Komatsu WHEEL LOADER WA320-8 Shop Manual SEN06597-07 PDF

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Komatsu WHEEL LOADER WA320-8 Shop Manual SEN06597-07 – PDF DOWNLOAD

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Komatsu WHEEL LOADER WA320-8 Shop Manual SEN06597-07 – PDF DOWNLOAD

Language : English
Pages :3286
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WHEEL LOADER WA320-8 Shop Manual SEN06597-07 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA320-8 Shop Manual SEN06597-07 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

COVER 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: WA320-8 103
SPECIFICATIONS 105
SPECIFICATIONS: WA320-8 105
WEIGHT TABLE 110
WEIGHT TABLE: WA320-8 110
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 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 215
FUNCTION OF KOMTRAX SYSTEM 215
COMPONENT PARTS OF CONTROL SYSTEM 216
MACHINE MONITOR 216
SWITCH PANEL 234
REARVIEW MONITOR 235
REARVIEW CAMERA 237
KOMTRAX TERMINAL 238
MONITOR CONTROLLER 240
HST CONTROLLER 245
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 319
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 350
HST MOTOR 352
TRANSFER 358
AXLE 366
TORQUE PROPORTIONING DIFFERENTIAL 368
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
SECONDARY STEERING VALVE 428
BRAKE SYSTEM 431
LAYOUT DRAWING OF BRAKE SYSTEM 431
PARKING BRAKE CONTROL SYSTEM 433
PARKING BRAKE CONTROL SYSTEM DIAGRAM 433
OPERATION OF PARKING BRAKE CONTROL SYSTEM 433
COMPONENT PARTS OF BRAKE SYSTEM 437
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE 437
PARKING BRAKE SOLENOID VALVE 441
BRAKE CIRCUIT ACCUMULATOR 443
BRAKE VALVE 445
SLACK ADJUSTER 448
BRAKE 450
PARKING BRAKE 453
AUTO-GREASING SYSTEM 455
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 455
SPECIFICATIONS OF AUTO-GREASING SYSTEM 456
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 463
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: WA320-8 477
STANDARD VALUE TABLE FOR MACHINE 481
STANDARD VALUE TABLE FOR MACHINE: WA320-8 481
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 495
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 654
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 702
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 744
ADJUSTMENT MENU 756
METHOD FOR PERFORMING NO-INJECTION CRANKING 790
KOMTRAX SETTINGS MENU 792
METHOD FOR DISPLAYING SERVICE MESSAGE 794
METHOD FOR STARTING UP KOMTRAX TERMINAL 796
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: WA320-8 814
40 TROUBLESHOOTING 821
CONTENTS 822
ABBREVIATION LIST 834
RELATED INFORMATION ON TROUBLESHOOTING 840
GENERAL TROUBLESHOOTING POINTS 840
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 841
SEQUENCE OF EVENTS IN TROUBLESHOOTING 853
CHECKS BEFORE TROUBLESHOOTING 855
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 857
WALK-AROUND CHECK 857
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 859
CHECK FUEL LEVEL AND TYPE 859
FUEL – CHECK FOR FOREIGN MATERIAL 859
CHECK AdBule/DEF LEVEL AND TYPE 860
CHECK FUEL PREFILTER 860
CHECK MAIN FILTER 862
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 863
CHECK COOLANT LEVEL (RESERVOIR TANK) 864
CHECK CLOGGING OF AIR CLEANER 865
OUTER ELEMENT – CLEAN 866
REPLACE ELEMENT 867
CHECK HYDRAULIC OIL LEVEL 869
CHECK HYDRAULIC OIL STRAINER 869
CHECK HYDRAULIC FILTER 872
CHECK THE OIL LEVEL IN THE TRANSFER CASE 872
CHECK OIL LEVEL IN FRONT AXLE CASE 874
CHECK OIL LEVEL IN REAR AXLE CASE 875
BLEED AIR FROM FUEL SYSTEM 875
BLEED AIR FROM HYDRAULIC SYSTEM 875
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 876
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 881
PROCEDURE FOR TESTING AND TROUBLESHOOTING 889
SYMPTOM AND TROUBLESHOOTING NUMBERS 891
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 895
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 897
CONNECTORS LIST AND LAYOUT 900
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 [AA10NX]1044
FAILURE CODE [AB00KE]1046
FAILURE CODE [AB00KY]1048
FAILURE CODE [AQ10N3]1050
FAILURE CODE [AS00N3]1052
FAILURE CODE [AS00R2]1054
FAILURE CODE [AS00R3]1055
FAILURE CODE [AS00R4]1056
FAILURE CODE [AS00R5]1057
FAILURE CODE [AS00R6]1058
FAILURE CODE [AS00ZK]1059
FAILURE CODE [AS10KM]1060
FAILURE CODE [AS10NR]1061
FAILURE CODE [AS10NT]1062
FAILURE CODE [B@BAZG]1063
FAILURE CODE [B@BAZK]1064
FAILURE CODE [B@BCNS]1066
FAILURE CODE [B@BCZK]1067
FAILURE CODE [B@C6NS]1069
FAILURE CODE [B@CRNS]1071
FAILURE CODE [CA115]1072
FAILURE CODE [CA122]1073
FAILURE CODE [CA123]1075
FAILURE CODE [CA131]1077
FAILURE CODE [CA132]1079
FAILURE CODE [CA144]1082
FAILURE CODE [CA145]1084
FAILURE CODE [CA153]1086
FAILURE CODE [CA154]1089
FAILURE CODE [CA187]1091
FAILURE CODE [CA221]1093
FAILURE CODE [CA222]1095
FAILURE CODE [CA227]1097
