Komatsu WHEEL LOADER WA270-8 Shop Manual VENBM31500 – PDF DOWNLOAD

Description

Komatsu WHEEL LOADER WA270-8 Shop Manual VENBM31500 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WHEEL LOADER WA270-8 Shop Manual VENBM31500 – PDF DOWNLOAD

Language : English
Pages :3306
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WHEEL LOADER WA270-8 Shop Manual VENBM31500 – PDF DOWNLOAD

SERIAL NUMBERS H75051 and up
83001 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.

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA270-8 Shop Manual VENBM31500 – PDF DOWNLOAD

SERIAL NUMBERS H75051 and up
83001 and up

VENBM31500 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: WA270-8 103
SPECIFICATIONS 105
SPECIFICATIONS: WA270-8 105
WEIGHT TABLE 110
WEIGHT TABLE: WA270-8 110
TABLE OF FUEL, COOLANT, AND LUBRICANTS 112
10 STRUCTURE AND FUNCTION 115
CONTENTS 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 132
COMPONENT PARTS OF UREA SCR SYSTEM 146
AdBlue/DEF MIXING TUBE 146
SCR ASSEMBLY 147
AdBlue/DEF TANK 149
AdBlue/DEF PUMP 151
AdBlue/DEF INJECTOR 152
AdBlue/DEF HOSE 153
AdBlue/DEF TANK HEATING VALVE 154
BOOT-UP SYSTEM 155
LAYOUT DRAWING OF BOOT-UP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 157
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 157
BATTERY DISCONNECT SWITCH 158
FUNCTION OF BATTERY DISCONNECT SWITCH 158
PREHEATING SYSTEM 159
PREHEATING SYSTEM DIAGRAM 159
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 159
OPERATION OF AUTOMATIC PREHEATING SYSTEM 159
FUNCTION OF MANUAL PREHEATING SYSTEM 160
OPERATION OF MANUAL PREHEATING SYSTEM 160
ENGINE SYSTEM 161
LAYOUT DRAWING OF ENGINE SYSTEM 161
FUNCTION OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 163
ENGINE CONTROL SYSTEM DIAGRAM 163
FUNCTION OF ENGINE CONTROL SYSTEM 165
OPERATION OF ENGINE CONTROL SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 171
DAMPER 171
VGT 172
EGR SYSTEM 176
EGR VALVE 178
EGR COOLER 180
KCCV SYSTEM 182
KCCV VENTILATOR 184
KDPF 186
COOLING SYSTEM 190
LAYOUT DRAWING OF COOLING SYSTEM 190
SPECIFICATIONS OF COOLING SYSTEM 191
COOLING FAN CONTROL SYSTEM 192
COOLING FAN CONTROL SYSTEM DIAGRAM 192
FUNCTION OF COOLING FAN CONTROL SYSTEM 192
COMPONENT PARTS OF COOLING SYSTEM 197
COOLING FAN MOTOR 197
CONTROL SYSTEM 210
LAYOUT DRAWING OF CONTROL SYSTEM 210
MACHINE MONITOR SYSTEM 212
MACHINE MONITOR SYSTEM DIAGRAM 212
FUNCTION OF MACHINE MONITOR SYSTEM 212
REARVIEW MONITOR SYSTEM 214
REARVIEW MONITOR SYSTEM DIAGRAM 214
FUNCTION OF REARVIEW MONITOR SYSTEM 214
KOMTRAX SYSTEM 215
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 215
FUNCTION OF KOMTRAX SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
SWITCH PANEL 233
REARVIEW MONITOR 234
REARVIEW CAMERA 236
KOMTRAX TERMINAL 237
MONITOR CONTROLLER 239
HST CONTROLLER 244
CAN TERMINATING RESISTOR 249
ENGINE CONTROLLER 250
ACCELERATOR PEDAL 257
HYDRAULIC SYSTEM 259
LAYOUT DRAWING OF HYDRAULIC SYSTEM 259
CLSS 260
STRUCTURE OF CLSS 260
FUNCTION OF CLSS 261
COMPONENT PARTS OF HYDRAULIC SYSTEM 263
HYDRAULIC TANK 263
HYDRAULIC OIL FILTER 266
STEERING AND WORK EQUIPMENT PUMP 267
BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP 280
CONTROL VALVE 281
POWER TRAIN SYSTEM 311
LAYOUT DRAWING OF POWER TRAIN SYSTEM 311
OPERATION OF POWER TRAIN SYSTEM 313
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 314
HST CONTROL SYSTEM 316
HST CONTROL SYSTEM DIAGRAM 316
ENGINE OVERRUN PREVENTION FUNCTION 317
NEUTRALIZER FUNCTION 317
HST CHARGE SYSTEM 318
SYSTEM DIAGRAM OF HST CHARGE SYSTEM 318
FUNCTION OF HST CHARGE SYSTEM 318
HST PUMP CONTROL SYSTEM 319
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM 319
DIRECTIONAL SELECTION FUNCTION 319
ABSORBING TORQUE CONTROL FUNCTION 320
INCHING CONTROL FUNCTION 320
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED) 320
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION 321
GEAR SHIFT FUNCTION 321
GEAR SHIFT DISPLAY FUNCTION 323
TRAVEL SPEED ADJUSTMENT FUNCTION 323
TRANSFER CLUTCH CONTROL FUNCTION 324
HST SYSTEM PROTECTION FUNCTION 325
TRANSFER PROTECTION FUNCTION 325
DIRECTION PROTECTION FUNCTION 325
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1 325
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2 326
TRAVEL SPEED LIMITATION FUNCTION 327
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL 328
FUNCTION OF MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL 328
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 331
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM 331
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) 331
COMPONENT PARTS OF POWER TRAIN SYSTEM 336
DRIVE SHAFT 336
HST PUMP 338
HST CHARGE PUMP 351
HST MOTOR 353
TRANSFER 359
AXLE 367
TORQUE PROPORTIONING DIFFERENTIAL 369
LIMITED SLIP DIFFERENTIAL 373
FINAL DRIVE 377
COMBINATION SWITCH 379
WORK EQUIPMENT SYSTEM 383
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 383
WORK EQUIPMENT CONTROL SYSTEM 385
WORK EQUIPMENT LEVER OPERATION FUNCTION 385
PZ AUTO TILT-IN COMPENSATION CONTROL FUNCTION 385
WORK EQUIPMENT LOCK SYSTEM 386
WORK EQUIPMENT LOCK SYSTEM DIAGRAM 386
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM 386
BUCKET POSITIONER SYSTEM 388
BUCKET POSITIONER SYSTEM DIAGRAM 388
FUNCTION OF BUCKET POSITIONER SYSTEM 388
OPERATION OF BUCKET POSITIONER SYSTEM 390
FORK POSITIONER SYSTEM 392
FORK POSITIONER SYSTEM DIAGRAM 392
FUNCTION OF FORK POSITIONER SYSTEM 392
OPERATION OF FORK POSITIONER SYSTEM 393
REMOTE POSITIONER SYSTEM 396
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 396
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 396
ECSS 399
ECSS DIAGRAM 399
FUNCTION OF ECSS 399
OPERATION OF ECSS 399
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 401
SELF-PRESSURE REDUCING VALVE 401
WORK EQUIPMENT LOCK SOLENOID VALVE 406
PILOT CIRCUIT ACCUMULATOR 407
ECSS CIRCUIT ACCUMULATOR 408
MULTIFUNCTION MONO-LEVER 409
MULTIFUNCTION MONO-LEVER PPC VALVE 411
STEERING SYSTEM 416
LAYOUT DRAWING OF STEERING SYSTEM 416
STEERING COLUMN 417
STRUCTURE OF STEERING COLUMN 417
COMPONENT PARTS OF STEERING SYSTEM 418
PRIORITY VALVE 418
ORBITROL VALVE 421
CUSHION VALVE 426
2-WAY RESTRICTOR VALVE 428
SECONDARY STEERING VALVE 429
BRAKE SYSTEM 432
LAYOUT DRAWING OF BRAKE SYSTEM 432
PARKING BRAKE CONTROL SYSTEM 434
PARKING BRAKE CONTROL SYSTEM DIAGRAM 434
OPERATION OF PARKING BRAKE CONTROL SYSTEM 434
COMPONENT PARTS OF BRAKE SYSTEM 438
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 438
PARKING BRAKE SOLENOID VALVE 442
BRAKE CIRCUIT ACCUMULATOR 444
BRAKE VALVE 446
SLACK ADJUSTER 449
BRAKE 451
PARKING BRAKE 454
AUTO-GREASING SYSTEM 456
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 456
SPECIFICATIONS OF AUTO-GREASING SYSTEM 457
FUNCTION OF AUTO-GREASING SYSTEM 458
COMPONENT PARTS OF AUTO-GREASING SYSTEM 459
AUTO-GREASING PUMP 459
UNDERCARRIAGE AND FRAME 460
FRAME, AXLE MOUNT AND CENTER HINGE PIN 460
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 460
