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM3606
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM3608
HYDRAULIC AUTO-GREASING DIAGRAM3610
ELECTRICAL CIRCUIT DIAGRAM3612
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3612
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/6)3616
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/6)3618
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/6)3620
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/6)3622
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/6)3624
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/6)3626
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (1/9)3628
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (2/9)3630
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (3/9)3632
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (4/9)3634
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (5/9)3636
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (6/9)3638
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (7/9)3640
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (8/9)3642
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (9/9)3644
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8)3646
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8)3648
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8)3650
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8)3652
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8)3654
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8)3656
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8)3658
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8)3660
INDEX3662

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24