FAILURE CODE [CA234]1098
FAILURE CODE [CA238]1099
FAILURE CODE [CA239]1101
FAILURE CODE [CA249]1103
FAILURE CODE [CA256]1105
FAILURE CODE [CA271]1107
FAILURE CODE [CA272]1109
FAILURE CODE [CA322]1111
FAILURE CODE [CA323]1113
FAILURE CODE [CA324]1115
FAILURE CODE [CA325]1117
FAILURE CODE [CA331]1119
FAILURE CODE [CA332]1121
FAILURE CODE [CA343]1123
FAILURE CODE [CA351]1124
FAILURE CODE [CA352]1125
FAILURE CODE [CA356]1128
FAILURE CODE [CA357]1130
FAILURE CODE [CA386]1133
FAILURE CODE [CA428]1134
FAILURE CODE [CA429]1136
FAILURE CODE [CA431]1138
FAILURE CODE [CA432]1141
FAILURE CODE [CA435]1145
FAILURE CODE [CA441]1147
FAILURE CODE [CA442]1149
FAILURE CODE [CA449]1150
FAILURE CODE [CA451]1151
FAILURE CODE [CA452]1153
FAILURE CODE [CA488]1155
FAILURE CODE [CA515]1156
FAILURE CODE [CA516]1158
FAILURE CODE [CA553]1160
FAILURE CODE [CA555]1161
FAILURE CODE [CA556]1162
FAILURE CODE [CA559]1163
FAILURE CODE [CA595]1166
FAILURE CODE [CA687]1167
FAILURE CODE [CA689]1169
FAILURE CODE [CA691]1172
FAILURE CODE [CA692]1174
FAILURE CODE [CA697]1176
FAILURE CODE [CA698]1177
FAILURE CODE [CA731]1178
FAILURE CODE [CA778]1180
FAILURE CODE [CA1117]1185
FAILURE CODE [CA1664]1186
FAILURE CODE [CA1669]1188
FAILURE CODE [CA1673]1189
FAILURE CODE [CA1677]1190
FAILURE CODE [CA1678]1191
FAILURE CODE [CA1682]1192
FAILURE CODE [CA1683]1196
FAILURE CODE [CA1684]1198
FAILURE CODE [CA1686]1200
FAILURE CODE [CA1691]1201
FAILURE CODE [CA1694]1204
FAILURE CODE [CA1695]1207
FAILURE CODE [CA1696]1208
FAILURE CODE [CA1712]1210
FAILURE CODE [CA1713]1213
FAILURE CODE [CA1714]1215
FAILURE CODE [CA1715]1216
FAILURE CODE [CA1776]1217
FAILURE CODE [CA1777]1220
FAILURE CODE [CA1843]1223
FAILURE CODE [CA1844]1225
FAILURE CODE [CA1879]1228
FAILURE CODE [CA1881]1231
FAILURE CODE [CA1883]1233
FAILURE CODE [CA1885]1237
FAILURE CODE [CA1887]1239
FAILURE CODE [CA1921]1241
FAILURE CODE [CA1922]1244
FAILURE CODE [CA1942]1249
FAILURE CODE [CA1993]1250
FAILURE CODE [CA2185]1253
FAILURE CODE [CA2186]1255
FAILURE CODE [CA2249]1257
FAILURE CODE [CA2271]1258
FAILURE CODE [CA2272]1261
FAILURE CODE [CA2288]1264
FAILURE CODE [CA2311]1265
FAILURE CODE [CA2349]1266
FAILURE CODE [CA2353]1269
FAILURE CODE [CA2357]1271
FAILURE CODE [CA2381]1272
FAILURE CODE [CA2382]1275
FAILURE CODE [CA2383]1278
FAILURE CODE [CA2386]1281
FAILURE CODE [CA2387]1283
FAILURE CODE [CA2555]1284
FAILURE CODE [CA2556]1287
FAILURE CODE [CA2637]1289
FAILURE CODE [CA2639]1291
FAILURE CODE [CA2771]1294
FAILURE CODE [CA2777]1300
FAILURE CODE [CA2976]1303
FAILURE CODE [CA3133]1305
FAILURE CODE [CA3134]1308
FAILURE CODE [CA3135]1310
FAILURE CODE [CA3142]1314
FAILURE CODE [CA3143]1315
FAILURE CODE [CA3144]1316
FAILURE CODE [CA3146]1319
FAILURE CODE [CA3147]1320
FAILURE CODE [CA3148]1321
FAILURE CODE [CA3151]1323
FAILURE CODE [CA3165]1329
FAILURE CODE [CA3229]1331
FAILURE CODE [CA3231]1333
FAILURE CODE [CA3232]1335
FAILURE CODE [CA3235]1339
FAILURE CODE [CA3239]1341
FAILURE CODE [CA3241]1344
FAILURE CODE [CA3242]1347
FAILURE CODE [CA3251]1350
FAILURE CODE [CA3253]1352
FAILURE CODE [CA3254]1355
FAILURE CODE [CA3255]1358
FAILURE CODE [CA3256]1362
FAILURE CODE [CA3311]1364
FAILURE CODE [CA3312]1366
FAILURE CODE [CA3313]1369
FAILURE CODE [CA3314]1370
FAILURE CODE [CA3315]1371
FAILURE CODE [CA3316]1374
FAILURE CODE [CA3317]1375
FAILURE CODE [CA3318]1376
FAILURE CODE [CA3319]1379
FAILURE CODE [CA3321]1380
FAILURE CODE [CA3322]1382
FAILURE CODE [CA3419]1385
FAILURE CODE [CA3421]1387
FAILURE CODE [CA3497]1389
FAILURE CODE [CA3498]1390
FAILURE CODE [CA3543]1391
FAILURE CODE [CA3545]1398
FAILURE CODE [CA3547]1400
FAILURE CODE [CA3558]1401
FAILURE CODE [CA3559]1403
FAILURE CODE [CA3562]1405
FAILURE CODE [CA3563]1407
FAILURE CODE [CA3567]1410
FAILURE CODE [CA3568]1413
FAILURE CODE [CA3571]1419
FAILURE CODE [CA3572]1421
FAILURE CODE [CA3574]1423
FAILURE CODE [CA3575]1425
FAILURE CODE [CA3577]1427
FAILURE CODE [CA3578]1429
FAILURE CODE [CA3582]1431
FAILURE CODE [CA3583]1439
FAILURE CODE [CA3596]1441
FAILURE CODE [CA3649]1444
FAILURE CODE [CA3681]1446
FAILURE CODE [CA3682]1451
FAILURE CODE [CA3713]1457
FAILURE CODE [CA3717]1460
FAILURE CODE [CA3718]1461
FAILURE CODE [CA3725]1462
FAILURE CODE [CA3741]1465
FAILURE CODE [CA3748]1466
FAILURE CODE [CA3751]1469
FAILURE CODE [CA3755]1471
FAILURE CODE [CA3866]1473
FAILURE CODE [CA3867]1477
FAILURE CODE [CA3868]1480
FAILURE CODE [CA3899]1484
FAILURE CODE [CA3911]1486
FAILURE CODE [CA3912]1490
FAILURE CODE [CA3932]1492
FAILURE CODE [CA3933]1494
FAILURE CODE [CA3934]1496
FAILURE CODE [CA3935]1499
FAILURE CODE [CA3936]1501
FAILURE CODE [CA4151]1503
FAILURE CODE [CA4152]1507
FAILURE CODE [CA4155]1511
FAILURE CODE [CA4156]1513
FAILURE CODE [CA4157]1516
FAILURE CODE [CA4158]1518
FAILURE CODE [CA4159]1519
FAILURE CODE [CA4161]1520
FAILURE CODE [CA4162]1523