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 461
TIRE 463
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 463
STRUCTURE OF RADIAL TIRE 463
FUNCTION OF RADIAL TIRE 464
STRUCTURE OF BIAS TIRE 464
FUNCTION OF BIAS TIRE 464
WORK EQUIPMENT 465
STRUCTURE OF WORK EQUIPMENT 465
STRUCTURE OF BUCKET 466
CAB AND ITS ATTACHMENTS 467
ROPS CAB 467
STRUCTURE OF ROPS CAB 467
FUNCTION OF ROPS CAB 467
CAB MOUNT 468
STRUCTURE OF CAB MOUNT 468
FUNCTION OF CAB MOUNT 468
20 STANDARD VALUE TABLE 469
CONTENTS 470
ABBREVIATION LIST 471
STANDARD VALUE TABLE FOR ENGINE 477
STANDARD VALUE TABLE FOR ENGINE: WA270-8 477
STANDARD VALUE TABLE FOR MACHINE 482
STANDARD VALUE TABLE FOR MACHINE: WA270-8 482
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 496
30 TESTING AND ADJUSTING 499
CONTENTS 500
ABBREVIATION LIST 504
RELATED INFORMATION ON TESTING AND ADJUSTING 510
TOOLS FOR TESTING AND ADJUSTING 510
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 519
ENGINE AND COOLING SYSTEM 520
TEST ENGINE SPEED 520
METHOD FOR TESTING ENGINE SPEED 520
TEST BOOST PRESSURE 523
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 523
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 524
TESTING EXHAUST GAS TEMPERATURE 526
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 526
TEST EXHAUST GAS COLOR 528
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 528
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 530
TEST AND ADJUST VALVE CLEARANCE 532
METHOD FOR TESTING VALVE CLEARANCE 532
METHOD FOR ADJUSTING VALVE CLEARANCE 533
TEST COMPRESSION PRESSURE 534
METHOD FOR TESTING COMPRESSION PRESSURE 534
TEST BLOWBY PRESSURE 539
METHOD FOR TESTING BLOWBY PRESSURE 539
TEST ENGINE OIL PRESSURE 542
METHOD FOR TESTING ENGINE OIL PRESSURE 542
TEST EGR VALVE AND VGT OIL PRESSURE 544
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 544
TEST FUEL PRESSURE 546
METHOD FOR TESTING FUEL PRESSURE 547
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 552
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 553
BLEED AIR FROM FUEL SYSTEM 559
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 559
TEST FUEL CIRCUIT FOR LEAKAGE 561
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 561
HANDLE CYLINDER CUT-OUT MODE OPERATION 563
HANDLE NO-INJECTION CRANKING OPERATION 564
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 565
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 565
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 566
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 566
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 567
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 567
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 568
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 568
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 568
TEST ALTERNATOR BELT 570
METHOD FOR TESTING ALTERNATOR BELT 570
TEST AUTOMATIC TENSIONER 572
METHOD FOR TESTING AUTOMATIC TENSIONER 572
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 575
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 575
TEST SCR RELATED FUNCTIONS 576
TEST AdBlue/DEF PUMP RAISED PRESSURE 580
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 583
TEST AdBlue/DEF LINE HEATER RELAY 1 589
TEST AdBlue/DEF LINE HEATER RELAY 2 593
TEST AdBlue/DEF PUMP HEATER RELAY 597
TEST AdBlue/DEF TANK HEATER VALVE 601
TEST SCR NOx REMOVAL EFFICIENCY 605
CLEAN AdBlue/DEF TANK 609
METHOD FOR CLEANING AdBlue/DEF TANK 609
POWER TRAIN 613
TEST AND ADJUST HST OIL PRESSURE 613
METHOD FOR TESTING HST OIL PRESSURE 613
METHOD FOR ADJUSTING HST OIL PRESSURE 615
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH 617
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH 617
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 619
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 619
STEERING SYSTEM 620
TEST STEERING WHEEL 620
METHOD FOR TESTING STEERING WHEEL 620
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 622
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE ON MACHINE MONITOR 622
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE BY TESTING TOOL 623
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 623
BLEED AIR FROM STEERING CYLINDER CIRCUIT 625
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 625
BRAKE SYSTEM 626
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 626
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 626
TEST WHEEL BRAKE OIL PRESSURE 627
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 627
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 629
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 629
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 630
BLEED AIR FROM BRAKE CIRCUIT 631
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 631
TEST BRAKING PERFORMANCE 632
METHOD FOR TESTING BRAKING PERFORMANCE 632
TEST BRAKE PEDAL 633
METHOD FOR TESTING BRAKE PEDAL 633
TEST LOWERING OF WHEEL BRAKE PRESSURE 634
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 635
TEST WEAR OF WHEEL BRAKE DISC 637
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 637
TEST PARKING BRAKE OIL PRESSURE 639
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 639
TEST PARKING BRAKE PERFORMANCE 641
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 641
RELEASE PARKING BRAKE MANUALLY 642
METHOD FOR RELEASING PARKING BRAKE MANUALLY 642
TEST WEAR AMOUNT OF PARKING BRAKE DISC 643
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 643
HYDRAULIC SYSTEM 644
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 644
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 644
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 646
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 646
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 650
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE 652
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE 652
METHOD FOR ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE 655
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 656
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 656
TEST COOLING FAN SPEED 658
METHOD FOR TESTING COOLING FAN SPEED 658
TEST COOLING FAN CIRCUIT OIL PRESSURE 659
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 659
BLEED AIR FROM COOLING FAN CIRCUIT 662
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 662
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 664
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 664
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 666
WORK EQUIPMENT 670
TEST AND ADJUST BUCKET POSITIONER 670
METHOD FOR TESTING BUCKET POSITIONER 670
METHOD FOR ADJUSTING BUCKET POSITIONER 670
TEST AND ADJUST BOOM POTENTIOMETER LEVER 672
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 672
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 672
CAB AND ITS ATTACHMENTS 673
TEST DIRECTIONAL LEVER 673
