Komatsu WHEEL LOADER WA600-8 Shop Manual SEN06579-18 PDF
$40.95
Komatsu WHEEL LOADER WA600-8 Shop Manual SEN06579-18 – PDF DOWNLOAD
SERIAL NUMBERS 80001 and up
Description
Komatsu WHEEL LOADER WA600-8 Shop Manual SEN06579-18 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA600-8 Shop Manual SEN06579-18 – PDF DOWNLOAD
Language : English
Pages :4274
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WHEEL LOADER WA600-8 Shop Manual SEN06579-18 – PDF DOWNLOAD
SERIAL NUMBERS 80001 and up
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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the 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 Specification
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.
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 Others
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 WA600-8 Shop Manual SEN06579-18 – PDF DOWNLOAD
SERIAL NUMBERS 80001 and up
Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 28
Foreword, Safety, Basic Information 34
How to Read the Shop Manual 34
Safety Notice for Operation 36
Precautions to Prevent Fire 44
Procedures If Fire Occurs 45
Precautions for Disposing of Waste Materials 45
Procedures for Exhaust Gas Regulations 46
Precautions for DEF 47
General Character and Precautions for Handling 47
Precautions for Adding 47
Precautions for Storage 47
Precautions for Fire Hazard and Leakage 47
Other Precautions 47
Store DEF 48
Precautions When You Handle Hydraulic Equipment 49
Precautions When You Disconnect and Connect Pipings 52
Precautions When You Handle Electrical Equipment 59
Precautions When You Handle Fuel System Equipment 61
Precautions When You Handle Intake System Equipment 62
Practical Use of KOMTRAX 63
Disconnect and Connect Push-Pull Type Coupler 64
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 64
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 65
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 66
Precautions for Disconnection and Connection of Connectors 68
How to Disconnect and Connect Deutsch Connector 72
How to Disconnect and Connect Slide Lock Type Connector 73
How to Disconnect and Connect Connector with Lock to Pull 74
How to Disconnect and Connect Connector with Lock to Push 75
How to Disconnect and Connect Connector with Housing to Rotate 77
How to Read the Codes for Electric Cable 78
Explanation of Terms for Maintenance Standard 82
Standard Tightening Torque Table 85
Conversion Table 92
01 Specifications 97
Table of Contents 98
Abbreviation List 99
Specifications 105
Specification Drawing 105
Specification Drawing: WA600-8 105
Specifications 107
Specifications: WA600-8 107
Weight Table 112
Weight Table: WA600-8 112
Fuel, Coolant, Lubricant 114
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 114
10 Structure and Function 117
Table of Contents 118
Abbreviation List 123
Urea SCR System 129
Layout Drawing of Urea SCR System 129
Urea SCR System Diagram 134
Function of Urea SCR System 136
Function of DEF System 136
Inducement Strategy 138
Component Parts of Urea SCR System 152
DEF Mixing Tube 152
SCR Assembly 153
DEF Tank 155
DEF Pump 158
DEF Injector 159
DEF Hose 160
DEF Tank Heating Valve 161
Boot-up System 162
Layout Drawing of Boot-up System 162
Layout Drawing of Boot-up System (For Emergency Engine Stop Switch Spec) 164
System Operating Lamp System 166
System Diagram of System Operating Lamp System 166
Function of Operation Lamp System 166
Battery Disconnect Switch 168
Layout Drawing of Battery Disconnect Switch 168
Function of Battery Disconnect Switch 168
Preheating System 170
System Diagram of Preheating System 170
Function of Automatic Preheating System 170
Operation of Automatic Preheating System 171
Function of Manual Preheating System 171
Operation of Manual Preheating System 171
Engine Shutdown Secondary Switch 172
Layout Drawing of Engine Shutdown Secondary Switch 172
Function of Engine Shutdown Secondary Switch 172
Operation of Engine Shutdown Secondary Switch 173
Engine System 174
Layout Drawing of Engine System 174
Function of Engine System 175
Engine Control System 176
System Diagram of Engine Control 176
Function of Engine Control System 177
Operation of Engine Control System 178
Engine Power Mode Selector System 180
Engine Power Mode Selector System Diagram 180
Function of Engine Power Mode Selector System 180
Operation of Engine Power Mode Selector System 180
Automatic Idle Stop System 181
Function of Automatic Idle Stop System 181
RPM Set 182
Function of RPM Set 182
Component Parts of Engine System 184
Damper 184
VGT 186
EGR System 190
EGR Valve 193
EGR Cooler 195
KCCV System 196
KCCV Ventilator 198
KDPF 200
Cooling System 204
Layout Drawing of Cooling System 204
Specifications of Cooling System 205
Cooling Fan Control System 207
System Diagram of Cooling Fan Control System 207
Function of Cooling Fan Control System 207
Component Parts of Cooling System 211
Brake and Cooling Fan Pump 211
Cooling Fan Motor 221
Control System 229
Layout Drawing of Control System 229
Machine Monitor System 231
System Diagram of Machine Monitor System 231
Function of Machine Monitor System 231
Rearview Monitor System 233
System Diagram of Rearview Monitor System 233
Function of Rearview Monitor System 233
KOMTRAX Plus System 234
System Diagram of KOMTRAX Plus System 234
Function of KOMTRAX Plus System 234
Load Meter System 236
System Diagram of Load Meter 236
Function of Load Meter System 236
Component Parts of Control System 242
Machine Monitor 242
Switch Panel 261
Rearview Monitor 262
Rearview Camera 264
KOMTRAX Terminal 265
KOMTRAX Plus Controller 267
Wireless LAN Unit 272
Transmission Controller 273
Work Equipment Controller 278