FAILURE CODE [CA4163]1526
FAILURE CODE [CA4164]1528
FAILURE CODE [CA4165]1530
FAILURE CODE [CA4166]1532
FAILURE CODE [CA4168]1534
FAILURE CODE [CA4169]1537
FAILURE CODE [CA4171]1539
FAILURE CODE [CA4249]1542
FAILURE CODE [CA4251]1544
FAILURE CODE [CA4259]1546
FAILURE CODE [CA4261]1549
FAILURE CODE [CA4277]1552
FAILURE CODE [CA4281]1556
FAILURE CODE [CA4459]1559
FAILURE CODE [CA4461]1562
FAILURE CODE [CA4658]1565
FAILURE CODE [CA4731]1569
FAILURE CODE [CA4732]1570
FAILURE CODE [CA4739]1571
FAILURE CODE [CA4768]1572
FAILURE CODE [CA4769]1574
FAILURE CODE [CA4842]1577
FAILURE CODE [CA4952]1581
FAILURE CODE [CA5115]1583
FAILURE CODE [CA5179]1586
FAILURE CODE [CA5181]1588
FAILURE CODE [CA5383]1590
FAILURE CODE [D110L4]1592
FAILURE CODE [D160KA]1594
FAILURE CODE [D160KY]1596
FAILURE CODE [D191KA]1597
FAILURE CODE [D191KB]1599
FAILURE CODE [D191KY]1601
FAILURE CODE [D192KA]1602
FAILURE CODE [D192KB]1603
FAILURE CODE [D192KY]1604
FAILURE CODE [D19JKZ]1605
FAILURE CODE [D1B0KA]1607
FAILURE CODE [D1B0KB]1609
FAILURE CODE [D1B0KY]1611
FAILURE CODE [D1B0MC]1613
FAILURE CODE [D1E6KA]1615
FAILURE CODE [D1E6KB]1617
FAILURE CODE [D1E6KY]1619
FAILURE CODE [D5ZHKA]1621
FAILURE CODE [D5ZHKB]1623
FAILURE CODE [D5ZHL6]1625
FAILURE CODE [D811MC]1626
FAILURE CODE [D862KA]1627
FAILURE CODE [D8ALKA]1628
FAILURE CODE [D8ALKB]1630
FAILURE CODE [D8AQK4]1632
FAILURE CODE [D8AQKR]1636
FAILURE CODE [DAF0KT]1640
FAILURE CODE [DAF0MB]1641
FAILURE CODE [DAF0MC]1642
FAILURE CODE [DAF3KK]1643
FAILURE CODE [DAF8KB]1645
FAILURE CODE [DAFDKB]1646
FAILURE CODE [DAFGMC]1648
FAILURE CODE [DAFLKA]1649
FAILURE CODE [DAFLKB]1651
FAILURE CODE [DAFQKR]1653
FAILURE CODE [DAJ0KK]1658
FAILURE CODE [DAJ0KT]1661
FAILURE CODE [DAJ0MC]1662
FAILURE CODE [DAJ1KA]1663
FAILURE CODE [DAJ2KK]1665
FAILURE CODE [DAJ4KB]1668
FAILURE CODE [DAJ4KZ]1670
FAILURE CODE [DAJ5KX]1672
FAILURE CODE [DAJ6KX]1674
FAILURE CODE [DAJ9KQ]1676
FAILURE CODE [DAJLKA]1677
FAILURE CODE [DAJLKB]1679
FAILURE CODE [DAJQKR]1681
FAILURE CODE [DAJRKR]1686
FAILURE CODE [DAJRMA]1691
FAILURE CODE [DAZ9KQ]1692
FAILURE CODE [DAZQKR]1693
FAILURE CODE [DB2QKR]1697
FAILURE CODE [DB2RKR]1703
FAILURE CODE [DD1ALD]1708
FAILURE CODE [DDAAL6]1710
FAILURE CODE [DDB2L4]1712
FAILURE CODE [DDB6L4]1714
FAILURE CODE [DDD7KA]1716
FAILURE CODE [DDD7KY]1718
FAILURE CODE [DDK3KA]1720
FAILURE CODE [DDK3KB]1723
FAILURE CODE [DDK6KA]1726
FAILURE CODE [DDK6KB]1729
FAILURE CODE [DDNRLD]1732
FAILURE CODE [DF10KA]1734
FAILURE CODE [DF10KB]1737
FAILURE CODE [DGH1KX]1740
FAILURE CODE [DGR2KB]1742
FAILURE CODE [DGR2KZ]1744
FAILURE CODE [DHA4KA]1746
FAILURE CODE [DHHBKA]1748
FAILURE CODE [DHHBKY]1750
FAILURE CODE [DHHCKA]1752
FAILURE CODE [DHHCKY]1754
FAILURE CODE [DHPCKA]1756
FAILURE CODE [DHPCKY]1758
FAILURE CODE [DHPEKA]1760
FAILURE CODE [DHPEKY]1762
FAILURE CODE [DHS8KA]1764
FAILURE CODE [DHS8KY]1766
FAILURE CODE [DHS9KA]1768
FAILURE CODE [DHS9KY]1770
FAILURE CODE [DHSDKA]1772
FAILURE CODE [DHSDKY]1774
FAILURE CODE [DHSNKA]1776
FAILURE CODE [DHSNKY]1778
FAILURE CODE [DHT8ZG]1780
FAILURE CODE [DHTCL6]1781
FAILURE CODE [DJF1KA]1783
FAILURE CODE [DK55KA]1784
FAILURE CODE [DK55KY]1786
FAILURE CODE [DK55L5]1788
FAILURE CODE [DK5DKA]1789
FAILURE CODE [DK5DKY]1792
FAILURE CODE [DK5DL8]1795
FAILURE CODE [DK5EKA]1799
FAILURE CODE [DK5EKY]1802
FAILURE CODE [DK70KA]1805
FAILURE CODE [DK70KY]1807
FAILURE CODE [DKA0KA]1809
FAILURE CODE [DKA0KY]1812
FAILURE CODE [DKA0L0]1814
FAILURE CODE [DLM3KA]1816
FAILURE CODE [DLM3LC]1817
FAILURE CODE [DLT3KX]1819
FAILURE CODE [DLT4KX]1821
FAILURE CODE [DLT4L0]1823
FAILURE CODE [DLT4LC]1824
FAILURE CODE [DPQ1KR]1826
FAILURE CODE [DPQ2KR]1829
FAILURE CODE [DPQ3KR]1832
FAILURE CODE [DSJ0KR]1836
FAILURE CODE [DT22KB]1841
FAILURE CODE [DV00KB]1843
FAILURE CODE [DW26KA]1844
FAILURE CODE [DW26KB]1846
FAILURE CODE [DW26KY]1848
FAILURE CODE [DW4BKA]1850
FAILURE CODE [DW4BKB]1852
FAILURE CODE [DW4BKY]1854
FAILURE CODE [DW4RKA]1855
FAILURE CODE [DW4RKB]1857
FAILURE CODE [DW4RKY]1859
FAILURE CODE [DWM1KA]1861
FAILURE CODE [DWM1KB]1862
FAILURE CODE [DWM1KY]1864
FAILURE CODE [DWN6KA]1865
FAILURE CODE [DWN6KB]1867
FAILURE CODE [DWN6KY]1869
FAILURE CODE [DWN8KA]1870
FAILURE CODE [DWN8KB]1871
FAILURE CODE [DWN8KY]1872
FAILURE CODE [DX19KA]1873
FAILURE CODE [DX19KB]1875
FAILURE CODE [DX19KY]1877
FAILURE CODE [DX20KA]1879
FAILURE CODE [DX20KB]1881
FAILURE CODE [DX20KY]1883
FAILURE CODE [DXAWKA]1884
FAILURE CODE [DXAWKB]1887
FAILURE CODE [DXAWKY]1890
FAILURE CODE [DXH7KA]1893
FAILURE CODE [DXH7KB]1895
FAILURE CODE [DXH7KY]1897
FAILURE CODE [DXH8KA]1899
FAILURE CODE [DXH8KB]1901
FAILURE CODE [DXH8KY]1903
FAILURE CODE [DXHJKA]1905
FAILURE CODE [DXHJKB]1907
FAILURE CODE [DXHJKY]1909
FAILURE CODE [DXHKKA]1910
FAILURE CODE [DXHKKB]1912
FAILURE CODE [DXHKKY]1914
FAILURE CODE [H2K0KA]1915
FAILURE CODE [H2K0KY]1917