METHOD FOR TESTING DIRECTIONAL LEVER 673
TEST MULTIFUNCTION MONO-LEVER 674
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER 674
TEST ACCELERATOR PEDAL 676
METHOD FOR TESTING ACCELERATOR PEDAL 676
ADJUST RATTLING OPERATOR’S SEAT 678
METHOD FOR ADJUSTING RATTLING OPERATOR’S SEAT 678
ELECTRICAL SYSTEM 679
SET AND ADJUST EACH EQUIPMENT 679
SET AND OPERATE MACHINE MONITOR 683
OPERATOR MODE 687
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 687
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 687
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 688
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 689
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 689
SERVICE MODE 693
METHOD FOR OPERATING SERVICE MODE 693
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 696
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 703
ABNORMALITY RECORD MENU 715
METHOD FOR CONFIRMING MAINTENANCE RECORD 720
METHOD FOR OPERATING MAINTENANCE MODE SETTING 723
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 729
DEFAULT MENU 730
DIAGNOSTIC TESTS MENU 745
ADJUSTMENT MENU 757
METHOD FOR PERFORMING NO-INJECTION CRANKING 791
KOMTRAX SETTINGS MENU 793
METHOD FOR DISPLAYING SERVICE MESSAGE 795
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 797
ADJUST REARVIEW CAMERA ANGLE 801
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 801
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 803
HANDLE BATTERY DISCONNECT SWITCH 804
TEST DIODES 805
METHOD FOR TESTING DIODE USING DIGITAL TESTER 805
METHOD FOR TESTING DIODE USING ANALOG TESTER 805
AUTO-GREASING DEVICE 806
BLEED THE AIR OF AUTO-GREASING SYSTEM 806
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 806
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 809
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 810
Pm CLINIC 812
Pm CLINIC SERVICE 812
Pm CLINIC CHECK SHEET: WA270-8 814
40 TROUBLESHOOTING 823
CONTENTS 824
ABBREVIATION LIST 835
RELATED INFORMATION ON TROUBLESHOOTING 841
GENERAL TROUBLESHOOTING POINTS 841
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 842
SEQUENCE OF EVENTS IN TROUBLESHOOTING 854
CHECKS BEFORE TROUBLESHOOTING 856
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 858
WALK-AROUND CHECK 858
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 860
CHECK FUEL LEVEL AND TYPE 860
FUEL – CHECK FOR FOREIGN MATERIAL 860
CHECK AdBule/DEF LEVEL AND TYPE 861
CHECK FUEL PREFILTER 861
CHECK MAIN FILTER 863
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 864
CHECK COOLANT LEVEL (RESERVOIR TANK) 865
CHECK CLOGGING OF AIR CLEANER 866
OUTER ELEMENT – CLEAN 866
REPLACE ELEMENT 868
CHECK HYDRAULIC OIL LEVEL 870
CHECK HYDRAULIC OIL STRAINER 870
CHECK HYDRAULIC FILTER 873
CHECK THE OIL LEVEL IN THE TRANSFER CASE 873
CHECK OIL LEVEL IN FRONT AXLE CASE 875
CHECK OIL LEVEL IN REAR AXLE CASE 876
BLEED AIR FROM FUEL SYSTEM 876
BLEED AIR FROM HYDRAULIC SYSTEM 876
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 877
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 882
PROCEDURE FOR TESTING AND TROUBLESHOOTING 890
SYMPTOM AND TROUBLESHOOTING NUMBERS 892
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 896
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 898
CONNECTORS LIST AND LAYOUT 901
CONNECTOR CONTACT IDENTIFICATION 921
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 961
FUSE LOCATION TABLE 967
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 970
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 974
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 976
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 982
FAILURE CODES TABLE 984
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1003
FAILURE CODE [2F00MA]1003
FAILURE CODE [2F00MB]1006
FAILURE CODE [2G42ZG]1008
FAILURE CODE [2G43ZG]1010
FAILURE CODE [6091NX]1012
FAILURE CODE [7RHYKA]1014
FAILURE CODE [7RHYKB]1016
FAILURE CODE [7RHYKY]1018
FAILURE CODE [879AKA]1020
FAILURE CODE [879AKB]1022
FAILURE CODE [879BKA]1024
FAILURE CODE [879BKB]1026
FAILURE CODE [879CKA]1028
FAILURE CODE [879CKB]1030
FAILURE CODE [879DKZ]1032
FAILURE CODE [879EMC]1034
FAILURE CODE [879FMC]1035
FAILURE CODE [989FN1]1036
FAILURE CODE [989L00]1037
FAILURE CODE [989M00]1038
FAILURE CODE [989N00]1039
FAILURE CODE [A1U0N3]1040
FAILURE CODE [A1U0N4]1042
FAILURE CODE [AB00KE]1044
FAILURE CODE [AB00KY]1046
FAILURE CODE [AQ10N3]1048
FAILURE CODE [AS00N3]1050
FAILURE CODE [AS00R2]1052
FAILURE CODE [AS00R3]1053
FAILURE CODE [AS00R4]1054
FAILURE CODE [AS00R5]1055
FAILURE CODE [AS00R6]1056
FAILURE CODE [AS00ZK]1057
FAILURE CODE [AS10KM]1058
FAILURE CODE [AS10NR]1059
FAILURE CODE [AS10NT]1060
FAILURE CODE [B@BAZG]1061
FAILURE CODE [B@BCNS]1062
FAILURE CODE [B@BCZK]1063
FAILURE CODE [B@C6NS]1065
FAILURE CODE [B@CRNS]1067
FAILURE CODE [CA115]1068
FAILURE CODE [CA122]1069
FAILURE CODE [CA123]1071
FAILURE CODE [CA131]1073
FAILURE CODE [CA132]1075
FAILURE CODE [CA144]1078
FAILURE CODE [CA145]1080
FAILURE CODE [CA153]1082
FAILURE CODE [CA154]1085
FAILURE CODE [CA187]1087
FAILURE CODE [CA221]1089
FAILURE CODE [CA222]1091
FAILURE CODE [CA227]1093
FAILURE CODE [CA234]1094
FAILURE CODE [CA238]1095
FAILURE CODE [CA239]1097
FAILURE CODE [CA249]1099
FAILURE CODE [CA256]1101
FAILURE CODE [CA271]1103
FAILURE CODE [CA272]1105
FAILURE CODE [CA322]1107
FAILURE CODE [CA323]1109
FAILURE CODE [CA324]1111
FAILURE CODE [CA325]1113
FAILURE CODE [CA331]1115
FAILURE CODE [CA332]1117
FAILURE CODE [CA343]1119
FAILURE CODE [CA351]1120
FAILURE CODE [CA352]1121
FAILURE CODE [CA356]1124
FAILURE CODE [CA357]1126
FAILURE CODE [CA386]1129
FAILURE CODE [CA428]1130
FAILURE CODE [CA429]1132
FAILURE CODE [CA431]1134
FAILURE CODE [CA432]1137
FAILURE CODE [CA435]1141
FAILURE CODE [CA441]1143
FAILURE CODE [CA442]1145
FAILURE CODE [CA449]1146
FAILURE CODE [CA451]1147
FAILURE CODE [CA452]1149
FAILURE CODE [CA488]1151
FAILURE CODE [CA515]1152
FAILURE CODE [CA516]1154
FAILURE CODE [CA553]1156
FAILURE CODE [CA555]1157
FAILURE CODE [CA556]1158
FAILURE CODE [CA559]1159
FAILURE CODE [CA595]1162
FAILURE CODE [CA687]1163
FAILURE CODE [CA689]1165
FAILURE CODE [CA691]1168
FAILURE CODE [CA692]1170
FAILURE CODE [CA697]1172
FAILURE CODE [CA698]1173
FAILURE CODE [CA731]1174
FAILURE CODE [CA778]1176
FAILURE CODE [CA1117]1181
FAILURE CODE [CA1664]1182
FAILURE CODE [CA1669]1184
FAILURE CODE [CA1673]1185
FAILURE CODE [CA1677]1186
FAILURE CODE [CA1678]1187
FAILURE CODE [CA1682]1188
FAILURE CODE [CA1683]1192
FAILURE CODE [CA1684]1194
FAILURE CODE [CA1686]1196
FAILURE CODE [CA1691]1197
FAILURE CODE [CA1694]1200
FAILURE CODE [CA1695]1203
FAILURE CODE [CA1696]1204
FAILURE CODE [CA1712]1206
FAILURE CODE [CA1713]1209
FAILURE CODE [CA1714]1211
FAILURE CODE [CA1715]1212
FAILURE CODE [CA1776]1213
FAILURE CODE [CA1777]1216
FAILURE CODE [CA1843]1219
FAILURE CODE [CA1844]1221
FAILURE CODE [CA1879]1224
FAILURE CODE [CA1881]1227
FAILURE CODE [CA1883]1229
FAILURE CODE [CA1885]1233
FAILURE CODE [CA1887]1235