Monitor Controller 283
Engine Controller 288
CAN Terminating Resistor 302
Accelerator Pedal 303
Fuel Feed Pump 305
Fuel Feed Pump Switch 306
Hydraulic System 308
Layout Drawing of Hydraulic System 308
CLSS 309
Structure of CLSS 309
Function of CLSS 310
Work Equipment Pump Control System 313
Swash Plate Control Function of Work Equipment Pump 313
Pickup Assistance Control Function When Engine Speed is Low 313
Component Parts of Hydraulic System 315
Hydraulic Tank 315
Work Equipment Pump 318
Steering Pump 337
Power Train Charge Duplex Pump 350
Control Valve 351
Power Train System 387
Layout Drawing of Power Train System 387
Operation of Power Train System 391
Transmission Control System 392
Transmission Control System Diagram 392
Transmission Gear Shift Control System 396
Electric Modulation Function System Diagram 396
Electric Modulation Function 397
Gear Shift Display Function 397
Automatic Gear Shift Function 397
Shift Hold Function 398
Kickdown Function 399
Automatic Kickdown Function 399
Torque Converter Lockup Function 400
Hunting Prevention Function 400
Transmission Initial Learning and ECMV Current Adjustment Function 400
Shift Point Changing Function 401
4th Gear Speed Limitation Function 401
Transmission Protection Function 402
Protection Function When Travel Direction is Changed 402
Shift Down Protection Function 402
Engine Overrun Prevention Function 403
Neutralizer Function 403
Modulation Clutch Control Function 404
Maximum Speed Limitation Function During Lockup 406
Component Parts of Power Train System 407
Drive Shaft 407
Torque Converter 410
Lockup Clutch ECMV 420
Modulation Clutch ECMV 423
Transmission 426
Transmission Control Valve 443
Forward and Reverse Clutch ECMV and 1st, 2nd, 3rd, 4th Clutch ECMV 446
Transfer 451
Torque Converter Regulator Valve 452
Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 454
Transmission Lubrication Relief Valve 460
Axle 461
Differential 466
Final Drive 471
AJSS Knob 473
Combination Switch 474
Shift Hold Switch 478
Kickdown Switch 479
Work Equipment System 480
Layout Drawing of Work Equipment System 480
Work Equipment System Diagram 482
Work Equipment Control System 484
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 484
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 485
Work Equipment Lever Operating Function System Diagram 486
Work Equipment Lever Operation Function 486
Bucket Priority Control Function 487
Boom Stop Modulation Function 487
Work Equipment Shock Reduction Function 488
Sub Total Switch Interlock Horn Function 491
Work Equipment Neutral Lock System 492
Work Equipment Neutral Lock System Diagram 492
Function of Work Equipment Neutral Lock System 492
Remote Positioner System 494
Remote Bucket Positioner System Diagram 494
Function of Remote Bucket Positioner System 494
Remote Boom Positioner System Diagram 495
Function of Remote Boom Positioner System 495
Bucket Positioner and Boom Positioner 499
Structure of Bucket Positioner and Boom Positioner 499
Auto-Digging System 500
Auto-Digging System Diagram 500
Function of Auto-Digging System 500
ECSS 502
ECSS Diagram 502
Function of ECSS 502
Operation of ECSS 502
Component Parts of Work Equipment System 504
Work Equipment Lock Solenoid Valve 504
Pilot Circuit Accumulator 505
ECSS Circuit Accumulator 506
Work Equipment Electric Lever 507
Steering System 510
Layout Drawing of Steering System 510
AJSS 512
Layout Drawing of AJSS 512
AJSS System Diagram 513
Function of AJSS 514
Neutralizer Function of AJSS 515
AJSS Neutral Interlock Function 516
AJSS Speed Sensing Steering Function 517
AJSS Turn Signal Pilot Lamp Control Function 518
Steering Column 520
Structure of Steering Column 520
Component Parts of Steering System 521
AJSS EPC Valve 521
Steering Lock Valve 522
Rotary Valve 523
Steering Unit 526
Stop Valve 530
Steering Valve 531
2-Way Restrictor Valve 543
Diverter Valve 545
Secondary Steering Relief Valve 551
Secondary Steering Pump 552
Brake System 553
Layout Drawing of Brake System 553
Parking Brake Control System 556
System Diagram of Parking Brake Control System 556
Operation of Parking Brake Control System 556
Component Parts of Brake System 558
Charge Valve 558
Parking Brake Solenoid Valve 563
Parking Brake Emergency Release Valve 565
Brake Circuit Accumulator 566
Brake Valve 567
Slack Adjuster 573
Brake 575
Parking Brake 577
Brake Cooling Pump 579
Undercarriage and Frame 580
Frame, Axle Mount and Center Hinge Pin 580
Structure of Frame, Axle Mount and Center Hinge Pin 580
Function of Frame, Axle Mount and Center Hinge Pin 582
Tires 583
Features of Radial Tire When Compared with Bias Tire 583
Structure of Radial Tire 583
Function of Radial Tire 584
Structure of Bias Tire 584
Function of Bias Tire 584
Work Equipment 585
Structure of Work Equipment 585
Structure of Bucket 586
Structure of Lubrication System for Work Equipment 587
CAB Related Parts 589
ROPS CAB 589
Structure of ROPS CAB 589
Function of ROPS CAB 590
20 Standard Value Table 591
Table of Contents 592
Abbreviation List 593
Standard Value Table for Engine 599
Standard Value Table for Engine: WA600-8 599
Standard Value Table for Machine 602
Standard Value Table for Machine: WA600-8 602
Machine Posture and Procedures to Measure Performance 620
30 Testing and Adjusting 623
Table of Contents 624
Precautions Before Work 628
Abbreviation List 629
Related Information on Testing and Adjusting 635
Tools for Testing and Adjusting 635
Sketch of Tools for Testing and Adjusting 647
Engine and Cooling System 648
Examine Engine Speed 648
How to Examine Engine Speed 648
Examine Boost Pressure 652
How to Examine Boost Pressure on Machine Monitor 652
How to Examine Boost Pressure by Testing Tool 653
