Komatsu WA480-8E0 Wheel Loader Shop Manual SEN06754-00 PDF

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Komatsu WA480-8E0 Wheel Loader Shop Manual SEN06754-00 – PDF DOWNLOAD

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Komatsu WA480-8E0 Wheel Loader Shop Manual SEN06754-00 – PDF DOWNLOAD 

Language : English
Pages : 3742
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA480-8E0 Wheel Loader Shop Manual SEN06754-00 – 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: WA480-8E0 105
SPECIFICATIONS 107
SPECIFICATIONS: WA480-8E0 107
WEIGHT TABLE 112
WEIGHT TABLE:WA480-8E0 112
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA) 114
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 114
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 116
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 116
10 STRUCTURE AND FUNCTION 119
CONTENTS 120
ABBREVIATION LIST 125
UREA SCR SYSTEM 131
LAYOUT DRAWING OF UREA SCR SYSTEM 131
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 151
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM 160
LAYOUT DRAWING OF BOOT-UP SYSTEM 160
SYSTEM OPERATING LAMP SYSTEM 162
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 162
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 162
BATTERY DISCONNECT SWITCH 163
FUNCTION OF BATTERY DISCONNECT SWITCH 163
PREHEATING SYSTEM 164
PREHEATING SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 164
OPERATION OF AUTOMATIC PREHEATING SYSTEM 164
FUNCTION OF MANUAL PREHEATING SYSTEM 165
OPERATION OF MANUAL PREHEATING SYSTEM 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE CONTROL SYSTEM 169
OPERATION OF ENGINE CONTROL SYSTEM 172
ENGINE POWER MODE SELECTOR SYSTEM 174
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 174
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 174
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM 175
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 175
COMPONENT PARTS OF ENGINE SYSTEM 176
VGT 176
EGR SYSTEM 180
EGR VALVE 182
EGR COOLER 184
KCCV SYSTEM 185
KCCV VENTILATOR 187
KDPF 189
COOLING SYSTEM 193
LAYOUT DRAWING OF COOLING SYSTEM 193
SPECIFICATIONS OF COOLING SYSTEM 194
COOLING FAN CONTROL SYSTEM 195
COOLING FAN CONTROL SYSTEM DIAGRAM 195
FUNCTION OF COOLING FAN CONTROL SYSTEM 195
COMPONENT PARTS OF COOLING SYSTEM 200
BRAKE AND COOLING FAN PUMP 200
COOLING FAN MOTOR 208
CONTROL SYSTEM 214
LAYOUT DRAWING OF CONTROL SYSTEM 214
MACHINE MONITOR SYSTEM 216
MACHINE MONITOR SYSTEM DIAGRAM 216
FUNCTION OF MACHINE MONITOR SYSTEM 216
REARVIEW MONITOR SYSTEM 218
REARVIEW MONITOR SYSTEM DIAGRAM 218
FUNCTION OF REARVIEW MONITOR SYSTEM 218
KOMTRAX SYSTEM 219
KOMTRAX SYSTEM DIAGRAM 219
FUNCTION OF KOMTRAX SYSTEM 219
LOAD METER SYSTEM 220
LOAD METER SYSTEM DIAGRAM 220
FUNCTION OF LOAD METER SYSTEM 220
COMPONENT PARTS OF CONTROL SYSTEM 226
MACHINE MONITOR 226
SWITCH PANEL 246
REARVIEW MONITOR 247
REARVIEW CAMERA 249
KOMTRAX TERMINAL 250
TRANSMISSION CONTROLLER 252
WORK EQUIPMENT CONTROLLER 256
MONITOR CONTROLLER 260
CAN TERMINATING RESISTOR 265
ENGINE CONTROLLER 266
ACCELERATOR PEDAL 273
HYDRAULIC SYSTEM 275
LAYOUT DRAWING OF HYDRAULIC SYSTEM 275
CLSS 276
STRUCTURE OF CLSS 276
FUNCTION OF CLSS 277
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 279
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 279
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 279
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 279
COMPONENT PARTS OF HYDRAULIC SYSTEM 280
HYDRAULIC TANK 280
WORK EQUIPMENT PUMP 283
STEERING PUMP 301
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 313
CONTROL VALVE 314
POWER TRAIN SYSTEM 348
LAYOUT DRAWING OF POWER TRAIN SYSTEM 348
OPERATION OF POWER TRAIN SYSTEM 351
TRANSMISSION CONTROL SYSTEM 352
TRANSMISSION CONTROL SYSTEM DIAGRAM 352
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 354
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 354
ELECTRIC MODULATION FUNCTION 355
DISPLAY FUNCTION OF GEAR SHIFT 355
AUTOMATIC GEAR SHIFT FUNCTION 355
SHIFT HOLD FUNCTION 356
KICKDOWN FUNCTION 356
AUTOMATIC KICKDOWN FUNCTION 357
TORQUE CONVERTER LOCKUP FUNCTION 357
HUNTING PREVENTION FUNCTION 358
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 358
SHIFT POINT CHANGING FUNCTION 358
4TH GEAR SPEED LIMITATION FUNCTION 358
TRANSMISSION PROTECTION FUNCTION 360
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 360
SHIFT DOWN PROTECTION FUNCTION 360
ENGINE OVERRUN PREVENTION FUNCTION 361
MAXIMUM SPEED LIMITATION FUNCTION 361
NEUTRALIZER FUNCTION 361
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 363
TRANSMISSION CUT-OFF FUNCTION 365
COMPONENT PARTS OF POWER TRAIN SYSTEM 367
DRIVE SHAFT 367
TORQUE CONVERTER 369
LOCKUP CLUTCH ECMV 372
TRANSMISSION 375
TRANSMISSION CONTROL VALVE 392
FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 395
3RD AND 4TH CLUTCH ECMV 400
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 405
AXLE 407
CONVENTIONAL DIFFERENTIAL 409
LIMITED SLIP DIFFERENTIAL 412
FINAL DRIVE 417
AJSS KNOB 419
COMBINATION SWITCH 420
SHIFT HOLD SWITCH 424
KICKDOWN SWITCH 425
WORK EQUIPMENT SYSTEM 426
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 426
WORK EQUIPMENT SYSTEM DIAGRAM 428
WORK EQUIPMENT CONTROL SYSTEM 430
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 430
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 430
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 431
WORK EQUIPMENT LEVER OPERATION FUNCTION 432
BUCKET PRIORITY CONTROL FUNCTION 432
BOOM STOP MODULATION FUNCTION 432
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 434
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 434
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 434
REMOTE POSITIONER SYSTEM 436
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 436
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 436
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 437
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 437
BUCKET POSITIONER AND BOOM POSITIONER 441
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 441
AUTO-DIGGING SYSTEM 442
AUTO-DIGGING SYSTEM DIAGRAM 442
FUNCTION OF AUTO-DIGGING SYSTEM 442
ECSS 444
ECSS DIAGRAM 444
FUNCTION OF ECSS 444
OPERATION OF ECSS 444
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 446
WORK EQUIPMENT LOCK SOLENOID VALVE 446
PILOT CIRCUIT ACCUMULATOR 447
ECSS CIRCUIT ACCUMULATOR 448
WORK EQUIPMENT ELECTRIC LEVER 450
MULTIFUNCTION MONO-LEVER 453
STEERING SYSTEM 454
LAYOUT DRAWING OF STEERING SYSTEM 454
SECONDARY STEERING SYSTEM 457
SECONDARY STEERING SYSTEM DIAGRAM 457
FUNCTION OF SECONDARY STEERING SYSTEM 457
AJSS 459
LAYOUT DRAWING OF AJSS 459
AJSS DIAGRAM 460
FUNCTION OF AJSS 461
NEUTRALIZER FUNCTION OF AJSS 462
NEUTRAL INTERLOCK FUNCTION OF AJSS 462
SPEED SENSING STEERING FUNCTION OF AJSS 463
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS 464
STEERING COLUMN 465
STRUCTURE OF STEERING COLUMN 465
COMPONENT PARTS OF STEERING SYSTEM 466
AJSS EPC VALVE 466
STEERING LOCK VALVE 467
ROTARY VALVE 468
ORBITROL VALVE 471
STOP VALVE 475
STEERING VALVE 476
SECONDARY STEERING PUMP 488
SECONDARY STEERING MOTOR 489
BRAKE SYSTEM 490
LAYOUT DRAWING OF BRAKE SYSTEM 490
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 491
PARKING BRAKE CONTROL SYSTEM 493
PARKING BRAKE CONTROL SYSTEM DIAGRAM 493
OPERATION OF PARKING BRAKE CONTROL SYSTEM 493
BRAKE COOLING CONTROL SYSTEM 495
BRAKE COOLING CONTROL SYSTEM DIAGRAM 495
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 495
COMPONENT PARTS OF BRAKE SYSTEM 496
CHARGE VALVE 496
PARKING BRAKE SOLENOID VALVE 502
PARKING BRAKE EMERGENCY RELEASE VALVE 504
BRAKE CIRCUIT ACCUMULATOR 505
BRAKE VALVE 507
SLACK ADJUSTER 511
BRAKE 513
PARKING BRAKE 516
FLOW PRIORITY VALVE 518
BRAKE COOLING MOTOR 520
BRAKE COOLING PUMP 521
BRAKE COOLING OIL COOLER 522
AUTO-GREASING SYSTEM 523
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 523
SPECIFICATIONS OF AUTO-GREASING SYSTEM 524
FUNCTION OF AUTO-GREASING SYSTEM 526