FAILURE CODE [CA1921]1237
FAILURE CODE [CA1922]1240
FAILURE CODE [CA1942]1245
FAILURE CODE [CA1993]1246
FAILURE CODE [CA2185]1249
FAILURE CODE [CA2186]1251
FAILURE CODE [CA2249]1253
FAILURE CODE [CA2271]1254
FAILURE CODE [CA2272]1257
FAILURE CODE [CA2288]1260
FAILURE CODE [CA2311]1261
FAILURE CODE [CA2349]1262
FAILURE CODE [CA2353]1265
FAILURE CODE [CA2357]1267
FAILURE CODE [CA2381]1268
FAILURE CODE [CA2382]1271
FAILURE CODE [CA2383]1274
FAILURE CODE [CA2386]1277
FAILURE CODE [CA2387]1279
FAILURE CODE [CA2555]1280
FAILURE CODE [CA2556]1283
FAILURE CODE [CA2637]1285
FAILURE CODE [CA2639]1287
FAILURE CODE [CA2771]1290
FAILURE CODE [CA2777]1296
FAILURE CODE [CA2976]1299
FAILURE CODE [CA3133]1301
FAILURE CODE [CA3134]1304
FAILURE CODE [CA3135]1306
FAILURE CODE [CA3142]1310
FAILURE CODE [CA3143]1311
FAILURE CODE [CA3144]1312
FAILURE CODE [CA3146]1315
FAILURE CODE [CA3147]1316
FAILURE CODE [CA3148]1317
FAILURE CODE [CA3151]1319
FAILURE CODE [CA3165]1325
FAILURE CODE [CA3229]1327
FAILURE CODE [CA3231]1329
FAILURE CODE [CA3232]1331
FAILURE CODE [CA3235]1335
FAILURE CODE [CA3239]1337
FAILURE CODE [CA3241]1340
FAILURE CODE [CA3242]1343
FAILURE CODE [CA3251]1346
FAILURE CODE [CA3253]1348
FAILURE CODE [CA3254]1351
FAILURE CODE [CA3255]1354
FAILURE CODE [CA3256]1358
FAILURE CODE [CA3311]1360
FAILURE CODE [CA3312]1362
FAILURE CODE [CA3313]1365
FAILURE CODE [CA3314]1366
FAILURE CODE [CA3315]1367
FAILURE CODE [CA3316]1370
FAILURE CODE [CA3317]1371
FAILURE CODE [CA3318]1372
FAILURE CODE [CA3319]1375
FAILURE CODE [CA3321]1376
FAILURE CODE [CA3322]1378
FAILURE CODE [CA3419]1381
FAILURE CODE [CA3421]1383
FAILURE CODE [CA3497]1385
FAILURE CODE [CA3498]1386
FAILURE CODE [CA3543]1387
FAILURE CODE [CA3545]1394
FAILURE CODE [CA3547]1396
FAILURE CODE [CA3558]1397
FAILURE CODE [CA3559]1399
FAILURE CODE [CA3562]1401
FAILURE CODE [CA3563]1403
FAILURE CODE [CA3567]1406
FAILURE CODE [CA3568]1409
FAILURE CODE [CA3571]1415
FAILURE CODE [CA3572]1417
FAILURE CODE [CA3574]1419
FAILURE CODE [CA3575]1421
FAILURE CODE [CA3577]1423
FAILURE CODE [CA3578]1425
FAILURE CODE [CA3582]1427
FAILURE CODE [CA3583]1435
FAILURE CODE [CA3596]1437
FAILURE CODE [CA3649]1440
FAILURE CODE [CA3681]1442
FAILURE CODE [CA3682]1447
FAILURE CODE [CA3713]1453
FAILURE CODE [CA3717]1456
FAILURE CODE [CA3718]1457
FAILURE CODE [CA3725]1458
FAILURE CODE [CA3741]1461
FAILURE CODE [CA3748]1462
FAILURE CODE [CA3751]1465
FAILURE CODE [CA3755]1467
FAILURE CODE [CA3866]1469
FAILURE CODE [CA3867]1473
FAILURE CODE [CA3868]1476
FAILURE CODE [CA3899]1480
FAILURE CODE [CA3911]1482
FAILURE CODE [CA3912]1486
FAILURE CODE [CA3932]1488
FAILURE CODE [CA3933]1490
FAILURE CODE [CA3934]1492
FAILURE CODE [CA3935]1495
FAILURE CODE [CA3936]1497
FAILURE CODE [CA4151]1499
FAILURE CODE [CA4152]1503
FAILURE CODE [CA4155]1507
FAILURE CODE [CA4156]1509
FAILURE CODE [CA4157]1512
FAILURE CODE [CA4158]1514
FAILURE CODE [CA4159]1515
FAILURE CODE [CA4161]1516
FAILURE CODE [CA4162]1519
FAILURE CODE [CA4163]1522
FAILURE CODE [CA4164]1524
FAILURE CODE [CA4165]1526
FAILURE CODE [CA4166]1528
FAILURE CODE [CA4168]1530
FAILURE CODE [CA4169]1533
FAILURE CODE [CA4171]1535
FAILURE CODE [CA4249]1538
FAILURE CODE [CA4251]1540
FAILURE CODE [CA4259]1542
FAILURE CODE [CA4261]1545
FAILURE CODE [CA4277]1548
FAILURE CODE [CA4281]1552
FAILURE CODE [CA4459]1555
FAILURE CODE [CA4461]1558
FAILURE CODE [CA4658]1561
FAILURE CODE [CA4731]1565
FAILURE CODE [CA4732]1566
FAILURE CODE [CA4739]1567
FAILURE CODE [CA4768]1568
FAILURE CODE [CA4769]1570
FAILURE CODE [CA4842]1573
FAILURE CODE [CA4952]1577
FAILURE CODE [CA5115]1579
FAILURE CODE [CA5179]1582
FAILURE CODE [CA5181]1584
FAILURE CODE [CA5383]1586
FAILURE CODE [D110L4]1588
FAILURE CODE [D160KA]1590
FAILURE CODE [D160KY]1592
FAILURE CODE [D191KA]1593
FAILURE CODE [D191KB]1595
FAILURE CODE [D191KY]1597
FAILURE CODE [D192KA]1598
FAILURE CODE [D192KB]1599
FAILURE CODE [D192KY]1600
FAILURE CODE [D19JKZ]1601
FAILURE CODE [D1B0KA]1603
FAILURE CODE [D1B0KB]1605
FAILURE CODE [D1B0KY]1607
FAILURE CODE [D1B0MC]1609
FAILURE CODE [D1E6KA]1611
FAILURE CODE [D1E6KB]1613
FAILURE CODE [D1E6KY]1615
FAILURE CODE [D5ZHKA]1617
FAILURE CODE [D5ZHKB]1619
FAILURE CODE [D5ZHL6]1621
FAILURE CODE [D811MC]1622
FAILURE CODE [D862KA]1623
FAILURE CODE [D8ALKA]1624
FAILURE CODE [D8ALKB]1626
FAILURE CODE [D8AQK4]1628
FAILURE CODE [D8AQKR]1632
FAILURE CODE [DAF0KT]1636
FAILURE CODE [DAF0MB]1637
FAILURE CODE [DAF0MC]1638
FAILURE CODE [DAF3KK]1639
FAILURE CODE [DAF8KB]1641
FAILURE CODE [DAFDKB]1642
FAILURE CODE [DAFGMC]1644
FAILURE CODE [DAFLKA]1645
FAILURE CODE [DAFLKB]1647
FAILURE CODE [DAFQKR]1649
FAILURE CODE [DAJ0KK]1654
FAILURE CODE [DAJ0KT]1657
FAILURE CODE [DAJ0MC]1658
FAILURE CODE [DAJ1KA]1659
FAILURE CODE [DAJ2KK]1661
FAILURE CODE [DAJ4KB]1664
FAILURE CODE [DAJ4KZ]1666
FAILURE CODE [DAJ5KX]1668
FAILURE CODE [DAJ6KX]1670
FAILURE CODE [DAJ9KQ]1672
FAILURE CODE [DAJLKA]1673
FAILURE CODE [DAJLKB]1675
FAILURE CODE [DAJQKR]1677
FAILURE CODE [DAJRKR]1682
FAILURE CODE [DAJRMA]1687
FAILURE CODE [DAZ9KQ]1688
FAILURE CODE [DAZQKR]1689
FAILURE CODE [DB2QKR]1693
FAILURE CODE [DB2RKR]1699
FAILURE CODE [DD1ALD]1704
FAILURE CODE [DDAAL6]1706
FAILURE CODE [DDB2L4]1708
FAILURE CODE [DDB6L4]1710
FAILURE CODE [DDD7KA]1712
FAILURE CODE [DDD7KY]1714
FAILURE CODE [DDK3KA]1716
FAILURE CODE [DDK3KB]1719
FAILURE CODE [DDK6KA]1722
FAILURE CODE [DDK6KB]1725
FAILURE CODE [DDNRLD]1728
FAILURE CODE [DF10KA]1730
FAILURE CODE [DF10KB]1733
FAILURE CODE [DGH1KX]1736
FAILURE CODE [DGR2KB]1738
FAILURE CODE [DGR2KZ]1740
FAILURE CODE [DHHBKA]1742
FAILURE CODE [DHHBKY]1744
FAILURE CODE [DHHCKA]1746
FAILURE CODE [DHHCKY]1748
FAILURE CODE [DHPCKA]1750
FAILURE CODE [DHPCKY]1752
FAILURE CODE [DHPEKA]1754
FAILURE CODE [DHPEKY]1756
FAILURE CODE [DHS8KA]1758
FAILURE CODE [DHS8KY]1760
FAILURE CODE [DHS9KA]1762
FAILURE CODE [DHS9KY]1764
FAILURE CODE [DHSDKA]1766
FAILURE CODE [DHSDKY]1768
FAILURE CODE [DHSNKA]1770
FAILURE CODE [DHSNKY]1772
FAILURE CODE [DHT8ZG]1774
FAILURE CODE [DHTCL6]1775
FAILURE CODE [DJF1KA]1777
FAILURE CODE [DK55KA]1778
FAILURE CODE [DK55KY]1780
FAILURE CODE [DK55L5]1782
FAILURE CODE [DK5DKA]1783
FAILURE CODE [DK5DKY]1786
FAILURE CODE [DK5DL8]1789
FAILURE CODE [DK5EKA]1793
FAILURE CODE [DK5EKY]1796
FAILURE CODE [DK70KA]1799
FAILURE CODE [DK70KY]1801
FAILURE CODE [DKA0KA]1803
FAILURE CODE [DKA0KY]1806
FAILURE CODE [DKA0L0]1808
FAILURE CODE [DLM3KA]1810
FAILURE CODE [DLM3LC]1811
FAILURE CODE [DLT3KX]1813
FAILURE CODE [DLT4KX]1815
FAILURE CODE [DLT4L0]1817
FAILURE CODE [DLT4LC]1818
FAILURE CODE [DPQ1KR]1820
FAILURE CODE [DPQ2KR]1823
FAILURE CODE [DPQ3KR]1826
FAILURE CODE [DSJ0KR]1830
FAILURE CODE [DT22KB]1835
FAILURE CODE [DV00KB]1837
FAILURE CODE [DW26KA]1838
FAILURE CODE [DW26KB]1840
FAILURE CODE [DW26KY]1842
FAILURE CODE [DW4BKA]1844
FAILURE CODE [DW4BKB]1846
FAILURE CODE [DW4BKY]1848
FAILURE CODE [DW4RKA]1849
FAILURE CODE [DW4RKB]1851
FAILURE CODE [DW4RKY]1853
FAILURE CODE [DWM1KA]1855