Examine Exhaust Gas Temperature 656
How to Examine Exhaust Gas Temperature 656
Examine Exhaust Gas Color 658
How to Examine Exhaust Gas Color with the Handy Smoke Checker 658
How to Examine Exhaust Gas Color with Smoke Meter 659
Examine Mass Air Flow and Temperature Sensor 661
How to Examine Mass Air Flow and Temperature Sensor 661
Examine and Adjust Valve Clearance 664
How to Examine Valve Clearance 664
How to Adjust Valve Clearance 665
Examine Compression Pressure 667
How to Examine Compression Pressure 667
Examine Blowby Pressure 671
How to Examine Blowby Pressure 671
Examine Engine Oil Pressure 674
How to Examine Engine Oil Pressure on Machine Monitor 674
How to Examine Engine Oil Pressure by Testing Tool 675
Examine EGR Valve and VGT Oil Pressure 677
How to Examine EGR Valve and VGT Oil Pressure 677
Examine Fuel Pressure 679
How to Examine Fuel Pressure 679
Examine Fuel Return Rate and Leakage 681
How to Examine Fuel Return Rate and Leakage 682
Bleed Air from Fuel System 685
How to Bleed Air from Fuel System 685
Examine Fuel Circuit for Leakage 687
How to Examine Fuel System for Leakage 687
Examine Supply Pump 689
How to Examine Supply Pump 689
Handle Cylinder Cut-out Mode Operation 692
Handle No-Injection Cranking Operation 693
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 694
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 694
Examine Installed Condition of Cylinder Heads and Manifolds 695
How to Examine Installed Condition of Cylinder Heads and Manifolds 695
Examine Engine Piping for Damage and Looseness 696
How to Examine Engine Piping for Damage and Looseness 696
Clean Fuel Doser 697
How to Clean Fuel Doser 697
Write Injector Compensation Value to Engine Controller 699
How to Write Injector Compensation Value 699
Write Correction for Ash in Soot Accumulation to Engine Controller 706
How to Write Correction for Ash in Soot Accumulation to Engine Controller 706
Examine SCR Related Functions 707
Examine DEF Pump Raised Pressure 711
Examine Injection Volume from DEF Injector 718
Examine DEF Line Heater Relay 1 727
Examine DEF Line Heater Relay 2 735
Examine DEF Pump Heater Relay 742
Examine DEF Tank Heater Valve 749
Examine SCR Denitration Efficiency 753
Clean DEF Tank 758
How to Clean DEF Tank 758
Bleed Air from Coolant Circuit of DEF Tank 763
How to Bleed Air from Coolant Circuit of DEF Tank 763
Clean DEF Pump 765
How to Clean DEF Pump 765
Bleed Air from Engine Coolant Circuit 772
How to Bleed Air from Engine Coolant Circuit 772
Power Train 774
Examine and Adjust Power Train Oil Pressure 774
How to Examine Power Train Oil Pressure 776
How to Adjust Power Train Oil Pressure 789
Adjust Modulation Clutch Rotation Sensor 791
How to Adjust Modulation Clutch Rotation Sensor 791
Adjust Transmission Output Shaft Speed Sensor 792
How to Adjust Transmission Output Shaft Speed Sensor 792
Flush Torque Converter and Transmission Hydraulic Circuit 794
How to Flush Torque Converter and Transmission Hydraulic Circuit 794
Move Disabled Machine Due to Transmission Valve Failure 797
How to Move Disabled Machine Due to Transmission Valve Failure 797
Examine Drive Shaft for Looseness, Backlash, and Damage 800
How to Examine Drive Shaft for Looseness, Backlash, and Damage 800
Steering System 801
Examine Steering Wheel (For Steering Wheel Spec) 801
How to Examine Steering Wheel 801
Examine and Adjust Steering Circuit Oil Pressure 803
How to Examine Steering Circuit Oil Pressure 803
How to Adjust Steering Circuit Oil Pressure 807
Bleed Air from Steering Cylinder Circuit 808
How to Bleed Air from Steering Cylinder Circuit 808
Examine and Adjust Steering Stop Valve (For Steering Wheel Spec) 809
How to Examine Steering Stop Valve 809
How to Adjust Steering Stop Valve 809
Brake System 811
Release Remained Pressure in Brake Accumulator Circuit 811
How to Release Remained Pressure in Brake Accumulator Circuit 811
Examine Wheel Brake Oil Pressure 812
How to Examine Wheel Brake Oil Pressure 812
Examine and Adjust Brake Accumulator Charge Pressure 814
How to Examine Brake Accumulator Charge Pressure on Machine Monitor 814
How to Examine Brake Accumulator Charge Pressure by Testing Tool 815
How to Adjust Brake Accumulator Charge Pressure 816
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 818
How to Examine Accumulator Nitrogen Gas Pressure for Brake 818
How to Charge Accumulator Nitrogen Gas for Brake 822
How to Release Nitrogen Gas When You Discard Accumulator 826
Bleed Air from Brake Circuit 827
How to Bleed Air from Brake Circuit 827
Examine Brake Performance 828
How to Examine Brake Performance 828
Examine Brake Pedal 829
How to Examine Brake Pedal 829
Adjust Right Brake Pedal Switch 830
How to Adjust Right Brake Pedal Switch 830
Examine Wear of Wheel Brake Disc 832
How to Examine Wear of Wheel Brake Disc 832
Examine Parking Brake Oil Pressure 834
How to Examine Parking Brake Oil Pressure 834
Examine Parking Brake Performance 838
How to Examine Parking Brake Performance 838
Release Parking Brake Manually 839
How to Release Parking Brake Manually 839
Examine Wear Volume of Parking Brake Disc 841
How to Examine Wear Quantity of Parking Brake Disc 841
Hydraulic System 843
Release Remained Pressure from Work Equipment Circuit 843
How to Release Remained Pressure from Work Equipment Circuit 843
Examine and Adjust Work Equipment Oil Pressure 845
How to Examine Work Equipment Oil Pressure 845
How to Adjust Work Equipment Oil Pressure 850
Examine and Adjust Work Equipment EPC Oil Pressure 852
How to Examine Work Equipment EPC Oil Pressure 852
How to Adjust Work Equipment EPC Oil Pressure 854
Bleed Air from Work Equipment Circuit 855
How to Bleed Air from Work Equipment Circuit 855