COMPONENT PARTS OF AUTO-GREASING SYSTEM 527
AUTO-GREASING PUMP 527
UNDERCARRIAGE AND FRAME 528
FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 528
TIRE 530
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 530
STRUCTURE OF RADIAL TIRE 530
FUNCTION OF RADIAL TIRE 530
STRUCTURE OF BIAS TIRE 531
FUNCTION OF BIAS TIRE 531
WORK EQUIPMENT 532
STRUCTURE OF WORK EQUIPMENT 532
STRUCTURE OF BUCKET 533
CAB AND ITS ATTACHMENTS 534
ROPS CAB 534
STRUCTURE OF ROPS CAB 534
FUNCTION OF ROPS CAB 534
20 STANDARD VALUE TABLE 535
CONTENTS 536
ABBREVIATION LIST 537
STANDARD VALUE TABLE FOR ENGINE 543
STANDARD VALUE TABLE FOR ENGINE: WA480-8E0 543
STANDARD VALUE TABLE FOR MACHINE 547
STANDARD VALUE TABLE FOR MACHINE: WA480-8E0 547
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 570
30 TESTING AND ADJUSTING 575
CONTENTS 576
ABBREVIATION LIST 580
RELATED INFORMATION ON TESTING AND ADJUSTING 586
TOOLS FOR TESTING AND ADJUSTING 586
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 595
ENGINE AND COOLING SYSTEM 597
TEST ENGINE SPEED 597
METHOD FOR TESTING ENGINE SPEED 597
TEST BOOST PRESSURE 602
METHOD FOR TESTING BOOST PRESSURE 602
TESTING EXHAUST GAS TEMPERATURE 605
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 605
TEST EXHAUST GAS COLOR 607
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 607
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 608
TEST AND ADJUST VALVE CLEARANCE 609
METHOD FOR TESTING VALVE CLEARANCE 609
METHOD FOR ADJUSTING VALVE CLEARANCE 611
TEST COMPRESSION PRESSURE 612
METHOD FOR TESTING COMPRESSION PRESSURE 612
TEST BLOWBY PRESSURE 616
METHOD FOR TESTING BLOWBY PRESSURE 616
TEST ENGINE OIL PRESSURE 619
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 619
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 619
TEST EGR VALVE AND VGT OIL PRESSURE 621
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 621
TEST FUEL PRESSURE 622
METHOD FOR TESTING FUEL PRESSURE 622
TEST FUEL RETURN RATE AND LEAKAGE 624
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 625
BLEEDING AIR FROM FUEL SYSTEM 628
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 629
TEST FUEL CIRCUIT FOR LEAKAGE 630
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 630
HANDLE CYLINDER CUT-OUT MODE OPERATION 632
HANDLE NO-INJECTION CRANKING OPERATION 633
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 634
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 634
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 635
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 635
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 636
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 636
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 637
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 637
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 637
TEST ALTERNATOR BELT 639
METHOD FOR TESTING ALTERNATOR BELT 639
TEST AUTOMATIC TENSIONER 641
METHOD FOR TESTING AUTOMATIC TENSIONER 641
CLEAN FUEL DOSER 644
METHOD FOR CLEANING FUEL DOSER 644
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 646
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 646
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 653
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 653
TEST SCR RELATED FUNCTIONS 654
TEST AdBlue/DEF PUMP RAISED PRESSURE 658
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 661
TEST AdBlue/DEF LINE HEATER RELAY 1 666
TEST AdBlue/DEF LINE HEATER RELAY 2 670
TEST AdBlue/DEF PUMP HEATER RELAY 674
TEST AdBlue/DEF TANK HEATER VALVE 678
TEST SCR NOx REMOVAL EFFICIENCY 682
CLEAN AdBlue/DEF TANK 686
METHOD FOR CLEANING AdBlue/DEF TANK 686
POWER TRAIN 690
TEST AND ADJUST POWER TRAIN OIL PRESSURE 690
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 692
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 710
ADJUST TRANSMISSION INPUT SPEED SENSOR 712
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 712
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 714
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 714
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 715
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 715
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 718
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 719
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 722
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 722
STEERING SYSTEM 723
TEST STEERING WHEEL 723
METHOD FOR TESTING STEERING WHEEL 723
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 725
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 725
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 729
BLEED AIR FROM STEERING CYLINDER CIRCUIT 731
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 731
TEST AND ADJUST STEERING STOP VALVE 733
METHOD FOR TESTING STEERING STOP VALVE 733
METHOD FOR ADJUSTING STEERING STOP VALVE 733
BRAKE SYSTEM 734
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 734
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 734
TEST WHEEL BRAKE OIL PRESSURE 735
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 735
TEST AND ADJUST ACCUMULATOR CHARGE PRESSURE 737
METHOD FOR TESTING ACCUMULATOR CHARGE PRESSURE 737
METHOD FOR ADJUSTING ACCUMULATOR CHARGE PRESSURE 738
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 739
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 739
Japanese Only 741
BLEED AIR FROM BRAKE CIRCUIT 744
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 744
TEST BRAKING PERFORMANCE 748
METHOD FOR TESTING BRAKING PERFORMANCE 748
TEST BRAKE PEDAL 749
METHOD FOR TESTING BRAKE PEDAL 749
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 750
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 750
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 750
TEST LOWERING OF WHEEL BRAKE PRESSURE 751
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 752
TEST WEAR OF WHEEL BRAKE DISC 754
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 754
TEST PARKING BRAKE OIL PRESSURE 756
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 756
TEST PARKING BRAKE PERFORMANCE 758
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 758
RELEASE PARKING BRAKE MANUALLY 759
METHOD FOR RELEASING PARKING BRAKE MANUALLY 759
TEST WEAR AMOUNT OF PARKING BRAKE DISC 762
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 762
HYDRAULIC SYSTEM 764
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 764
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 764
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 766
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 766
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 770
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 772
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 772
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 775
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 777
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 777
TEST COOLING FAN SPEED 778
METHOD FOR TESTING COOLING FAN SPEED 778
TEST COOLING FAN CIRCUIT OIL PRESSURE 779
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 779
BLEED AIR FROM COOLING FAN CIRCUIT 782
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 782
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 784
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 784
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 786
WORK EQUIPMENT 790
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 790
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 790
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 790
TEST AND ADJUST BOOM POTENTIOMETER LEVER 791
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 791
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 791
CAB AND ITS ATTACHMENTS 792
TEST DIRECTIONAL LEVER 792
METHOD FOR TESTING DIRECTIONAL LEVER 792
TEST WORK EQUIPMENT CONTROL LEVER 793
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 793
TEST AJSS LEVER (FOR AJSS SPEC) 796