FAILURE CODE [DWM1KB]1856
FAILURE CODE [DWM1KY]1858
FAILURE CODE [DWN6KA]1859
FAILURE CODE [DWN6KB]1861
FAILURE CODE [DWN6KY]1863
FAILURE CODE [DWN8KA]1864
FAILURE CODE [DWN8KB]1865
FAILURE CODE [DWN8KY]1866
FAILURE CODE [DX19KA]1867
FAILURE CODE [DX19KB]1869
FAILURE CODE [DX19KY]1871
FAILURE CODE [DX20KA]1873
FAILURE CODE [DX20KB]1875
FAILURE CODE [DX20KY]1877
FAILURE CODE [DXAWKA]1878
FAILURE CODE [DXAWKB]1881
FAILURE CODE [DXAWKY]1884
FAILURE CODE [DXH7KA]1887
FAILURE CODE [DXH7KB]1889
FAILURE CODE [DXH7KY]1891
FAILURE CODE [DXH8KA]1893
FAILURE CODE [DXH8KB]1895
FAILURE CODE [DXH8KY]1897
FAILURE CODE [DXHJKA]1899
FAILURE CODE [DXHJKB]1901
FAILURE CODE [DXHJKY]1903
FAILURE CODE [DXHKKA]1904
FAILURE CODE [DXHKKB]1906
FAILURE CODE [DXHKKY]1908
FAILURE CODE [H2K0KA]1909
FAILURE CODE [H2K0KY]1911
FAILURE CODE [J141N1]1913
FAILURE CODE [LA00L3]1914
FAILURE CODE [M100N1]1915
FAILURE CODE [M400N1]1916
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1917
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1917
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1925
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1928
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1931
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING1933
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING1936
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)1938
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY1940
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL1942
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL1945
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL1949
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY1951
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION1954
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL1957
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY1960
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY1961
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS1964
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY1967
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED1971
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL1975
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP1977
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION1979
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1983
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1984
E-25 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP1985
E-26 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES1986
E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1988
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL1990
E-29 ALARM BUZZER DOES NOT SOUND1991
E-30 ALARM BUZZER DOES NOT STOP SOUNDING1993
E-31 WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS OPERATED, IT DOES NOT WORK OR WHEN THE EMERGENCY HST PUMP DRIVE SWITCH IS NOT OPERATED, IT WORKS1994
E-32 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH1997
E-33 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED1999
E-34 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED2001
E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED2004
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED2008
E-37 PZ AUTO TILT-IN DOES NOT WORK2010
E-38 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX TRACTION SWITCH IS TURNED ON2013
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED2015
E-40 HORN DOES NOT SOUND2017
E-41 HORN DOES NOT STOP SOUNDING2020
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2022
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT2024
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2028
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT2032
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2036
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2040
E-48 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2042
E-49 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2044
E-50 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2046
E-51 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT2048
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT2053
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT2057
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT2060
E-55 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2063
E-56 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT2066
E-57 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2070
E-58 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED2074
E-59 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION)2078
E-60 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT2082
E-61 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION)2086
E-62 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND2090
E-63 FRONT WIPER DOES NOT OPERATE2092
E-64 REAR WIPER DOES NOT OPERATE2096
E-65 WINDOW WASHER DOES NOT OPERATE2099
E-66 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2102
E-67 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2103
E-68 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2104
E-69 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP2105
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2106
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2106
FAILURE MODE AND CAUSE TABLE2107
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE2121
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)2124
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)2125
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW2126
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)2130
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)2131
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2132
H-8 MACHINE DOES NOT TURN2134
H-9 STEERING WHEEL IS HEAVY TO OPERATE2136
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS2138
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS2139
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK2140
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG2142
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK2143
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS2144
H-16 BOOM DOES NOT RISE2146
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE2149
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT2152
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND2153
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE2155
H-21 BOOM MOVES UP AND DOWN DURING OPERATION2156
H-22 BUCKET DOES NOT TILT BACK2157
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE2160
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION2163
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND2164
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE2166
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)2167
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE2168
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2169