Examine Cooling Fan Speed 856
How to Examine Cooling Fan Speed 856
Examine Cooling Fan Circuit Oil Pressure 858
How to Examine Cooling Fan Circuit Oil Pressure 858
Bleed Air from Cooling Fan Circuit 860
How to Bleed Air from Cooling Fan Circuit 860
Examine ECSS Accumulator Charge Pressure 862
How to Examine ECSS Accumulator Charge Pressure 862
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 864
How to Examine ECSS Accumulator Nitrogen Gas Pressure 864
How to Charge ECSS Accumulator with Nitrogen Gas 866
Work Equipment 870
Examine and Adjust Bucket Potentiometer Lever 870
How to Examine Bucket Potentiometer Lever 870
How to Adjust Bucket Potentiometer Lever 870
Examine and Adjust Boom Potentiometer Lever 872
How to Examine Boom Potentiometer Lever 872
How to Adjust Boom Potentiometer Lever 872
CAB Related Parts 874
Examine Directional Lever (For Steering Wheel Spec) 874
How to Examine Directional Lever 874
Examine Work Equipment Control Lever 875
How to Examine Work Equipment Control Lever 875
Examine AJSS Lever (For AJSS Spec) 877
How to Examine AJSS Lever 877
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications) 880
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 880
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 880
Examine and Adjust Steering Stopper Bolt (For AJSS Spec) 882
How to Examine Steering Stopper Bolt 882
How to Adjust Steering Stopper Bolt 882
Adjust Play of Operator Seat 884
How to Adjust Play of Operator Seat 884
Adjust Door Lock Link 885
How to Adjust Door Lock Link 885
Electrical System 888
Set and Adjust Each Equipment 888
Set and Operate Machine Monitor 893
Operator Mode 897
Function to Show Technician Identification Status Screen 897
Function to Show Operator Identification Input Screen 897
Examine Function by LCD (Liquid Crystal Display) 898
Examine Function of Service Meter and Odometer 899
How to Set Usage Limitation and Change Maintenance Password 899
Service Mode 903
How to Operate Service Mode 903
How to See Pre-defined Monitoring Information 907
How to Examine Self-Define Monitor Information 916
Abnormality Record Menu 934
How to See Maintenance Record 939
Maintenance Mode Setting 941
How to Set Phone Number Entry 946
Default Menu 948
Diagnostic Tests Menu 964
Adjustment Menu 978
No-Injection Cranking Operation1018
KOMTRAX Settings Menu1021
How to Show Service Message1023
How to Operate Snap Shot1025
How to Start Up KOMTRAX Terminal1027
Default Setting of KOMTRAX Plus Controller1032
How to do the Default Setting of KOMTRAX Plus Controller1032
Default Setting of Wireless LAN Modem1035
Default Setting of Wireless LAN Modem1035
How to Examine Wireless LAN Modem Communication1036
Download Data from KOMTRAX Plus Controller1038
How to Download Data from KOMTRAX Plus Controller1038
Adjust After Replacement of KOMTRAX Plus Controller1042
How to Adjust After Replacement of KOMTRAX Plus Controller1042
Adjust After Replacement of Wireless LAN Modem1045
How to Adjust After Replacement of Wireless LAN Modem1045
Adjust Rearview Camera Angle1048
How to Adjust Rearview Camera Angle1048
Handle Voltage Circuit of Engine Controller1049
Handle Battery Disconnect Switch1050
Examine Diodes1051
How to Examine Diodes by Digital Tester1051
How to Examine Diodes by Analog Tester1051
Pm Clinic1052
Pm Clinic Service1052
Pm Clinic Check Sheet: WA600-81055
Perform Quick Pm1066
How to Perform Quick Pm1066
40 Troubleshooting1069
Table of Contents1070
Precautions Before Work1086
Abbreviation List1087
Related Information to Troubleshooting1093
General Troubleshooting Points1093
Troubleshooting Points for Urea SCR System1094
Sequence of Events in Troubleshooting1109
Checks Before Troubleshooting1111
Inspection Procedure Before Troubleshooting1113
Walk-Around Check1113
Test in Accordance with Testing Procedure1115
Examine Fuel Level and Type1115
Examine for Impure Ingredient in Fuel1115
Examine DEF Level and Type1116
Examine Fuel Prefilter1116
Examine Fuel Main Filter1118
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1120
Examine Coolant Level (Reservoir Tank)1122
Examine Air Cleaner Clogging1123
Clean Outer Element1124
Replace Element1126
Examine Hydraulic Oil Level1128
Examine Hydraulic Oil Strainer1129
Examine Hydraulic Oil Filter1130
Examine Oil Level in Transmission Case1131
Examine Oil Level in Axle Case1132
Bleed Air from Fuel System1133
Bleed Air from Hydraulic System1133
How to Examine Electric Equipment1133
Preparation for Troubleshooting of Electrical System1141
Procedure for Troubleshooting1151
Symptom and Troubleshooting Numbers1153
Information Shown in Troubleshooting Table1157
Connector List and Layout1159
Connector Contact Connection Table1190
T-Branch Box and T-Branch Adapter Table1230
Fuse Location Table1236
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1239
Prepare Troubleshoot Machine Monitor1243
Procedure to Make Harness Checker on Machine Monitor LCD Unit1245
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1251
Failure Code Table1253
Troubleshooting by Failure Code (Display of Code)1284
Failure Code [1500L0]1284
Failure Code [15SAL1]1285
Failure Code [15SALH]1287
Failure Code [15SBL1]1289
Failure Code [15SBLH]1291
Failure Code [15SEL1]1293
Failure Code [15SELH]1295
Failure Code [15SFL1]1297
Failure Code [15SFLH]1299
Failure Code [15SGL1]1301
Failure Code [15SGLH]1303
Failure Code [15SHL1]1305
Failure Code [15SHLH]1307
Failure Code [15W0NT]1309
Failure Code [2F00MA]1310
Failure Code [2F00MB]1314
Failure Code [2G42ZG]1317
Failure Code [2G43ZG]1319
Failure Code [879AKA]1321
Failure Code [879AKB]1322
Failure Code [879BKA]1323
Failure Code [879BKB]1325
Failure Code [879CKA]1327
Failure Code [879CKB]1328