FAILURE CODE [J141N1]1919
FAILURE CODE [LA00L3]1920
FAILURE CODE [M100N1]1921
FAILURE CODE [M400N1]1922
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1923
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1923
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1931
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1934
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1937
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING1939
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING1942
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)1944
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY1946
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL1948
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL1951
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL1955
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY1957
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION1960
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL1963
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY1966
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY1967
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS1970
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY1973
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED1977
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL1981
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP1983
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP1985
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION1986
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1990
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP1991
E-26 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP1992
E-27 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES1993
E-28 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL1995
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL1997
E-30 ALARM BUZZER DOES NOT SOUND1998
E-31 ALARM BUZZER DOES NOT STOP SOUNDING1999
E-32 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 WORKS2000
E-33 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH2003
E-34 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED2005
E-35 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED2007
E-36 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED2010
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED2014
E-38 PZ AUTO TILT-IN DOES NOT WORK2016
E-39 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX TRACTION SWITCH IS TURNED ON2019
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED2021
E-41 HORN DOES NOT SOUND2023
E-42 HORN DOES NOT STOP SOUNDING2026
E-43 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS2028
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT2030
E-45 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2034
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT2038
E-47 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2042
E-48 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2046
E-49 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2048
E-50 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT2050
E-51 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2052
E-52 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT2054
E-53 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT2059
E-54 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT2063
E-55 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT2066
E-56 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2069
E-57 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT2072
E-58 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION)2076
E-59 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED2080
E-60 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION)2084
E-61 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT2088
E-62 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION)2092
E-63 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND2096
E-64 FRONT WIPER DOES NOT OPERATE2098
E-65 REAR WIPER DOES NOT OPERATE2102
E-66 WINDOW WASHER DOES NOT OPERATE2105
E-67 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2108
E-68 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2109
E-69 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP2110
E-70 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP2111
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2112
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2112
FAILURE MODE AND CAUSE TABLE2113
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE2127
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY)2130
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY)2131
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW2132
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY)2136