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS2170
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2172
H-32 ECSS (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES2173
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2174
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN2177
TROUBLESHOOTING OF ENGINE (S-MODE)2178
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2178
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2179
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2180
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2181
S-4 ENGINE STARTABILITY IS POOR2183
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2185
S-6 ENGINE STOPS DURING OPERATION2187
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2189
S-8 ENGINE LACKS POWER2190
S-9 KDPF GETS CLOGGED IN A SHORT TIME2192
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2194
S-11 OIL BECOMES CONTAMINATED QUICKLY2195
S-12 FUEL CONSUMPTION IS EXCESSIVE2196
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2197
S-14 OIL PRESSURE DROPS2198
S-15 FUEL MIXES INTO ENGINE OIL2200
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2201
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2202
S-18 UNUSUAL NOISE IS HEARD2203
S-19 VIBRATION IS EXCESSIVE2204
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2205
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2206
S-22 ACTIVE REGENERATION TAKES TIME2208
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2209
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2210
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2212
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM2213
OUTLINE OF FAILURE DISPLAY2213
TROUBLESHOOTING FOR FCS2214
REPLACEMENT OF PUMP ELEMENT2215
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM2216
REPLACEMENT OF AUTO-GREASING CONTROLLER2218
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING2219
50 DISASSEMBLY AND ASSEMBLY2221
CONTENTS2222
ABBREVIATION LIST2226
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2232
HOW TO READ THIS MANUAL2232
COATING MATERIALS LIST2234
SPECIAL TOOLS LIST2238
SKETCHES OF SPECIAL TOOLS2261
ENGINE AND COOLING SYSTEM2281
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2281
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2282
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2287
REMOVE AND INSTALL INJECTOR ASSEMBLY2294
METHOD FOR REMOVING INJECTOR ASSEMBLY2294
METHOD FOR INSTALLING INJECTOR ASSEMBLY2302
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2312
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2313
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2324
REMOVE AND INSTALL EGR VALVE ASSEMBLY2339
METHOD FOR REMOVING EGR VALVE ASSEMBLY2339
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2343
REMOVE AND INSTALL EGR COOLER ASSEMBLY2347
METHOD FOR REMOVING EGR COOLER ASSEMBLY2347
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2351
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2355
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2355
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2357
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2360
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2360
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2361
REMOVE AND INSTALL ALTERNATOR BELT2363
METHOD FOR REMOVING ALTERNATOR BELT2363
METHOD FOR INSTALLING ALTERNATOR BELT2366
REMOVE AND INSTALL ALTERNATOR ASSEMBLY2368
METHOD FOR REMOVING ALTERNATOR ASSEMBLY2368
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY2371
REMOVE AND INSTALL AUTOMATIC TENSIONER2375
METHOD FOR REMOVING AUTOMATIC TENSIONER2375
METHOD FOR INSTALLING AUTOMATIC TENSIONER2375
REMOVE AND INSTALL RADIATOR ASSEMBLY2377
METHOD FOR REMOVING RADIATOR ASSEMBLY2377
METHOD FOR INSTALLING RADIATOR ASSEMBLY2381
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2384
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2384
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2387
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2391
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2391
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2393
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2395
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2395
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2396
REMOVE AND INSTALL ENGINE ASSEMBLY2398
METHOD FOR REMOVING ENGINE ASSEMBLY2399
METHOD FOR INSTALLING ENGINE ASSEMBLY2417
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2437
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2437
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2439
REMOVE AND INSTALL ENGINE REAR OIL SEAL2442
METHOD FOR REMOVING ENGINE REAR OIL SEAL2442
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2444
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2448
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2448
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2454
REMOVE AND INSTALL FUEL TANK ASSEMBLY2461
METHOD FOR REMOVING FUEL TANK ASSEMBLY2461
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2465
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2470
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2471
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2478
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2484
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2484
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2486
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2489
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2489
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2490
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2497
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2497
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2498
REMOVE AND INSTALL KDPF ASSEMBLY2499
METHOD FOR REMOVING KDPF ASSEMBLY2500
METHOD FOR INSTALLING KDPF ASSEMBLY2510
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2522
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2522
METHOD FOR ASSEMBLING KDPF ASSEMBLY2527
REMOVE AND INSTALL SCR ASSEMBLY2532
METHOD FOR REMOVING SCR ASSEMBLY2533
METHOD FOR INSTALLING SCR ASSEMBLY2543
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2556
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2557
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2567
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2582
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2582
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2585
REMOVE AND INSTALL KCCV ASSEMBLY2590
METHOD FOR REMOVING KCCV ASSEMBLY2590
METHOD FOR INSTALLING KCCV ASSEMBLY2592
REMOVE AND INSTALL VGT ASSEMBLY2595
METHOD FOR REMOVING VGT ASSEMBLY2595
METHOD FOR INSTALLING VGT ASSEMBLY2602
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2611
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2612
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2617