Failure Code [879DKZ]1329
Failure Code [879EMC]1331
Failure Code [879FMC]1332
Failure Code [879GKX]1333
Failure Code [989A00]1335
Failure Code [989L00]1336
Failure Code [989M00]1337
Failure Code [989N00]1338
Failure Code [A1U0N3]1339
Failure Code [A1U0N4]1341
Failure Code [AA10NX]1343
Failure Code [AB00KE]1345
Failure Code [AB00KY]1347
Failure Code [AQ00N3]1349
Failure Code [AQ00N4]1350
Failure Code [AQ10N3]1351
Failure Code [AS00N3]1353
Failure Code [AS00R2]1355
Failure Code [AS00R3]1356
Failure Code [AS00R4]1357
Failure Code [AS00R5]1358
Failure Code [AS00R6]1359
Failure Code [AS00ZK]1360
Failure Code [AS10NR]1361
Failure Code [B@BAZG]1362
Failure Code [B@BAZK]1363
Failure Code [B@BCNS]1365
Failure Code [B@BCQA]1366
Failure Code [B@BCZK]1368
Failure Code [B@C7NS]1370
Failure Code [B@CENS]1372
Failure Code [B@GAZK]1373
Failure Code [B@HANS]1374
Failure Code [CA115]1375
Failure Code [CA122]1379
Failure Code [CA123]1381
Failure Code [CA131]1383
Failure Code [CA132]1385
Failure Code [CA135]1387
Failure Code [CA141]1389
Failure Code [CA144]1391
Failure Code [CA145]1393
Failure Code [CA153]1395
Failure Code [CA154]1398
Failure Code [CA187]1400
Failure Code [CA212]1402
Failure Code [CA213]1404
Failure Code [CA221]1406
Failure Code [CA222]1408
Failure Code [CA227]1410
Failure Code [CA234]1412
Failure Code [CA238]1413
Failure Code [CA239]1415
Failure Code [CA249]1417
Failure Code [CA256]1419
Failure Code [CA271]1421
Failure Code [CA272]1423
Failure Code [CA273]1424
Failure Code [CA274]1426
Failure Code [CA322]1427
Failure Code [CA323]1429
Failure Code [CA324]1431
Failure Code [CA325]1433
Failure Code [CA331]1435
Failure Code [CA332]1437
Failure Code [CA343]1439
Failure Code [CA351]1441
Failure Code [CA352]1443
Failure Code [CA356]1445
Failure Code [CA357]1447
Failure Code [CA386]1449
Failure Code [CA431]1451
Failure Code [CA432]1454
Failure Code [CA441]1457
Failure Code [CA442]1459
Failure Code [CA449]1461
Failure Code [CA451]1462
Failure Code [CA452]1464
Failure Code [CA515]1466
Failure Code [CA516]1468
Failure Code [CA553]1470
Failure Code [CA555]1471
Failure Code [CA556]1473
Failure Code [CA559]1475
Failure Code [CA595]1481
Failure Code [CA687]1483
Failure Code [CA689]1485
Failure Code [CA691]1487
Failure Code [CA692]1489
Failure Code [CA697]1491
Failure Code [CA698]1492
Failure Code [CA731]1493
Failure Code [CA778]1497
Failure Code [CA1117]1500
Failure Code [CA1135]1502
Failure Code [CA1257]1504
Failure Code [CA1664]1505
Failure Code [CA1669]1509
Failure Code [CA1673]1510
Failure Code [CA1677]1511
Failure Code [CA1678]1512
Failure Code [CA1682]1513
Failure Code [CA1683]1518
Failure Code [CA1684]1520
Failure Code [CA1686]1522
Failure Code [CA1691]1523
Failure Code [CA1694]1525
Failure Code [CA1695]1527
Failure Code [CA1696]1529
Failure Code [CA1712]1531
Failure Code [CA1713]1534
Failure Code [CA1714]1536
Failure Code [CA1715]1537
Failure Code [CA1776]1538
Failure Code [CA1777]1541
Failure Code [CA1843]1544
Failure Code [CA1844]1546
Failure Code [CA1879]1548
Failure Code [CA1881]1550
Failure Code [CA1883]1552
Failure Code [CA1885]1556
Failure Code [CA1887]1558
Failure Code [CA1921]1560
Failure Code [CA1922]1563
Failure Code [CA1923]1568
Failure Code [CA1924]1570
Failure Code [CA1925]1575
Failure Code [CA1927]1579
Failure Code [CA1928]1581
Failure Code [CA1942]1583
Failure Code [CA1963]1585
Failure Code [CA1977]1592
Failure Code [CA1993]1594
Failure Code [CA2185]1597
Failure Code [CA2186]1599
Failure Code [CA2249]1601
Failure Code [CA2265]1606
Failure Code [CA2266]1608
Failure Code [CA2271]1610
Failure Code [CA2272]1612
Failure Code [CA2349]1614
Failure Code [CA2353]1616
Failure Code [CA2357]1618
Failure Code [CA2381]1621
Failure Code [CA2382]1623
Failure Code [CA2383]1625
Failure Code [CA2386]1627
Failure Code [CA2387]1629
Troubleshooting Flowchart1633
Failure Code [CA2555]1634
Failure Code [CA2556]1636
Failure Code [CA2637]1638
Failure Code [CA2639]1640
Failure Code [CA2732]1643
Failure Code [CA2733]1645
Failure Code [CA2741]1647
Failure Code [CA2765]1651
Failure Code [CA2771]1652
Failure Code [CA2777]1658
Failure Code [CA2878]1661
Failure Code [CA2881]1667
Failure Code [CA2976]1673
Failure Code [CA3133]1675
Failure Code [CA3134]1677
Failure Code [CA3135]1679
Failure Code [CA3142]1683
Failure Code [CA3143]1684
Failure Code [CA3144]1685
Failure Code [CA3146]1688
Failure Code [CA3147]1689
Failure Code [CA3148]1690
Failure Code [CA3151]1693
Failure Code [CA3165]1698
Failure Code [CA3167]1700
Failure Code [CA3229]1706
Failure Code [CA3231]1709
Failure Code [CA3232]1712
Failure Code [CA3235]1717
Failure Code [CA3239]1719
Failure Code [CA3241]1722
Failure Code [CA3242]1725
Failure Code [CA3251]1728
Failure Code [CA3253]1731
Failure Code [CA3254]1736
Failure Code [CA3255]1740
Failure Code [CA3256]1743
Failure Code [CA3311]1746
Failure Code [CA3312]1749
Failure Code [CA3313]1752
Failure Code [CA3314]1753
Failure Code [CA3315]1754
Failure Code [CA3316]1758
Failure Code [CA3317]1759
Failure Code [CA3318]1760
Failure Code [CA3319]1764
Failure Code [CA3321]1765
Failure Code [CA3322]1766
Failure Code [CA3419]1770
Failure Code [CA3421]1772
Failure Code [CA3497]1774
Failure Code [CA3498]1775
Failure Code [CA3543]1776
Failure Code [CA3545]1781
Failure Code [CA3547]1783
Failure Code [CA3558]1784
Failure Code [CA3559]1786
Failure Code [CA3562]1788
Failure Code [CA3563]1790
Failure Code [CA3567]1793
Failure Code [CA3568]1797
Failure Code [CA3571]1804
Failure Code [CA3572]1806
Failure Code [CA3574]1808
Failure Code [CA3575]1811
Failure Code [CA3577]1812
Failure Code [CA3578]1814
Failure Code [CA3582]1816
Failure Code [CA3583]1824
Failure Code [CA3596]1826
Failure Code [CA3649]1830
Failure Code [CA3681]1833