METHOD FOR TESTING AJSS LEVER 796
TEST STEERING LOCK LEVER(FOR AJSS SPEC) 799
METHOD FOR TESTING OF STEERING LOCK LEVER 799
TEST AND ADJUST AJSS LEVER/FRAME ANGLE SENSOR (FOR AJSS SPEC) 800
METHOD FOR TESTING AJSS LEVER/FRAME ANGLE SENSOR 800
METHOD FOR ADJUSTING AJSS LEVER/FRAME ANGLE SENSOR 800
TEST AND AJUST STEERING STOPPER BOLT (FOR AJSS SPEC) 802
METHOD FOR TESTING STEERING STOPPER VALVE 802
METHOD FOR ADJUSTING STEERING STOPPER VALVE 802
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 808
METHOD FOR ADJUSTING TRANSMISSION ECMV CURRENT 809
METHOD FOR SETTING AND RESETTING TRANSMISSION INITIAL LEARNING 812
SET AND OPERATE MACHINE MONITOR 817
OPERATOR MODE 820
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 826
METHOD FOR OPERATING SERVICE MODE 826
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 830
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 843
ABNORMALITY RECORD MENU 859
METHOD FOR CONFIRMING MAINTENANCE RECORD 864
METHOD FOR OPERATING MAINTENANCE MODE SETTING 866
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 871
DEFAULT MENU 872
DIAGNOSTIC TESTS MENU 888
ADJUSTMENT MENU 899
METHOD FOR PERFORMING NO-INJECTION CRANKING 937
KOMTRAX SETTINGS MENU 939
METHOD FOR DISPLAYING SERVICE MESSAGE 942
METHOD FOR STARTING UP KOMTRAX TERMINAL 944
ADJUST REARVIEW CAMERA ANGLE 949
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 949
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 951
HANDLE BATTERY DISCONNECT SWITCH 952
TEST DIODES 953
METHOD FOR TESTING DIODE USING DIGITAL TESTER 953
METHOD FOR TESTING DIODE USING ANALOG TESTER 953
AUTO-GREASING DEVICE 954
BLEED THE AIR OF AUTO-GREASING SYSTEM 954
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 954
CORREPONDENCE IN CASE OF GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 957
CORREPONDING METHOD FOR GREASE LEAKAGE FROM OVER PRESSURE PROTECTION VALVE 957
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 958
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 959
Pm CLINIC 961
Pm CLINIC SERVICE 961
Pm CLINIC CHECK SHEET: WA480-8E0 964
40 TROUBLESHOOTING 975
CONTENTS 976
ABBREVIATION LIST 989
RELATED INFORMATION ON TROUBLESHOOTING 995
GENERAL TROUBLESHOOTING POINTS 995
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 996
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1008
CHECKS BEFORE TROUBLESHOOTING 1010
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1012
WALK-AROUND CHECK 1012
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1014
CHECK FUEL LEVEL AND TYPE 1014
CHECK IMPURE INGREDIENT IN FUEL 1014
CHECK AdBule/DEF LEVEL AND TYPE 1015
CHECK FUEL PREFILTER 1015
CHECK MAIN FILTER 1017
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 1018
CHECK COOLANT LEVEL (RESERVOIR TANK) 1018
CHECK CLOGGING OF AIR CLEANER 1019
OUTER ELEMENT – CLEAN 1020
REPLACE ELEMENT 1022
CHECK HYDRAULIC OIL LEVEL 1023
CHECK HYDRAULIC OIL STRAINER 1024
CHECK HYDRAULIC FILTER 1025
CHECK OIL LEVEL IN TRANSMISSION CASE 1026
CHECK OIL LEVEL IN FRONT AXLE CASE 1028
CHECK OIL LEVEL IN REAR AXLE CASE 1029
BLEED AIR FROM FUEL SYSTEM 1029
BLEED AIR FROM HYDRAULIC SYSTEM 1029
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 1029
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1035
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1047
SYMPTOM AND TROUBLESHOOTING NUMBERS 1049
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1054
CONNECTORS LIST AND LAYOUT 1056
CONNECTOR CONTACT IDENTIFICATION 1083
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1123
FUSE LOCATION TABLE 1129
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1133
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1137
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1139
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1145
FAILURE CODES TABLE 1147
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1171
FAILURE CODE [1500L0] 1171
FAILURE CODE [15SAL1] 1172
FAILURE CODE [15SALH] 1174
FAILURE CODE [15SBL1] 1176
FAILURE CODE [15SBLH] 1178
FAILURE CODE [15SEL1] 1180
FAILURE CODE [15SELH] 1182
FAILURE CODE [15SFL1] 1184
FAILURE CODE [15SFLH] 1186
FAILURE CODE [15SGL1] 1188
FAILURE CODE [15SGLH] 1190
FAILURE CODE [15SHL1] 1192
FAILURE CODE [15SHLH] 1194
FAILURE CODE [2F00MA] 1197
FAILURE CODE [2F00MB] 1201
FAILURE CODE [2G42ZG] 1204
FAILURE CODE [2G43ZG] 1206
FAILURE CODE [879AKA] 1208
FAILURE CODE [879AKB] 1210
FAILURE CODE [879BKA] 1212
FAILURE CODE [879BKB] 1214
FAILURE CODE [879CKA] 1216
FAILURE CODE [879CKB] 1218
FAILURE CODE [879DKZ] 1220
FAILURE CODE [879EMC] 1222
FAILURE CODE [879FMC] 1225
FAILURE CODE [989A00] 1228
FAILURE CODE [989L00] 1229
FAILURE CODE [989M00] 1230
FAILURE CODE [989N00] 1231
FAILURE CODE [A1U0N3] 1232
FAILURE CODE [A1U0N4] 1234
FAILURE CODE [AA10NX] 1236
FAILURE CODE [AB00KE] 1238
FAILURE CODE [AB00KY] 1240
FAILURE CODE [AQ10N3] 1242
FAILURE CODE [AS00N3] 1244
FAILURE CODE [AS00R2] 1246
FAILURE CODE [AS00R3] 1247
FAILURE CODE [AS00R4] 1248
FAILURE CODE [AS00R5] 1249
FAILURE CODE [AS00R6] 1250
FAILURE CODE [AS00ZK] 1251
FAILURE CODE [AS10KM] 1252
FAILURE CODE [AS10NR] 1253
FAILURE CODE [AS10NT] 1254
FAILURE CODE [B@BAZG] 1255
FAILURE CODE [B@BAZK] 1256
FAILURE CODE [B@BCNS] 1258
FAILURE CODE [B@BCZK] 1259
FAILURE CODE [B@C7NS] 1261
FAILURE CODE [B@CENS] 1263
FAILURE CODE [B@HANS] 1264
FAILURE CODE [CA115] 1265
FAILURE CODE [CA122] 1266
FAILURE CODE [CA123] 1268
FAILURE CODE [CA131] 1270
FAILURE CODE [CA132] 1272
FAILURE CODE [CA135] 1275
FAILURE CODE [CA141] 1277
FAILURE CODE [CA144] 1279
FAILURE CODE [CA145] 1281
FAILURE CODE [CA153] 1283
FAILURE CODE [CA154] 1286
FAILURE CODE [CA187] 1289
FAILURE CODE [CA221] 1291
FAILURE CODE [CA222] 1293
FAILURE CODE [CA227] 1295
FAILURE CODE [CA234] 1296
FAILURE CODE [CA238] 1297
FAILURE CODE [CA239] 1299
FAILURE CODE [CA249] 1301
FAILURE CODE [CA256] 1303
FAILURE CODE [CA271] 1305
FAILURE CODE [CA272] 1307
FAILURE CODE [CA273] 1308
FAILURE CODE [CA274] 1310
FAILURE CODE [CA322] 1311
FAILURE CODE [CA323] 1313
FAILURE CODE [CA324] 1315
FAILURE CODE [CA325] 1317
FAILURE CODE [CA331] 1319
FAILURE CODE [CA332] 1321
FAILURE CODE [CA343] 1323
FAILURE CODE [CA351] 1324
FAILURE CODE [CA352] 1325
FAILURE CODE [CA356] 1328
FAILURE CODE [CA357] 1330
FAILURE CODE [CA386] 1332
FAILURE CODE [CA431] 1333
FAILURE CODE [CA432] 1336
FAILURE CODE [CA441] 1340
FAILURE CODE [CA442] 1342
FAILURE CODE [CA449] 1343
FAILURE CODE [CA451] 1344
FAILURE CODE [CA452] 1346
FAILURE CODE [CA515] 1348
FAILURE CODE [CA516] 1350
FAILURE CODE [CA553] 1352
FAILURE CODE [CA555] 1353
FAILURE CODE [CA556] 1354
FAILURE CODE [CA559] 1355
FAILURE CODE [CA595] 1360
FAILURE CODE [CA687] 1361
FAILURE CODE [CA689] 1363
FAILURE CODE [CA691] 1365
FAILURE CODE [CA692] 1367
FAILURE CODE [CA697] 1369
FAILURE CODE [CA698] 1370
FAILURE CODE [CA731] 1371
FAILURE CODE [CA778] 1372
FAILURE CODE [CA1117] 1375
FAILURE CODE [CA1664] 1376
FAILURE CODE [CA1669] 1379
FAILURE CODE [CA1673] 1380
FAILURE CODE [CA1677] 1381
FAILURE CODE [CA1678] 1382
FAILURE CODE [CA1682] 1383
FAILURE CODE [CA1683] 1387
FAILURE CODE [CA1684] 1389
FAILURE CODE [CA1686] 1391
FAILURE CODE [CA1691] 1392
FAILURE CODE [CA1694] 1395
FAILURE CODE [CA1695] 1397
FAILURE CODE [CA1696] 1398
FAILURE CODE [CA1712] 1400
FAILURE CODE [CA1713] 1403
FAILURE CODE [CA1714] 1405
FAILURE CODE [CA1715] 1406
FAILURE CODE [CA1776] 1407
FAILURE CODE [CA1777] 1410
FAILURE CODE [CA1843] 1413
FAILURE CODE [CA1844] 1415
FAILURE CODE [CA1879] 1418
FAILURE CODE [CA1881] 1421
FAILURE CODE [CA1883] 1423
FAILURE CODE [CA1885] 1427
FAILURE CODE [CA1887] 1429
FAILURE CODE [CA1921] 1431
FAILURE CODE [CA1922] 1434
FAILURE CODE [CA1923] 1439
FAILURE CODE [CA1924] 1441
FAILURE CODE [CA1925] 1443
FAILURE CODE [CA1927] 1445
FAILURE CODE [CA1928] 1447
FAILURE CODE [CA1942] 1449
FAILURE CODE [CA1963] 1450
FAILURE CODE [CA1977] 1454
FAILURE CODE [CA1993] 1457
FAILURE CODE [CA2185] 1460
FAILURE CODE [CA2186] 1462
FAILURE CODE [CA2249] 1464
FAILURE CODE [CA2265] 1465