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY)2137
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2138
H-8 MACHINE DOES NOT TURN2140
H-9 STEERING WHEEL IS HEAVY TO OPERATE2142
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS2144
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS2145
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK2146
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG2148
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK2149
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS2150
H-16 BOOM DOES NOT RISE2152
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE2155
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT2158
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND2159
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE2161
H-21 BOOM MOVES UP AND DOWN DURING OPERATION2162
H-22 BUCKET DOES NOT TILT BACK2163
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE2166
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION2169
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND2170
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE2172
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD)2173
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE2174
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2175
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS2176
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2178
H-32 ECSS (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES2179
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2180
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN2183
TROUBLESHOOTING OF ENGINE (S-MODE)2184
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2184
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2185
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2186
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2187
S-4 ENGINE STARTABILITY IS POOR2189
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2191
S-6 ENGINE STOPS DURING OPERATION2193
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2195
S-8 ENGINE LACKS POWER2196
S-9 KDPF GETS CLOGGED IN A SHORT TIME2198
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2200
S-11 OIL BECOMES CONTAMINATED QUICKLY2201
S-12 FUEL CONSUMPTION IS EXCESSIVE2202
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2203
S-14 OIL PRESSURE DROPS2204
S-15 FUEL MIXES INTO ENGINE OIL2206
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2207
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2208
S-18 UNUSUAL NOISE IS HEARD2209
S-19 VIBRATION IS EXCESSIVE2210
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2211
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2212
S-22 ACTIVE REGENERATION TAKES TIME2214
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2215
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2216
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2218
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM2219
OUTLINE OF FAILURE DISPLAY2219
TROUBLESHOOTING FOR FCS2220
TROUBLESHOOTING FOR AUTO-GREASING PUMP2221
REPLACEMENT OF PUMP ELEMENT2224
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM2225
REPLACEMENT OF AUTO-GREASING CONTROLLER2227
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING2228
50 DISASSEMBLY AND ASSEMBLY2229
CONTENTS2230
ABBREVIATION LIST2234
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2240
HOW TO READ THIS MANUAL2240
COATING MATERIALS LIST2242
SPECIAL TOOLS LIST2246
SKETCHES OF SPECIAL TOOLS2269
ENGINE AND COOLING SYSTEM2283
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2283
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2284
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2288
REMOVE AND INSTALL INJECTOR ASSEMBLY2295
METHOD FOR REMOVING INJECTOR ASSEMBLY2295
METHOD FOR INSTALLING INJECTOR ASSEMBLY2303
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2313
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2314
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2325
REMOVE AND INSTALL EGR VALVE ASSEMBLY2340
METHOD FOR REMOVING EGR VALVE ASSEMBLY2340
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2344
REMOVE AND INSTALL EGR COOLER ASSEMBLY2348
METHOD FOR REMOVING EGR COOLER ASSEMBLY2348
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2351
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2356
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2356
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2358
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT2362
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT2362
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT2363
REMOVE AND INSTALL ALTERNATOR BELT2365
METHOD FOR REMOVING ALTERNATOR BELT2365
METHOD FOR INSTALLING ALTERNATOR BELT2368
REMOVE AND INSTALL ALTERNATOR ASSEMBLY2371