Failure Code [CA3682]1838
Failure Code [CA3713]1844
Failure Code [CA3717]1847
Failure Code [CA3718]1848
Failure Code [CA3725]1849
Failure Code [CA3748]1852
Failure Code [CA3751]1854
Failure Code [CA3755]1856
Failure Code [CA3866]1858
Failure Code [CA3867]1862
Failure Code [CA3868]1865
Failure Code [CA3899]1869
Failure Code [CA3911]1871
Failure Code [CA3912]1875
Failure Code [CA3932]1877
Failure Code [CA3933]1879
Failure Code [CA3934]1881
Failure Code [CA3935]1884
Failure Code [CA3936]1886
Failure Code [CA4151]1888
Failure Code [CA4152]1892
Failure Code [CA4155]1896
Failure Code [CA4156]1899
Failure Code [CA4157]1902
Failure Code [CA4158]1904
Failure Code [CA4159]1905
Failure Code [CA4161]1906
Failure Code [CA4162]1909
Failure Code [CA4163]1912
Failure Code [CA4164]1914
Failure Code [CA4165]1917
Failure Code [CA4166]1920
Failure Code [CA4168]1922
Failure Code [CA4169]1926
Failure Code [CA4171]1931
Failure Code [CA4249]1936
Failure Code [CA4251]1940
Failure Code [CA4259]1943
Failure Code [CA4261]1947
Failure Code [CA4277]1950
Failure Code [CA4281]1953
Failure Code [CA4459]1957
Failure Code [CA4461]1959
Failure Code [CA4658]1962
Failure Code [CA4731]1966
Failure Code [CA4732]1967
Failure Code [CA4739]1968
Failure Code [CA4768]1969
Failure Code [CA4769]1971
Failure Code [CA4842]1974
Failure Code [CA4952]1978
Failure Code [CA5115]1980
Failure Code [CA5179]1983
Failure Code [CA5181]1985
Failure Code [CA5383]1987
Failure Code [CB115]1989
Failure Code [CB187]1992
Failure Code [CB227]1994
Failure Code [CB238]1995
Failure Code [CB239]1997
Failure Code [CB271]1999
Failure Code [CB272]2001
Failure Code [CB273]2002
Failure Code [CB274]2004
Failure Code [CB343]2005
Failure Code [CB352]2007
Failure Code [CB386]2009
Failure Code [CB441]2011
Failure Code [CB442]2013
Failure Code [CB689]2015
Failure Code [CB697]2017
Failure Code [CB698]2018
Failure Code [CB731]2019
Failure Code [CB778]2022
Failure Code [CB1117]2024
Failure Code [CB1257]2026
Failure Code [CB1664]2027
Failure Code [CB1682]2030
Failure Code [CB1691]2035
Failure Code [CB1694]2037
Failure Code [CB1695]2039
Failure Code [CB1696]2041
Failure Code [CB1776]2043
Failure Code [CB1777]2046
Failure Code [CB1879]2049
Failure Code [CB1881]2051
Failure Code [CB1883]2053
Failure Code [CB1887]2057
Failure Code [CB1921]2059
Failure Code [CB1922]2062
Failure Code [CB1923]2067
Failure Code [CB1924]2069
Failure Code [CB1925]2074
Failure Code [CB1927]2078
Failure Code [CB1928]2080
Failure Code [CB1963]2082
Failure Code [CB1977]2089
Failure Code [CB1993]2091
Failure Code [CB2265]2094
Failure Code [CB2266]2096
Failure Code [CB2637]2098
Failure Code [CB2639]2100
Failure Code [CB2732]2103
Failure Code [CB2733]2105
Failure Code [CB2741]2107
Failure Code [CB2771]2111
Failure Code [CB2777]2117
Failure Code [CB2878]2120
Failure Code [CB2881]2126
Failure Code [CB2976]2132
Failure Code [CB3133]2134
Failure Code [CB3134]2136
Failure Code [CB3135]2138
Failure Code [CB3142]2142
Failure Code [CB3143]2143
Failure Code [CB3144]2144
Failure Code [CB3146]2147
Failure Code [CB3147]2148
Failure Code [CB3148]2149
Failure Code [CB3151]2152
Failure Code [CB3165]2157
Failure Code [CB3167]2159
Failure Code [CB3229]2165
Failure Code [CB3231]2168
Failure Code [CB3235]2171
Failure Code [CB3239]2173
Failure Code [CB3241]2176
Failure Code [CB3251]2179
Failure Code [CB3253]2182
Failure Code [CB3254]2187
Failure Code [CB3255]2191
Failure Code [CB3256]2194
Failure Code [CB3311]2197
Failure Code [CB3312]2200
Failure Code [CB3313]2203
Failure Code [CB3314]2204
Failure Code [CB3315]2205
Failure Code [CB3316]2209
Failure Code [CB3317]2210
Failure Code [CB3318]2211
Failure Code [CB3319]2215
Failure Code [CB3321]2216
Failure Code [CB3322]2217
Failure Code [CB3545]2221
Failure Code [CB3558]2223
Failure Code [CB3559]2225
Failure Code [CB3562]2227
Failure Code [CB3563]2229
Failure Code [CB3567]2232
Failure Code [CB3568]2236
Failure Code [CB3571]2243
Failure Code [CB3572]2245
Failure Code [CB3574]2247
Failure Code [CB3575]2250
Failure Code [CB3577]2252
Failure Code [CB3578]2254
Failure Code [CB3582]2256
Failure Code [CB3583]2264
Failure Code [CB3596]2266
Failure Code [CB3681]2270
Failure Code [CB3713]2275
Failure Code [CB3717]2278
Failure Code [CB3751]2279
Failure Code [CB3755]2281
Failure Code [CB3899]2283
Failure Code [CB3911]2285
Failure Code [CB3912]2289
Failure Code [CB3932]2291
Failure Code [CB3933]2293
Failure Code [CB3934]2295
Failure Code [CB3935]2297
Failure Code [CB3936]2299
Failure Code [CB4151]2301
Failure Code [CB4152]2305
Failure Code [CB4155]2309
Failure Code [CB4156]2312
Failure Code [CB4157]2315
Failure Code [CB4158]2317
Failure Code [CB4159]2318
Failure Code [CB4161]2319
Failure Code [CB4162]2322
Failure Code [CB4163]2325
Failure Code [CB4164]2327
Failure Code [CB4165]2330
Failure Code [CB4166]2333
Failure Code [CB4168]2335
Failure Code [CB4169]2338
Failure Code [CB4171]2341
Failure Code [CB4249]2345
Failure Code [CB4251]2348
Failure Code [CB4259]2351
Failure Code [CB4261]2354
Failure Code [CB4459]2357
Failure Code [CB4461]2359
Failure Code [CB4658]2362
Failure Code [CB4952]2366
Failure Code [CB5115]2368
Failure Code [CB5383]2371
Failure Code [D162KA]2373
Failure Code [D162KA]2375
Failure Code [D162KB]2377
Failure Code [D162KB]2379
Failure Code [D162KY]2381
Failure Code [D162KY]2383
Failure Code [D191KA]2385
Failure Code [D191KB]2388
Failure Code [D191KY]2391
Failure Code [D192KA]2393
Failure Code [D192KB]2395
Failure Code [D192KY]2397
Failure Code [D19JKZ]2398
Failure Code [D1E6KA]2400
Failure Code [D1E6KB]2402
Failure Code [D1E6KY]2404
Failure Code [D5ZHKA]2406
Failure Code [D5ZHKB]2408
Failure Code [D5ZHKZ]2410
Failure Code [D5ZHL6]2413
Failure Code [D5ZMLD]2415