FAILURE CODE [CA2266] 1467
FAILURE CODE [CA2271] 1470
FAILURE CODE [CA2272] 1472
FAILURE CODE [CA2349] 1474
FAILURE CODE [CA2353] 1476
FAILURE CODE [CA2357] 1478
FAILURE CODE [CA2381] 1479
FAILURE CODE [CA2382] 1481
FAILURE CODE [CA2383] 1483
FAILURE CODE [CA2386] 1485
FAILURE CODE [CA2387] 1487
FAILURE CODE [CA2555] 1488
FAILURE CODE [CA2556] 1490
FAILURE CODE [CA2637] 1492
FAILURE CODE [CA2639] 1494
FAILURE CODE [CA2732] 1497
FAILURE CODE [CA2733] 1499
FAILURE CODE [CA2741] 1501
FAILURE CODE [CA2765] 1502
FAILURE CODE [CA2771] 1503
FAILURE CODE [CA2777] 1509
FAILURE CODE [CA2878] 1512
FAILURE CODE [CA2881] 1515
FAILURE CODE [CA2976] 1518
FAILURE CODE [CA3133] 1520
FAILURE CODE [CA3134] 1522
FAILURE CODE [CA3135] 1524
FAILURE CODE [CA3142] 1528
FAILURE CODE [CA3143] 1529
FAILURE CODE [CA3144] 1530
FAILURE CODE [CA3146] 1533
FAILURE CODE [CA3147] 1534
FAILURE CODE [CA3148] 1535
FAILURE CODE [CA3151] 1537
FAILURE CODE [CA3165] 1543
FAILURE CODE [CA3167] 1545
FAILURE CODE [CA3229] 1548
FAILURE CODE [CA3231] 1550
FAILURE CODE [CA3232] 1552
FAILURE CODE [CA3235] 1556
FAILURE CODE [CA3239] 1558
FAILURE CODE [CA3241] 1561
FAILURE CODE [CA3242] 1564
FAILURE CODE [CA3251] 1567
FAILURE CODE [CA3253] 1569
FAILURE CODE [CA3254] 1572
FAILURE CODE [CA3255] 1575
FAILURE CODE [CA3256] 1579
FAILURE CODE [CA3311] 1581
FAILURE CODE [CA3312] 1583
FAILURE CODE [CA3313] 1586
FAILURE CODE [CA3314] 1587
FAILURE CODE [CA3315] 1588
FAILURE CODE [CA3316] 1591
FAILURE CODE [CA3317] 1592
FAILURE CODE [CA3318] 1593
FAILURE CODE [CA3319] 1596
FAILURE CODE [CA3321] 1597
FAILURE CODE [CA3322] 1599
FAILURE CODE [CA3419] 1602
FAILURE CODE [CA3421] 1604
FAILURE CODE [CA3497] 1606
FAILURE CODE [CA3498] 1607
FAILURE CODE [CA3543] 1608
FAILURE CODE [CA3545] 1615
FAILURE CODE [CA3547] 1617
FAILURE CODE [CA3558] 1618
FAILURE CODE [CA3559] 1620
FAILURE CODE [CA3562] 1622
FAILURE CODE [CA3563] 1624
FAILURE CODE [CA3567] 1627
FAILURE CODE [CA3568] 1630
FAILURE CODE [CA3571] 1636
FAILURE CODE [CA3572] 1638
FAILURE CODE [CA3574] 1640
FAILURE CODE [CA3575] 1642
FAILURE CODE [CA3577] 1644
FAILURE CODE [CA3578] 1646
FAILURE CODE [CA3582] 1648
FAILURE CODE [CA3583] 1656
FAILURE CODE [CA3596] 1658
FAILURE CODE [CA3649] 1661
FAILURE CODE [CA3681] 1663
FAILURE CODE [CA3682] 1668
FAILURE CODE [CA3713] 1674
FAILURE CODE [CA3717] 1677
FAILURE CODE [CA3718] 1678
FAILURE CODE [CA3725] 1679
FAILURE CODE [CA3748] 1682
FAILURE CODE [CA3751] 1685
FAILURE CODE [CA3755] 1687
FAILURE CODE [CA3866] 1689
FAILURE CODE [CA3867] 1693
FAILURE CODE [CA3868] 1696
FAILURE CODE [CA3899] 1700
FAILURE CODE [CA3911] 1702
FAILURE CODE [CA3912] 1706
FAILURE CODE [CA3932] 1708
FAILURE CODE [CA3933] 1710
FAILURE CODE [CA3934] 1712
FAILURE CODE [CA3935] 1715
FAILURE CODE [CA3936] 1717
FAILURE CODE [CA4151] 1719
FAILURE CODE [CA4152] 1723
FAILURE CODE [CA4155] 1727
FAILURE CODE [CA4156] 1729
FAILURE CODE [CA4157] 1732
FAILURE CODE [CA4158] 1734
FAILURE CODE [CA4159] 1735
FAILURE CODE [CA4161] 1736
FAILURE CODE [CA4162] 1739
FAILURE CODE [CA4163] 1742
FAILURE CODE [CA4164] 1744
FAILURE CODE [CA4165] 1746
FAILURE CODE [CA4166] 1748
FAILURE CODE [CA4168] 1750
FAILURE CODE [CA4169] 1753
FAILURE CODE [CA4171] 1755
FAILURE CODE [CA4249] 1758
FAILURE CODE [CA4251] 1760
FAILURE CODE [CA4259] 1762
FAILURE CODE [CA4261] 1765
FAILURE CODE [CA4277] 1768
FAILURE CODE [CA4281] 1772
FAILURE CODE [CA4459] 1775
FAILURE CODE [CA4461] 1778
FAILURE CODE [CA4658] 1781
FAILURE CODE [CA4731] 1785
FAILURE CODE [CA4732] 1786
FAILURE CODE [CA4739] 1787
FAILURE CODE [CA4768] 1788
FAILURE CODE [CA4769] 1790
FAILURE CODE [CA4842] 1793
FAILURE CODE [CA4952] 1797
FAILURE CODE [CA5115] 1799
FAILURE CODE [CA5179] 1802
FAILURE CODE [CA5181] 1804
FAILURE CODE [CA5383] 1806
FAILURE CODE [D150KA] 1808
FAILURE CODE [D150KB] 1810
FAILURE CODE [D150KY] 1812
FAILURE CODE [D160KA] 1814
FAILURE CODE [D160KB] 1816
FAILURE CODE [D160KY] 1818
FAILURE CODE [D191KA] 1820
FAILURE CODE [D191KB] 1823
FAILURE CODE [D191KY] 1826
FAILURE CODE [D192KA] 1828
FAILURE CODE [D192KB] 1830
FAILURE CODE [D192KY] 1832
FAILURE CODE [D19JKZ] 1833
FAILURE CODE [D1E6KA] 1835
FAILURE CODE [D1E6KB] 1837
FAILURE CODE [D1E6KY] 1839
FAILURE CODE [D5ZHKA] 1841
FAILURE CODE [D5ZHKB] 1843
FAILURE CODE [D5ZHKZ] 1845
FAILURE CODE [D5ZHL6] 1848
FAILURE CODE [D811MC] 1850
FAILURE CODE [D862KA] 1851
FAILURE CODE [D8ALKA] 1852
FAILURE CODE [D8ALKB] 1854
FAILURE CODE [D8AQK4] 1856
FAILURE CODE [D8AQKR] 1857
FAILURE CODE [DAF0KT] 1859
FAILURE CODE [DAF0MB] 1860
FAILURE CODE [DAF0MC] 1861
FAILURE CODE [DAF3KK] 1862
FAILURE CODE [DAF8KB] 1864
FAILURE CODE [DAFDKB] 1866
FAILURE CODE [DAFGMC] 1868
FAILURE CODE [DAFLKA] 1869
FAILURE CODE [DAFLKB] 1871
FAILURE CODE [DAFQKR] 1873
FAILURE CODE [DAQ0KK] 1874
FAILURE CODE [DAQ0KT] 1877
FAILURE CODE [DAQ0MC] 1878
FAILURE CODE [DAQ1KA] 1879
FAILURE CODE [DAQ2KK] 1881
FAILURE CODE [DAQ4KB] 1884
FAILURE CODE [DAQ9KQ] 1886
FAILURE CODE [DAQLKA] 1887
FAILURE CODE [DAQLKB] 1889
FAILURE CODE [DAQQKR] 1891
FAILURE CODE [DAQRKR] 1892
FAILURE CODE [DAQRMA] 1893
FAILURE CODE [DAZ9KQ] 1894
FAILURE CODE [DAZQKR] 1895
FAILURE CODE [DB2QKR] 1896
FAILURE CODE [DB2RKR] 1901
FAILURE CODE [DB90KK] 1907
FAILURE CODE [DB90KT] 1910
FAILURE CODE [DB90MC] 1911
FAILURE CODE [DB91KA] 1912
FAILURE CODE [DB92KK] 1914
FAILURE CODE [DB95KX] 1917
FAILURE CODE [DB96KX] 1920
FAILURE CODE [DB99KQ] 1922
FAILURE CODE [DB9LKA] 1923
FAILURE CODE [DB9LKB] 1925
FAILURE CODE [DB9QKR] 1927
FAILURE CODE [DB9RKR] 1928
FAILURE CODE [DB9RMA] 1929
FAILURE CODE [DBE5KX] 1930
FAILURE CODE [DBE6KX] 1932
FAILURE CODE [DD1ALD] 1934
FAILURE CODE [DDAAL6] 1936
FAILURE CODE [DDB6L4] 1938
FAILURE CODE [DDD1LD] 1941
FAILURE CODE [DDK3KA] 1943
FAILURE CODE [DDK3KB] 1946
FAILURE CODE [DDK4KA] 1949
FAILURE CODE [DDK4KB] 1952
FAILURE CODE [DDK5L4] 1954
FAILURE CODE [DDK6KA] 1956
FAILURE CODE [DDK6KB] 1959
FAILURE CODE [DDKLKA] 1962
FAILURE CODE [DDKLKB] 1965
FAILURE CODE [DDNRKY] 1967
FAILURE CODE [DDP5KA] 1969
FAILURE CODE [DDT0L4] 1971
FAILURE CODE [DDT4LD] 1973
FAILURE CODE [DDT9LD] 1975
FAILURE CODE [DDTALD] 1977
FAILURE CODE [DDW9LD] 1979
FAILURE CODE [DDWLLD] 1981
FAILURE CODE [DF10KA] 1983
FAILURE CODE [DF10KB] 1986
FAILURE CODE [DGF1KA] 1989
FAILURE CODE [DGF1KB] 1991
FAILURE CODE [DGH2KX] 1993
FAILURE CODE [DGR2KB] 1995
FAILURE CODE [DGR2KZ] 1997
FAILURE CODE [DGT1KA] 1999
FAILURE CODE [DGT1KB] 2001
FAILURE CODE [DH21KA] 2003
FAILURE CODE [DH21KB] 2006
FAILURE CODE [DHA4KA] 2008
FAILURE CODE [DHAAMA] 2010
FAILURE CODE [DHACMA] 2012
FAILURE CODE [DHPCKX] 2014
FAILURE CODE [DHPDKX] 2017
FAILURE CODE [DHT1KX] 2020
FAILURE CODE [DHT5KX] 2023
FAILURE CODE [DHT7KX] 2026
FAILURE CODE [DHT8KA] 2029
FAILURE CODE [DHT8KB] 2032
FAILURE CODE [DHT8ZG] 2034
FAILURE CODE [DHUDKA] 2035
FAILURE CODE [DHUDKB] 2038
FAILURE CODE [DJF1KA] 2040
FAILURE CODE [DK30KA] 2042
FAILURE CODE [DK30KY] 2044
FAILURE CODE [DK55KA] 2046
FAILURE CODE [DK55KY] 2049
FAILURE CODE [DK55L5] 2051
FAILURE CODE [DK59KA] 2052
FAILURE CODE [DK59KY] 2056
FAILURE CODE [DK59L8] 2060
FAILURE CODE [DK5AKA] 2065
FAILURE CODE [DK5AKY] 2069
FAILURE CODE [DK5BKA] 2073
FAILURE CODE [DK5BKY] 2077
FAILURE CODE [DK5BL8] 2081
FAILURE CODE [DK5CKA] 2086
FAILURE CODE [DK5CKY] 2090
FAILURE CODE [DK5DKA] 2094
FAILURE CODE [DK5DKY] 2097
FAILURE CODE [DK5DL8] 2100
FAILURE CODE [DK5EKA] 2104
FAILURE CODE [DK5EKY] 2107
FAILURE CODE [DKA0KA] 2110
FAILURE CODE [DKA0KY] 2113
FAILURE CODE [DKA0L0] 2116
FAILURE CODE [DKA1KA] 2119
FAILURE CODE [DKA1KY] 2122
FAILURE CODE [DKD0KA] 2125
FAILURE CODE [DKD0KY] 2127
FAILURE CODE [DKD0L8] 2129
FAILURE CODE [DLF1KA] 2130
FAILURE CODE [DLF1LC] 2132
FAILURE CODE [DLM3KA] 2134
FAILURE CODE [DLM3LC] 2136
FAILURE CODE [DLT3KA] 2138
FAILURE CODE [DLT3LC] 2140
FAILURE CODE [DPQ1KR] 2142
FAILURE CODE [DPQ2KR] 2145
FAILURE CODE [DPQ3KR] 2148
FAILURE CODE [DSJ0KR] 2151
FAILURE CODE [DT20KB] 2154
FAILURE CODE [DT22KB] 2156
FAILURE CODE [DT23KB] 2158
FAILURE CODE [DV00KB] 2160
FAILURE CODE [DW4PKA] 2162