METHOD FOR REMOVING ALTERNATOR ASSEMBLY2371
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY2373
REMOVE AND INSTALL AUTOMATIC TENSIONER2378
METHOD FOR REMOVING AUTOMATIC TENSIONER2378
METHOD FOR INSTALLING AUTOMATIC TENSIONER2378
REMOVE AND INSTALL RADIATOR ASSEMBLY2379
METHOD FOR REMOVING RADIATOR ASSEMBLY2379
METHOD FOR INSTALLING RADIATOR ASSEMBLY2382
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2385
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2385
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2388
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2392
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2392
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 ASSEMBLY2418
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2438
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2438
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2440
REMOVE AND INSTALL ENGINE REAR OIL SEAL2443
METHOD FOR REMOVING ENGINE REAR OIL SEAL2443
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2445
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2449
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2449
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2456
REMOVE AND INSTALL FUEL TANK ASSEMBLY2463
METHOD FOR REMOVING FUEL TANK ASSEMBLY2463
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2467
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2471
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2472
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2478
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2483
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2483
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2485
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2488
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2488
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2489
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2496
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2496
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2497
REMOVE AND INSTALL KDPF ASSEMBLY2498
METHOD FOR REMOVING KDPF ASSEMBLY2499
METHOD FOR INSTALLING KDPF ASSEMBLY2509
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 ASSEMBLY2557
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2558
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2568
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY2583
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY2583
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY2586
REMOVE AND INSTALL KCCV ASSEMBLY2591
METHOD FOR REMOVING KCCV ASSEMBLY2591
METHOD FOR INSTALLING KCCV ASSEMBLY2593
REMOVE AND INSTALL VGT ASSEMBLY2596
METHOD FOR REMOVING VGT ASSEMBLY2596
METHOD FOR INSTALLING VGT ASSEMBLY2603
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2612
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2613
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2618
REMOVE AND INSTALL AdBlue/DEF INJECTOR2625
METHOD FOR REMOVING AdBlue/DEF INJECTOR2625
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2628
REMOVE AND INSTALL AdBlue/DEF PUMP2633
METHOD FOR REMOVING AdBlue/DEF PUMP2633
METHOD FOR INSTALLING AdBlue/DEF PUMP2635
REMOVE AND INSTALL AdBlue/DEF HOSE2638
METHOD FOR REMOVING AdBlue/DEF HOSE2638
METHOD FOR INSTALLING AdBlue/DEF HOSE2646
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2654
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2654
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2657
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2660
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2661
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2663
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2665
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2665
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2667
POWER TRAIN2670
REMOVE AND INSTALL HST PUMP ASSEMBLY2670
METHOD FOR REMOVING HST PUMP ASSEMBLY2671
METHOD FOR INSTALLING HST PUMP ASSEMBLY2677
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY2686
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY2686
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY2689
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY2692
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY2693
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY2701
REMOVE AND INSTALL TRANSFER ASSEMBLY2711
METHOD FOR REMOVING TRANSFER ASSEMBLY2712
METHOD FOR INSTALLING TRANSFER ASSEMBLY2716
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY2723
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY2725
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY2745
REMOVE AND INSTALL FRONT AXLE ASSEMBLY2770
METHOD FOR REMOVING FRONT AXLE ASSEMBLY2770
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY2772