Failure Code [D862KA]2417
Failure Code [DA80L4]2418
Failure Code [DAF0KT]2420
Failure Code [DAF0MB]2421
Failure Code [DAF0MC]2422
Failure Code [DAF3KK]2423
Failure Code [DAF8KB]2425
Failure Code [DAFDKB]2426
Failure Code [DAFGMC]2428
Failure Code [DAFLKA]2429
Failure Code [DAFLKB]2431
Failure Code [DAFQKR]2433
Failure Code [DAQ0KK]2434
Failure Code [DAQ0KT]2437
Failure Code [DAQ0MC]2438
Failure Code [DAQ1KA]2439
Failure Code [DAQ2KK]2442
Failure Code [DAQ4KB]2445
Failure Code [DAQ9KQ]2447
Failure Code [DAQLKA]2448
Failure Code [DAQLKB]2450
Failure Code [DAQQKR]2452
Failure Code [DAQRKR]2453
Failure Code [DAQRMA]2454
Failure Code [DAZ9KQ]2455
Failure Code [DAZQKR]2456
Failure Code [DB2QKR]2457
Failure Code [DB2RKR]2465
Failure Code [DB90KK]2470
Failure Code [DB90KT]2473
Failure Code [DB90MC]2474
Failure Code [DB91KA]2475
Failure Code [DB92KK]2478
Failure Code [DB95KX]2481
Failure Code [DB96KX]2483
Failure Code [DB97KX]2486
Failure Code [DB99KQ]2487
Failure Code [DB9LKA]2488
Failure Code [DB9LKB]2490
Failure Code [DB9QKR]2492
Failure Code [DB9RKR]2493
Failure Code [DB9RMA]2494
Failure Code [DBE5KX]2495
Failure Code [DBE6KX]2497
Failure Code [DBV0MC]2499
Failure Code [DBV1KK]2500
Failure Code [DBV5KX]2502
Failure Code [DBV6KX]2504
Failure Code [DBV7KX]2506
Failure Code [DBV8KX]2507
Failure Code [DBVLKA]2508
Failure Code [DBVLKB]2510
Failure Code [DBVQK4]2512
Failure Code [DBVQKR]2513
Failure Code [DBVRKR]2514
Failure Code [DBVVKR]2515
Failure Code [DBVWKR]2516
Failure Code [DD1ALD]2517
Failure Code [DDA8KB]2519
Failure Code [DDA9KB]2521
Failure Code [DDAAL6]2523
Failure Code [DDAAL6]2525
Failure Code [DDB6L4]2528
Failure Code [DDD1LD]2531
Failure Code [DDDBKA]2533
Failure Code [DDDBKB]2535
Failure Code [DDE5KA]2537
Failure Code [DDK4KA]2538
Failure Code [DDK4KB]2541
Failure Code [DDK5L4]2543
Failure Code [DDK6KA]2545
Failure Code [DDK6KB]2548
Failure Code [DDNRKY]2551
Failure Code [DDP5KA]2553
Failure Code [DDW9LD]2555
Failure Code [DDWLLD]2557
Failure Code [DF10KA]2559
Failure Code [DF10KB]2563
Failure Code [DGE5KA]2566
Failure Code [DGE5KB]2568
Failure Code [DGF1KA]2570
Failure Code [DGF1KB]2572
Failure Code [DGH2KX]2574
Failure Code [DGR2KB]2576
Failure Code [DGR2KZ]2578
Failure Code [DGR4KB]2580
Failure Code [DGR4KZ]2582
Failure Code [DGT1KA]2584
Failure Code [DGT1KB]2586
Failure Code [DGT4KA]2588
Failure Code [DGT4KY]2590
Failure Code [DH21KA]2592
Failure Code [DH21KY]2595
Failure Code [DHA4KA]2597
Failure Code [DHAAMA]2599
Failure Code [DHABMA]2600
Failure Code [DHACMA]2601
Failure Code [DHADMA]2602
Failure Code [DHPCKA]2603
Failure Code [DHPCKY]2605
Failure Code [DHPDKA]2607
Failure Code [DHPDKY]2609
Failure Code [DHQ2KX]2611
Failure Code [DHT2L6]2613
Failure Code [DHT5KX]2614
Failure Code [DHT7KX]2617
Failure Code [DHT8KA]2620
Failure Code [DHT8KY]2623
Failure Code [DHTBKA]2625
Failure Code [DHTBKB]2627
Failure Code [DHU2KA]2629
Failure Code [DHU2KY]2631
Failure Code [DHU3KA]2633
Failure Code [DHU3KY]2635
Failure Code [DJF1KA]2637
Failure Code [DK30KA]2639
Failure Code [DK30KY]2641
Failure Code [DK55KA]2643
Failure Code [DK55KY]2646
Failure Code [DK55L5]2648
Failure Code [DK59KA]2649
Failure Code [DK59KY]2654
Failure Code [DK59L8]2658
Failure Code [DK5AKA]2663
Failure Code [DK5AKY]2667
Failure Code [DK5BKA]2671
Failure Code [DK5BKY]2675
Failure Code [DK5BL8]2679
Failure Code [DK5CKA]2684
Failure Code [DK5CKY]2688
Failure Code [DK5DKA]2692
Failure Code [DK5DKY]2695
Failure Code [DK5DL8]2698
Failure Code [DK5EKA]2703
Failure Code [DK5EKY]2706
Failure Code [DKA0KA]2709
Failure Code [DKA0KY]2712
Failure Code [DKA0L0]2715
Failure Code [DKA1KA]2718
Failure Code [DKA1KY]2721
Failure Code [DKD0KA]2723
Failure Code [DKD0KY]2725
Failure Code [DKD0L8]2727
Failure Code [DLFAKA]2728
Failure Code [DLFALC]2730
Failure Code [DLM3KA]2732
Failure Code [DLM3LC]2734
Failure Code [DLT3KA]2736
Failure Code [DLT3LC]2738
Failure Code [DLT4KB]2740
Failure Code [DLT4KX]2742
Failure Code [DPQ1KR]2744
Failure Code [DPQ2KR]2747
Failure Code [DPQ3KR]2750
Failure Code [DSJ0KR]2754
Failure Code [DT22KB]2758
Failure Code [DV00KB]2760
Failure Code [DW2BKA]2762
Failure Code [DW2BKB]2764
Failure Code [DW2BKY]2766
Failure Code [DW2BL1]2768
Failure Code [DW2BLH]2770
Failure Code [DW4PKA]2771
Failure Code [DW4PKB]2773
Failure Code [DW4PKY]2775
Failure Code [DW4QKA]2777
Failure Code [DW4QKB]2779
Failure Code [DW4QKY]2781
Failure Code [DW4RKA]2783
Failure Code [DW4RKB]2785
Failure Code [DW4RKY]2787
Failure Code [DW4SKA]2789
Failure Code [DW4SKB]2791
Failure Code [DW4SKY]2793
Failure Code [DW7BKA]2795
Failure Code [DW7BKB]2797
Failure Code [DW7BKY]2799
Failure Code [DWM1KA]2801
Failure Code [DWM1KB]2803
Failure Code [DWM1KY]2805
Failure Code [DWN6KA]2807
Failure Code [DWN6KB]2809
Failure Code [DWN6KY]2811
Failure Code [DWN8KA]2813
Failure Code [DWN8KB]2815
Failure Code [DWN8KY]2817
Failure Code [DWNFKA]2819
Failure Code [DWNFKB]2821
Failure Code [DWNFKY]2823
Failure Code [DX16KA]2825
Failure Code [DX16KB]2827
Failure Code [DX16KY]2829
Failure Code [DXA1KA]2831
Failure Code [DXA1KB]2833
Failure Code [DXA1KY]2835
Failure Code [DXF0KA]2836
Failure Code [DXF0KB]2838
Failure Code [DXF0KY]2840
Failure Code [DXH1KA]2842
Failure Code [DXH1KB]2844
Failure Code [DXH1KY]2846
Failure Code [DXH4KA]2848
Failure Code [DXH4KB]2850
Failure Code [DXH4KY]2852
Failure Code [DXH5KA]2854
Failure Code [DXH5KB]2856
Failure Code [DXH5KY]2858
Failure Code [DXH6KA]2860
Failure Code [DXH6KB]2862
Failure Code [DXH6KY]2864
Failure Code [DXH7KA]2866
Failure Code [DXH7KB]2868
Failure Code [DXH7KY]2870
Failure Code [DXH8KA]2872
Failure Code [DXH8KB]2874
Failure Code [DXH8KY]2876
Failure Code [DXHHKA]2878
Failure Code [DXHHKB]2880