FAILURE CODE [DW4PKB] 2164
FAILURE CODE [DW4PKY] 2166
FAILURE CODE [DW4QKA] 2168
FAILURE CODE [DW4QKB] 2170
FAILURE CODE [DW4QKY] 2172
FAILURE CODE [DW4RKA] 2174
FAILURE CODE [DW4RKB] 2176
FAILURE CODE [DW4RKY] 2178
FAILURE CODE [DW4SKA] 2180
FAILURE CODE [DW4SKB] 2182
FAILURE CODE [DW4SKY] 2184
FAILURE CODE [DW7BKA] 2186
FAILURE CODE [DW7BKB] 2188
FAILURE CODE [DW7BKY] 2190
FAILURE CODE [DWM1KA] 2192
FAILURE CODE [DWM1KB] 2194
FAILURE CODE [DWM1KY] 2196
FAILURE CODE [DWN6KA] 2198
FAILURE CODE [DWN6KB] 2200
FAILURE CODE [DWN6KY] 2202
FAILURE CODE [DWN8KA] 2204
FAILURE CODE [DWN8KB] 2206
FAILURE CODE [DWN8KY] 2208
FAILURE CODE [DX16KA] 2210
FAILURE CODE [DX16KB] 2212
FAILURE CODE [DX16KY] 2214
FAILURE CODE [DXA1KA] 2216
FAILURE CODE [DXA1KB] 2218
FAILURE CODE [DXA1KY] 2220
FAILURE CODE [DXANKA] 2222
FAILURE CODE [DXANKB] 2224
FAILURE CODE [DXANKY] 2226
FAILURE CODE [DXF0KA] 2228
FAILURE CODE [DXF0KB] 2230
FAILURE CODE [DXF0KY] 2232
FAILURE CODE [DXH1KA] 2234
FAILURE CODE [DXH1KB] 2236
FAILURE CODE [DXH1KY] 2238
FAILURE CODE [DXH4KA] 2240
FAILURE CODE [DXH4KB] 2242
FAILURE CODE [DXH4KY] 2244
FAILURE CODE [DXH5KA] 2246
FAILURE CODE [DXH5KB] 2248
FAILURE CODE [DXH5KY] 2250
FAILURE CODE [DXH6KA] 2252
FAILURE CODE [DXH6KB] 2254
FAILURE CODE [DXH6KY] 2256
FAILURE CODE [DXH7KA] 2258
FAILURE CODE [DXH7KB] 2260
FAILURE CODE [DXH7KY] 2262
FAILURE CODE [DXH8KA] 2264
FAILURE CODE [DXH8KB] 2266
FAILURE CODE [DXH8KY] 2268
FAILURE CODE [DXHHKA] 2270
FAILURE CODE [DXHHKB] 2272
FAILURE CODE [DXHHKY] 2274
FAILURE CODE [DXHJKA] 2276
FAILURE CODE [DXHJKB] 2278
FAILURE CODE [DXHJKY] 2280
FAILURE CODE [DXHKKA] 2282
FAILURE CODE [DXHKKB] 2284
FAILURE CODE [DXHKKY] 2286
FAILURE CODE [DY30MA] 2288
FAILURE CODE [DY30MC] 2292
FAILURE CODE [DY30ME] 2297
FAILURE CODE [LA00L3] 2299
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2300
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2300
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2309
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2312
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2315
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2317
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2320
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2323
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2326
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2329
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2332
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2336
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2338
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2341
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2344
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2347
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2348
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2351
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2354
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2357
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2361
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP 2363
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 2365
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2367
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2371
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2372
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2373
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2375
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 2376
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2378
E-30 ALARM BUZZER DOES NOT SOUND 2379
E-31 ALARM BUZZER DOES NOT STOP SOUNDING 2381
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2382
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2384
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 2386
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED 2390
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED 2392
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2394
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2396
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE 2398
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2399
E-41 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED (FOR AJSS SPEC) 2401
E-42 HORN DOES NOT SOUND 2403
E-43 HORN DOES NOT SOUND (FOR AJSS SPEC) 2406
E-44 HORN DOES NOT STOP SOUNDING 2409
E-45 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2412
E-46 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS (FOR AJSS SPEC) 2414
E-47 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2416
E-48 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2420
E-49 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2424
E-50 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 2428
E-51 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2432
E-52 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2436
E-53 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2440
E-54 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2442
E-55 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2444
E-56 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2446
E-57 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2448
E-58 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2450
E-59 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2452
E-60 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2457
E-61 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2462
E-62 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2466
E-63 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 2471
E-64 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2474
E-65 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 2477
E-66 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR AJSS SPEC) 2480
E-67 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2484
E-68 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 2487
E-69 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2492
E-70 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2496
E-71 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2500
E-72 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2503
E-73 FRONT WIPER DOES NOT OPERATE 2505
E-74 FRONT WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2509
E-75 REAR WIPER DOES NOT OPERATE 2513
E-76 REAR WIPER DOES NOT OPERATE (FOR AJSS SPEC) 2516
E-77 FUEL FEED PUMP DOES NOT OPERATE OR STOP AUTOMATICALLY 2519
E-78 FAN DOES NOT ROTATE IN REVERSE 2522
E-79 FAN REMAINS ROTATED IN REVERSE 2523
E-80 WINDOW WASHER DOES NOT OPERATE 2524
E-81 WINDOW WASHER DOES NOT OPERATE (FOR AJSS SPEC) 2527
E-82 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2530
E-83 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2531
E-84 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2533
E-85 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP 2534
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2536
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2536
FAILURE MODE AND CAUSE TABLE 2537
H-1 MACHINE DOES NOT START 2557
H-2 LOCKUP IS NOT RELEASED 2561
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2562
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2563
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2567
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2570
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2573
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2576
H-9 MACHINE DOES NOT TURN (AJSS SPECIFICATION) 2578
H-10 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2580
H-11 TURNING RESPONSE IS POOR (AJSS SPECIFICATION) 2582
H-12 STEERING WHEEL IS HEAVY TO OPERATE 2584
H-13 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2585
H-14 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (AJSS SPECIFICATION) 2587
H-15 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS 2589
H-16 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2590
H-17 WHEEL BRAKES ARE NOT RELEASED OR DRAG 2592