REMOVE AND INSTALL REAR AXLE ASSEMBLY2775
METHOD FOR REMOVING REAR AXLE ASSEMBLY2775
METHOD FOR INSTALLING REAR AXLE ASSEMBLY2779
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY2783
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY2784
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY2792
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY2802
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY2803
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY2816
UNDERCARRIAGE AND FRAME2836
REMOVE AND INSTALL CENTER HINGE PIN2836
METHOD FOR REMOVING CENTER HINGE PIN2837
METHOD FOR INSTALLING CENTER HINGE PIN2843
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2854
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2854
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2860
HYDRAULIC SYSTEM2865
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2865
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2865
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2876
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 ATTACHMENTS2933
REMOVE AND INSTALL OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2933
METHOD FOR REMOVING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2934
METHOD FOR INSTALLING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY2942
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2950
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS)2950
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS)2951
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2960
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2960
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2966
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY2973
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY2973
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY2973
REMOVE AND INSTALL SEAT BELT2975
METHOD FOR REMOVING SEAT BELT2975
METHOD FOR INSTALLING SEAT BELT2975
ELECTRICAL SYSTEM2977
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2977
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2977
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2981
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY2988
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY2988
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY2990
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY2992
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY2992
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY2993
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY2995
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY2995
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY2998
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3000
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3000
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3003
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3006
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3006
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3007
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3008
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3008
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3009
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR3011
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR3011
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR3013
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR3016
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR3016
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR3019
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 SENSOR3024
METHOD FOR INSTALLING AMMONIA SENSOR3026
REMOVE AND INSTALL SCR OUTLET NOx SENSOR3029
METHOD FOR REMOVING SCR OUTLET NOx SENSOR3029
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR3031
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY3034
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY3034
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY3035
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 FINAL DRIVE3067
STEERING SYSTEM3069
MAINTENANCE STANDARD OF STEERING COLUMN3069
MAINTENANCE STANDARD OF PRIORITY VALVE3070
MAINTENANCE STANDARD OF STEERING CYLINDER3071
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE3074
BRAKE SYSTEM3075
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE3075
MAINTENANCE STANDARD OF SLACK ADJUSTER3076
MAINTENANCE STANDARD OF FRONT BRAKE3077
MAINTENANCE STANDARD OF REAR BRAKE3078
MAINTENANCE STANDARD OF PARKING BRAKE3079
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE3081
UNDERCARRIAGE AND FRAME3082
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN3082
HYDRAULIC SYSTEM3087
MAINTENANCE STANDARD OF HYDRAULIC TANK3087
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP3088