REMOVE AND INSTALL AdBlue/DEF INJECTOR2624
METHOD FOR REMOVING AdBlue/DEF INJECTOR2624
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2626
REMOVE AND INSTALL AdBlue/DEF PUMP2630
METHOD FOR REMOVING AdBlue/DEF PUMP2630
METHOD FOR INSTALLING AdBlue/DEF PUMP2633
REMOVE AND INSTALL AdBlue/DEF HOSE2637
METHOD FOR REMOVING AdBlue/DEF HOSE2637
METHOD FOR INSTALLING AdBlue/DEF HOSE2647
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2657
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2657
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2660
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2663
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2664
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2666
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2669
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2669
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2671
POWER TRAIN2674
REMOVE AND INSTALL HST PUMP ASSEMBLY2674
METHOD FOR REMOVING HST PUMP ASSEMBLY2675
METHOD FOR INSTALLING HST PUMP ASSEMBLY2681
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY2690
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY2690
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY2693
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY2696
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY2697
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY2705
REMOVE AND INSTALL TRANSFER ASSEMBLY2714
METHOD FOR REMOVING TRANSFER ASSEMBLY2715
METHOD FOR INSTALLING TRANSFER ASSEMBLY2719
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY2724
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY2727
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY2746
REMOVE AND INSTALL FRONT AXLE ASSEMBLY2771
METHOD FOR REMOVING FRONT AXLE ASSEMBLY2771
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY2773
REMOVE AND INSTALL REAR AXLE ASSEMBLY2776
METHOD FOR REMOVING REAR AXLE ASSEMBLY2776
METHOD FOR INSTALLING REAR AXLE ASSEMBLY2780
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY2784
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY2785
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY2793
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY2803
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY2804
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY2817
UNDERCARRIAGE AND FRAME2837
REMOVE AND INSTALL CENTER HINGE PIN2837
METHOD FOR REMOVING CENTER HINGE PIN2838
METHOD FOR INSTALLING CENTER HINGE PIN2845
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2856
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2856
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2862
HYDRAULIC SYSTEM2867
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2867
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2867
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2877
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2886
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2886
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2892
REMOVE AND INSTALL QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2898
METHOD FOR REMOVING QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2898
METHOD FOR INSTALLING QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY2901
WORK EQUIPMENT2904
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2904
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2905
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2909
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2920
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2921
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2925
CAB AND ITS ATTACHMENTS2932
REMOVE AND INSTALL OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2932
METHOD FOR REMOVING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2933
METHOD FOR INSTALLING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2940
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2949
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)2949
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)2950
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2959
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2959
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2965
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY2972
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY2972
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY2972
REMOVE AND INSTALL SEAT BELT2974
METHOD FOR REMOVING SEAT BELT2974
METHOD FOR INSTALLING SEAT BELT2974
ELECTRICAL SYSTEM2976
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2976
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2976
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2980
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY2985
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2985
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2987
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY2989
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY2989
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY2990
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY2992
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY2992
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY2995
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2997
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2997
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3000
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3003
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3003
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3004
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3005
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3005
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3006
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR3008
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR3008
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR3011
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR3014
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR3015
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR3018
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3021
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3021
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3022
REMOVE AND INSTALL AMMONIA SENSOR3024
METHOD FOR REMOVING AMMONIA SENSOR3025
METHOD FOR INSTALLING AMMONIA SENSOR3027
REMOVE AND INSTALL SCR OUTLET NOx SENSOR3029
METHOD FOR REMOVING SCR OUTLET NOx SENSOR3030
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR3032
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3035
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3035
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3036
60 MAINTENANCE STANDARD3037
CONTENTS3038
ABBREVIATION LIST3039
ENGINE AND COOLING SYSTEM3045
MAINTENANCE STANDARD OF ENGINE MOUNT3045