H-18 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 2593
H-19 PARKING BRAKE IS NOT RELEASED OR DRAGS 2594
H-20 BOOM DOES NOT RISE 2596
H-21 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 2598
H-22 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2600
H-23 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2601
H-24 HYDRAULIC DRIFT OF BOOM IS LARGE 2603
H-25 BOOM MOVES UP AND DOWN DURING OPERATION 2604
H-26 BUCKET DOES NOT TILT BACK 2605
H-27 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2607
H-28 BUCKET DECELERATES DURING TILT-BACK OPERATION 2609
H-29 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2610
H-30 HYDRAULIC DRIFT OF BUCKET IS LARGE 2612
H-31 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 2613
H-32 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE 2614
H-33 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2615
H-34 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2616
H-35 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2619
H-36 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2620
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2621
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2623
TROUBLESHOOTING OF ENGINE (S-MODE) 2624
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2624
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2625
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2626
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2627
S-4 ENGINE STARTABILITY IS POOR 2628
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2630
S-6 ENGINE STOPS DURING OPERATION 2632
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2634
S-8 ENGINE LACKS POWER 2635
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2637
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2639
S-11 OIL BECOMES CONTAMINATED QUICKLY 2640
S-12 FUEL CONSUMPTION IS EXCESSIVE 2641
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2642
S-14 OIL PRESSURE DROPS 2643
S-15 FUEL MIXES INTO ENGINE OIL 2645
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2646
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2647
S-18 UNUSUAL NOISE IS HEARD 2648
S-19 VIBRATION IS EXCESSIVE 2649
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2650
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2651
S-22 ACTIVE REGENERATION TAKES TIME 2653
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2655
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2656
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2658
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2659
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM 2660
OUTLINE OF FAILURE DISPLAY 2660
TROUBLESHOOTING FOR FCS 2661
TROUBLESHOOTING FOR AUTO-GREASING PUMP 2662
REPLACEMENT OF PUMP ELEMENT 2665
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM 2666
REPLACEMENT OF AUTO-GREASING CONTROLLER 2668
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2669
50 DISASSEMBLY AND ASSEMBLY 2671
CONTENTS 2672
ABBREVIATION LIST 2677
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2683
HOW TO READ THIS MANUAL 2683
COATING MATERIALS LIST 2685
SPECIAL TOOLS LIST 2689
SKETCHES OF SPECIAL TOOLS 2710
ENGINE AND COOLING SYSTEM 2716
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2716
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2716
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2720
REMOVE AND INSTALL INJECTOR ASSEMBLY 2726
METHOD FOR REMOVING INJECTOR ASSEMBLY 2726
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2730
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2738
METHOD FOR REMOVING FUEL DOSER ASSEMBLY 2738
METHOD FOR INSTALLING FUEL DOSER ASSEMBLY 2739
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2742
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2742
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2753
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2770
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2770
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2770
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2772
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2772
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2774
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2777
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2777
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2778
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 2780
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2780
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2782
REMOVE AND INSTALL ALTERNATOR BELT 2785
METHOD FOR REMOVING ALTERNATOR BELT 2785
METHOD FOR INSTALLING ALTERNATOR BELT 2786
REMOVE AND INSTALL AUTOMATIC TENSIONER 2788
METHOD FOR REMOVING AUTOMATIC TENSIONER 2788
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2788
REMOVE AND INSTALL RADIATOR ASSEMBLY 2789
METHOD FOR REMOVING RADIATOR ASSEMBLY 2789
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2794
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2799
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2799
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2802
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2804
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2804
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2806
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2808
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2808
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2812
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 2816
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2816
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2821
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2827
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2828
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2845
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2862
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2862
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2863
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2865
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2865
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2866
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2869
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2869
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2870
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2877
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2877
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2883
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2890
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2890
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2893
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2898
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2898
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2902
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2906
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2906
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2911
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2915
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2915
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2916
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2922
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2922
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2922
REMOVE AND INSTALL KDPF ASSEMBLY 2923
METHOD FOR REMOVING KDPF ASSEMBLY 2924
METHOD FOR INSTALLING KDPF ASSEMBLY 2937
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2952
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2952
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2956
REMOVE AND INSTALL SCR ASSEMBLY 2962
METHOD FOR REMOVING SCR ASSEMBLY 2963
METHOD FOR INSTALLING SCR ASSEMBLY 2973
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2987
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2988