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP3089
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP3092
MAINTENANCE STANDARD OF CONTROL VALVE3093
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE3105
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE3107
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE3109
WORK EQUIPMENT3110
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3110
MAINTENANCE STANDARD OF BUCKET3114
MAINTENANCE STANDARD OF LIFT CYLINDER3116
MAINTENANCE STANDARD OF BUCKET CYLINDER3117
CAB AND ITS ATTACHMENTS3118
MAINTENANCE STANDARD OF CAB MOUNT3118
80 APPENDIX3119
CONTENTS3120
ABBREVIATION LIST3122
AIR CONDITIONER SYSTEM3128
PRECAUTIONS FOR REFRIGERANT3128
AIR CONDITIONER COMPONENT3129
SPECIFICATIONS OF AIR CONDITIONER3131
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3132
OUTLINE OF REFRIGERATION CYCLE3133
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3135
AIR CONDITIONER UNIT3135
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3135
FUNCTION OF AIR CONDITIONER UNIT3136
COMPONENT PARTS OF AIR CONDITIONER UNIT3137
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3137
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3137
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3138
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3139
FUNCTION OF DUAL PRESSURE SWITCH3139
AIR CONDITIONER CONTROLLER3140
STRUCTURE OF AIR CONDITIONER CONTROLLER3140
COMPRESSOR3141
STRUCTURE OF COMPRESSOR3141
SPECIFICATIONS OF COMPRESSOR3141
FUNCTION OF COMPRESSOR3141
CONDENSER3142
STRUCTURE OF CONDENSER3142
SPECIFICATIONS OF CONDENSER3142
FUNCTION OF CONDENSER3142
RECEIVER DRIER3143
STRUCTURE OF RECEIVER DRIER3143
SPECIFICATIONS OF RECEIVER DRIER3143
FUNCTION OF RECEIVER DRIER3143
SENSORS FOR AIR CONDITIONER SYSTEM3144
FUNCTION OF SUNLIGHT SENSOR3144
FUNCTION OF AMBIENT TEMPERATURE SENSOR3144
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3145
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3147
AIR CONDITIONER SYSTEM DIAGRAM3150
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3151
FUNCTION OF AIR CONDITIONER CONTROLLER3152
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3153
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3159
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3160
CHECK TEMPERATURE CONTROL FUNCTION3161
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION3161
TEST VENT (MODE) CHANGEOVER3163
METHOD FOR TESTING VENT (MODE) CHANGEOVER3163
TESTING FRESH/RECIRC AIR CHANGEOVER3165
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3165
TEST EVAPORATOR TEMPERATURE SENSOR3167
TEST RELAYS3169
METHOD FOR TESTING RELAYS3169
AIR CONDITIONER TROUBLESHOOTING CHART 13171
AIR CONDITIONER TROUBLESHOOTING CHART 23172
FAILURE CODE [879AKA]3175
FAILURE CODE [879AKB]3177
FAILURE CODE [879BKA]3179
FAILURE CODE [879BKB]3181
FAILURE CODE [879CKA]3183
FAILURE CODE [879CKB]3185
FAILURE CODE [879DKZ]3187
FAILURE CODE [879EMC]3189
FAILURE CODE [879FMC]3190
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3191
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3194
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3197
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3201
TROUBLESHOOTING USING GAUGE PRESSURE3203
CONNECTION OF SERVICE TOOL3206
METHOD FOR CONNECTING SERVICE TOOL3207
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3208
HANDLE COMPRESSOR OIL3210
90 CIRCUIT DIAGRAMS3213
CONTENTS3214
ABBREVIATION LIST3215
HYDRAULIC CIRCUIT DIAGRAM3221
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3221
HYDRAULIC CIRCUIT DIAGRAM (1/2)3225
HYDRAULIC CIRCUIT DIAGRAM (2/2)3227
HYDRAULIC AUTO-GREASING DIAGRAM3229
ELECTRICAL CIRCUIT DIAGRAM3231
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3231
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7)3235
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7)3237
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7)3239
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7)3241
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7)3243
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7)3245
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7)3247
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9)3249
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9)3251
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9)3253
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9)3255
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9)3257
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9)3259
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9)3261
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9)3263
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9)3265
INDEX3267

IMAGES PREVIEW OF THE MANUAL:

S.M 28/12/24