MAINTENANCE STANDARD OF DAMPER3046
MAINTENANCE STANDARD OF COOLING FAN MOTOR3047
POWER TRAIN3049
MAINTENANCE STANDARD OF DRIVE SHAFT3049
MAINTENANCE STANDARD OF TRANSFER3050
MAINTENANCE STANDARD OF TRANSFER MOUNT3058
MAINTENANCE STANDARD OF FRONT AXLE3059
MAINTENANCE STANDARD OF REAR AXLE3060
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL3061
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL3063
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL3065
MAINTENANCE STANDARD OF FRONT FINAL DRIVE3067
MAINTENANCE STANDARD OF REAR FINAL DRIVE3069
STEERING SYSTEM3071
MAINTENANCE STANDARD OF STEERING COLUMN3071
MAINTENANCE STANDARD OF PRIORITY VALVE3072
MAINTENANCE STANDARD OF STEERING CYLINDER3073
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE3076
BRAKE SYSTEM3077
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE3077
MAINTENANCE STANDARD OF SLACK ADJUSTER3078
MAINTENANCE STANDARD OF FRONT BRAKE3079
MAINTENANCE STANDARD OF REAR BRAKE3080
MAINTENANCE STANDARD OF PARKING BRAKE3081
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE3083
UNDERCARRIAGE AND FRAME3084
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN3084
HYDRAULIC SYSTEM3090
MAINTENANCE STANDARD OF HYDRAULIC TANK3090
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP3091
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP3092
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP3095
MAINTENANCE STANDARD OF CONTROL VALVE3096
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE3108
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE3110
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE3112
WORK EQUIPMENT3113
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3113
MAINTENANCE STANDARD OF BUCKET3117
MAINTENANCE STANDARD OF LIFT CYLINDER3118
MAINTENANCE STANDARD OF BUCKET CYLINDER3119
CAB AND ITS ATTACHMENTS3120
MAINTENANCE STANDARD OF CAB MOUNT3120
80 APPENDIX3121
CONTENTS3122
ABBREVIATION LIST3124
AIR CONDITIONER SYSTEM3130
PRECAUTIONS FOR REFRIGERANT3130
AIR CONDITIONER COMPONENT3131
SPECIFICATIONS OF AIR CONDITIONER3133
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3134
OUTLINE OF REFRIGERATION CYCLE3135
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3137
AIR CONDITIONER UNIT3137
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3137
FUNCTION OF AIR CONDITIONER UNIT3138
COMPONENT PARTS OF AIR CONDITIONER UNIT3139
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3139
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3139
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT3140
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT3140
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT3140
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3140
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3140
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3141
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3141
FUNCTION OF DUAL PRESSURE SWITCH3142
AIR CONDITIONER CONTROLLER3143
STRUCTURE OF AIR CONDITIONER CONTROLLER3143
COMPRESSOR3144
STRUCTURE OF COMPRESSOR3144
SPECIFICATIONS OF COMPRESSOR3144
FUNCTION OF COMPRESSOR3144
CONDENSER3145
STRUCTURE OF CONDENSER3145
SPECIFICATIONS OF CONDENSER3145
FUNCTION OF CONDENSER3145
RECEIVER DRIER3146
STRUCTURE OF RECEIVER DRIER3146
SPECIFICATIONS OF RECEIVER DRIER3146
FUNCTION OF RECEIVER DRIER3146
SENSORS FOR AIR CONDITIONER SYSTEM3147
FUNCTION OF SUNLIGHT SENSOR3147
FUNCTION OF AMBIENT TEMPERATURE SENSOR3147
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3148
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3150
AIR CONDITIONER SYSTEM DIAGRAM3153
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3154
FUNCTION OF AIR CONDITIONER CONTROLLER3155
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3156
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3162
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3163
CHECK TEMPERATURE CONTROL FUNCTION3164
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION3164
TEST VENT (MODE) CHANGEOVER3166
METHOD FOR TESTING VENT (MODE) CHANGEOVER3166
TESTING FRESH/RECIRC AIR CHANGEOVER3168
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3168
TEST EVAPORATOR TEMPERATURE SENSOR3170
TEST RELAYS3172
METHOD FOR TESTING RELAYS3172
AIR CONDITIONER TROUBLESHOOTING CHART 13174
AIR CONDITIONER TROUBLESHOOTING CHART 23175
FAILURE CODE [879AKA]3178
FAILURE CODE [879AKB]3180
FAILURE CODE [879BKA]3182
FAILURE CODE [879BKB]3184
FAILURE CODE [879CKA]3186
FAILURE CODE [879CKB]3188
FAILURE CODE [879DKZ]3190
FAILURE CODE [879EMC]3192
FAILURE CODE [879FMC]3193
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3194
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3197
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3200
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3204
TROUBLESHOOTING USING GAUGE PRESSURE3206
CONNECTION OF SERVICE TOOL3209
METHOD FOR CONNECTING SERVICE TOOL3210
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3211
HANDLE COMPRESSOR OIL3213
KOMATSU SHORT LEVER JOYSTICK STEERING (K-SLS)3215
FUNCTION AND STRUCTURE3215
TESTING AND ADJUSTING3220
CONNECT TO JOYSTICK STEERING CONTROLLER3220
EC WS DESCRIPTION MENUS3220
TROUBLESHOOTING3226
E-01 JOYSTICK STEERING CANNOT BE ACTIVATED3226
E-02 MACHINE TURNS SLOWLY BY USING JOYSTICK STEERING3227
E-03 MACHINE STARTS TO TURN AFTER JSS IS ACTIVATED3227
E-04 MACHINE ONLY TURNS TO ONE SIDE3228
E-05 MACHINE DOES NOT DRIVE FORWARD OR BACKWARD WITH DIRECTIONAL SELECTOR (FNR) SWITCH ON LEFT ARM REST3229
90 CIRCUIT DIAGRAMS3231
CONTENTS3232
ABBREVIATION LIST3233
HYDRAULIC CIRCUIT DIAGRAM3239
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3239
HYDRAULIC CIRCUIT DIAGRAM (1/2)3243
HYDRAULIC CIRCUIT DIAGRAM (2/2)3245
HYDRAULIC AUTO-GREASING DIAGRAM3247
ELECTRICAL CIRCUIT DIAGRAM3249
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3249
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7)3253
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7)3255
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7)3257
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7)3259
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7)3261
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7)3263
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7)3265
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)3267
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)3269
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)3271
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)3273
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)3275
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)3277
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)3279
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)3281
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)3283
ELECTRICAL CIRCUIT DIAGRAM OF EXIDOR (JSS)3285
INDEX3287

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24