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2999
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 3010
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 3010
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 3015
REMOVE AND INSTALL KCCV ASSEMBLY 3023
METHOD FOR REMOVING KCCV ASSEMBLY 3023
METHOD FOR INSTALLING KCCV ASSEMBLY 3023
REMOVE AND INSTALL VGT ASSEMBLY 3025
METHOD FOR REMOVING VGT ASSEMBLY 3025
METHOD FOR INSTALLING VGT ASSEMBLY 3031
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3037
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3038
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3044
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3054
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3054
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3058
REMOVE AND INSTALL AdBlue/DEF PUMP 3062
METHOD FOR REMOVING AdBlue/DEF PUMP 3062
METHOD FOR INSTALLING AdBlue/DEF PUMP 3065
REMOVE AND INSTALL AdBlue/DEF HOSE 3068
METHOD FOR REMOVING AdBlue/DEF HOSE 3069
METHOD FOR INSTALLING AdBlue/DEF HOSE 3078
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3089
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3089
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3090
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3092
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3092
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3093
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3095
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3095
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3096
POWER TRAIN 3098
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 3098
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 3098
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3102
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 3110
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3112
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3130
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3157
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3158
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3174
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 3194
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3194
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3196
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3198
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3198
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3205
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 3213
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY 3214
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3219
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 3227
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY 3228
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3237
STEERING SYSTEM 3256
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 3256
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3256
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3258
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY (FOR AJSS SPEC) 3261
METHOD FOR REMOVING ROTARY VALVE ASSEMBLY 3261
METHOD FOR INSTALLING ROTARY VALVE ASSEMBLY 3266
BRAKE SYSTEM 3275
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3275
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE 3275
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE 3278
UNDERCARRIAGE AND FRAME 3281
REMOVE AND INSTALL CENTER HINGE PIN 3281
METHOD FOR REMOVING CENTER HINGE PIN 3281
METHOD FOR INSTALLING CENTER HINGE PIN 3287
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3294
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3294
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3296
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY 3300
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3300
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3301
HYDRAULIC SYSTEM 3302
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3302
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3302
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3306
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3310
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3310
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND COOLING FAN PUMP ASSEMBLY 3311
REMOVE AND INSTALL STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3313
METHOD FOR REMOVING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3313
METHOD FOR INSTALLING STEERING PUMP AND POWER TRAIN PUMP ASSEMBLY 3314
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3317
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3317
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3320
WORK EQUIPMENT 3324
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3324
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3324
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3328
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 3333
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3334
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3337
CAB AND ITS ATTACHMENTS 3343
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3343
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3343
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3349
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3356
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3356
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3357
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3366
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3366
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3372
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3377
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3377
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3379
REMOVE AND INSTALL SEAT BELT 3381
METHOD FOR REMOVING SEAT BELT 3381
METHOD FOR INSTALLING SEAT BELT 3381
ELECTRICAL SYSTEM 3383
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3383
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3383
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3385
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3388
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3388
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3389
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3392
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3392
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3392
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3394
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3394
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3396
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3398
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3398
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3399
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3401
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3401
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3402
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3403
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3403
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3404
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR 3405
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3405
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3409
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3414
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3414
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3418
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3422
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3422
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3426
REMOVE AND INSTALL AMMONIA SENSOR 3430
METHOD FOR REMOVING AMMONIA SENSOR 3430
METHOD FOR INSTALLING AMMONIA SENSOR 3433
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 3437
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3437
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3440
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3445
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3445
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3446
60 MAINTENANCE STANDARD 3447
CONTENTS 3448
ABBREVIATION LIST 3450
ENGINE AND COOLING SYSTEM 3456
MAINTENANCE STANDARD OF ENGINE MOUNT 3456
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP 3457
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3459
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3460
POWER TRAIN 3462
MAINTENANCE STANDARD OF DRIVE SHAFT 3462
MAINTENANCE STANDARD OF TORQUE CONVERTER 3463
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3465
MAINTENANCE STANDARD OF TRANSMISSION 3466
MAINTENANCE STANDARD OF F, 1ST CLUTCH 3472
MAINTENANCE STANDARD OF R, 2ND CLUTCH 3474
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH 3476
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3478
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND 1ST, 2ND CLUTCH ECMV 3480
MAINTENANCE STANDARD OF 3RD, 4TH CLUTCH ECMV 3481
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3482
MAINTENANCE STANDARD OF FRONT AXLE 3483
MAINTENANCE STANDARD OF REAR AXLE 3484
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3485
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL 3488
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3491
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL 3493
MAINTENANCE STANDARD OF FINAL DRIVE 3495
STEERING SYSTEM 3498
MAINTENANCE STANDARD OF STEERING COLUMN 3498
MAINTENANCE STANDARD OF STEERING PUMP 3499
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP 3502
MAINTENANCE STANDARD OF STEERING VALVE 3503
MAINTENANCE STANDARD OF STEERING CYLINDER 3505
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3507
BRAKE SYSTEM 3508
MAINTENANCE STANDARD OF CHARGE VALVE 3508
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3510
MAINTENANCE STANDARD OF SLACK ADJUSTER 3511
MAINTENANCE STANDARD OF FRONT BRAKE 3512
MAINTENANCE STANDARD OF REAR BRAKE 3513
MAINTENANCE STANDARD OF PARKING BRAKE 3514
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE 3516
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3517
MAINTENANCE STANDARD OF BRAKE COOLING PUMP 3518
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER 3519
UNDERCARRIAGE AND FRAME 3520
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 3520
HYDRAULIC SYSTEM 3525
MAINTENANCE STANDARD OF HYDRAULIC TANK 3525
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3527
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 3529
MAINTENANCE STANDARD OF CONTROL VALVE 3530
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 3539
WORK EQUIPMENT 3540
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3540
MAINTENANCE STANDARD OF BUCKET 3544
MAINTENANCE STANDARD OF LIFT CYLINDER 3545
MAINTENANCE STANDARD OF BUCKET CYLINDER 3546
80 APPENDIX 3547
CONTENTS 3548
ABBREVIATION LIST 3550
AIR CONDITIONER SYSTEM 3556
PRECAUTIONS FOR REFRIGERANT 3556
AIR CONDITIONER COMPONENT 3557
SPECIFICATIONS OF AIR CONDITIONER 3559
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3560
OUTLINE OF REFRIGERATION CYCLE 3561
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3563
AIR CONDITIONER UNIT 3563
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3563
FUNCTION OF AIR CONDITIONER UNIT 3564
COMPONENT PARTS OF AIR CONDITIONER UNIT 3565
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3565
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3565
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3566
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3567
FUNCTION OF DUAL PRESSURE SWITCH 3567
AIR CONDITIONER CONTROLLER 3568
STRUCTURE OF AIR CONDITIONER CONTROLLER 3568
COMPRESSOR 3569
STRUCTURE OF COMPRESSOR 3569
SPECIFICATIONS OF COMPRESSOR 3569
FUNCTION OF COMPRESSOR 3569
CONDENSER 3570
STRUCTURE OF CONDENSER 3570
SPECIFICATIONS OF CONDENSER 3570
FUNCTION OF CONDENSER 3570
RECEIVER DRIER 3571
STRUCTURE OF RECEIVER DRIER 3571
SPECIFICATIONS OF RECEIVER DRIER 3571
FUNCTION OF RECEIVER DRIER 3571
SENSORS FOR AIR CONDITIONER SYSTEM 3572
FUNCTION OF SUNLIGHT SENSOR 3572
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3572
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3573
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3575
AIR CONDITIONER SYSTEM DIAGRAM 3578
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3579
FUNCTION OF AIR CONDITIONER CONTROLLER 3580
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3581
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3587
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3588
CHECK TEMPERATURE CONTROL FUNCTION 3589
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 3589
TEST VENT (MODE) CHANGEOVER 3591
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3591
TESTING FRESH/RECIRC AIR CHANGEOVER 3593
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3593
TEST EVAPORATOR TEMPERATURE SENSOR 3595
TEST RELAYS 3597
METHOD FOR TESTING RELAYS 3597
AIR CONDITIONER TROUBLESHOOTING CHART 1 3599
AIR CONDITIONER TROUBLESHOOTING CHART 2 3600
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3603
FAILURE CODE [879AKA] 3605
FAILURE CODE [879AKB] 3607
FAILURE CODE [879BKA] 3609
FAILURE CODE [879BKB] 3611
FAILURE CODE [879CKA] 3613
FAILURE CODE [879CKB] 3615
FAILURE CODE [879DKZ] 3617
FAILURE CODE [879EMC] 3619
FAILURE CODE [879FMC] 3622
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3625
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3628
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3631
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3635
TROUBLESHOOTING USING GAUGE PRESSURE 3637
CONNECTION OF SERVICE TOOL 3640
METHOD FOR CONNECTING SERVICE TOOL 3641
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3642
HANDLE COMPRESSOR OIL 3644
90 CIRCUIT DIAGRAMS 3647
CONTENTS 3648
ABBREVIATION LIST 3649
HYDRAULIC CIRCUIT DIAGRAM 3655
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3655
HYDRAULIC CIRCUIT DIAGRAM (FOR AJSS SPEC) 3659
HYDRAULIC CIRCUIT DIAGRAM (FOR STEERING WHEEL SPEC) 3661
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3663
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM 3665
HYDRAULIC AUTO-GREASING DIAGRAM 3667
ELECTRICAL CIRCUIT DIAGRAM 3669
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3669
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/6) 3673
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/6) 3675
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/6) 3677
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/6) 3679
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/6) 3681
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/6) 3683
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (1/9) 3685
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (2/9) 3687
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (3/9) 3689
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (4/9) 3691
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (5/9) 3693
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (6/9) 3695
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (7/9) 3697
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (8/9) 3699
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR AJSS SPEC) (9/9) 3701
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) 3703
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) 3705
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) 3707
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) 3709
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) 3711
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) 3713
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) 3715
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) 3717
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) 3719
INDEX 3721

DESCRIPTION:

Komatsu WA480-8E0 Wheel Loader Shop Manual SEN06754-00 – 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.

S.V 30/12/24