Failure Code [DXHHKY]2882
Failure Code [DXHJKA]2884
Failure Code [DXHJKB]2886
Failure Code [DXHJKY]2888
Failure Code [DXHKKA]2890
Failure Code [DXHKKB]2892
Failure Code [DXHKKY]2894
Failure Code [DXHPKA]2896
Failure Code [DXHPKB]2898
Failure Code [DXHPKY]2900
Failure Code [DXHPMA]2902
Failure Code [DXHPMB]2904
Troubleshooting of Electrical System (E-Mode)2906
E-1 Engine Does Not Start (Engine Does Not Crank)2906
E-2 Manual Preheating System Does Not Operate2915
E-3 Automatic Preheating System Does Not Operate2918
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On2921
E-5 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing2923
E-6 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing (For Machines to Which Emergency Engine Stop Switch is Installed)2926
E-7 LCD Unit on Machine Monitor Displays Nothing2929
E-8 Backlight of LCD Unit on Machine Monitor is Abnormal, (Backlight Goes Out or Flickers)2931
E-9 LCD on Machine Monitor Does Not Show Correctly2933
E-10 Meter Unit Display on Machine Monitor is Abnormal2935
E-11 Night Lighting Lamp of Meter Unit on Machine Monitor is Abnormal2938
E-12 LED Unit Lamp on Machine Monitor is Abnormal2941
E-13 Night Lighting Lamp of Switch Panel on Machine Monitor is Abnormal or Switch Does Not Operate Correctly2943
E-14 2 Switches Operation of Switch Panel on Machine Monitor Does Not Function2946
E-15 Switch Panel Buzzer of Machine Monitor is Abnormal2949
E-16 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly2952
E-17 Rearview Monitor Does Not Come On or Backlight Flickers2953
E-18 Rearview Monitor Images are Not Shown Clearly2956
E-19 Rearview Monitor Brightness Cannot be Adjusted2959
E-20 Night Lighting Lamp of Rearview Monitor is Abnormal2962
E-21 Air Cleaner Clogging Indicator Lamp Does Not Come On2964
E-22 Radiator Coolant Level Caution Lamp Does Not Come On2966
E-23 Parking Brake Indicator Lamp Does Not Light When the Parking Brake is Set to ON (Parking) Position2968
E-24 When Front Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On2972
E-25 When Rear Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On2974
E-26 Fuel Level Gauge Does Not Show Correct Level2976
E-27 Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On2978
E-28 Indication of Hydraulic Oil Temperature Gauge Does Not Increase, or Hydraulic Oil Temperature Caution Lamp Does Not Light2979
E-29 Seat Belt Caution Lamp Indication is Abnormal2981
E-30 Alarm Buzzer Does Not Sound2982
E-31 Alarm Buzzer Does Not Stop2984
E-32 Kickdown Does Not Work When Kickdown Switch is Turned ON2985
E-33 Hold Switch Does Not Work When It is Pushed2987
E-34 Brake Does Not Work When Parking Brake is Applied or Brake Drags in Forward or Reverse Travel When Parking Brake is Released2989
E-35 Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated2993
E-36 Flow of Loader Pump Does Not Increase from the Minimum Rate2995
E-37 ECSS Function Cannot be Selected or Cannot be Released2996
E-38 Horn Does Not Sound2998
E-39 Horn Does Not Stop3001
E-40 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light3003
E-41 Clearance Lamp and Tail Lamp Do Not Come On or Go Out3005
E-42 Both High and Low Beams of Headlamp Do Not Come On or Go Out3009
E-43 Low Beam of Headlamp Does Not Come On or Go Out3013
E-44 High Beam of Headlamp Does Not Come On or Go Out3015
E-45 Front Working Lamp Does Not Come On or Go Out3017
E-46 Rear Working Lamp Does Not Come On or Go Out3021
E-47 All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Out3025
E-48 Turn Signal Lamps Do Not Come On or Go Out3028
E-49 Hazard Lamp Does Not Come On or Go Out3032
E-50 Brake Lamp Does Not Light or Stays Lighted3034
E-51 Backup Lamp Does Not Come On or Does Not Go Out3037
E-52 Backup Buzzer Does Not Sound or Continues to Sound3039
E-53 Front Wiper Does Not Operate3041
E-54 Rear Wiper Does Not Operate3045
E-55 Fuel Feed Pump Does Not Operate or Stop Automatically3048
E-56 Window Washer Does Not Operate3053
E-57 KOMTRAX Plus System Does Not Operate Normally3056
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3057
Failure Mode and Cause Table3057
H-1 Machine Does Not Start3079
H-2 Lockup is Not Released3082
H-3 Torque Converter Lockup Clutch Does Not Engage3083
H-4 Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift3084
H-5 Large Shock is Made When Machine Moves Off or Gear is Shifted3087
H-6 Large Time Lag is Monitored When Machine Starts and Gear is Shifted3090
H-7 Oil Temperature of Torque Converter is High3093
H-8 Machine Does Not Turn (For Steering Wheel Spec)3095
H-9 Machine Does Not Turn (AJSS Specification)3097
H-10 Turning Response is Unsatisfactory (For Steering Wheel Spec)3099
H-11 Turning Response is Unsatisfactory (AJSS Specification)3101
H-12 Steering Wheel is Heavy to Operate3103
H-13 Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Spec)3104
H-14 Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification)3106
H-15 Turning Radius is Different Between Right and Left Turns3108
H-16 Wheel Brakes Do Not Work or are Weak3109
H-17 Wheel Brakes are Not Released or Drag3111
H-18 Parking Brake Does Not Work or It is Weak3112
H-19 Parking Brake is Not Released or Drags3113
H-20 Boom Does Not Rise3115
H-21 Boom Moves Slow or Boom Lacks Lifting Force3117
H-22 Rising Boom Slows Down at Some Height3119
H-23 Lift Cylinders Can Not Hold Bucket on Ground3120
H-24 Hydraulic Drift of Boom is Large3121
H-25 Boom Moves Up and Down During Operation3122
H-26 Bucket Does Not Tilt Back3123
H-27 Bucket Moves Slow or Lacks Tilt-Back Force3125
H-28 Bucket Decreases Speed During Tilt-Back Operation3127
H-29 Bucket Cylinder Does Not Hold Bucket on Ground3128
H-30 Hydraulic Drift of Bucket is Large3129
H-31 Bucket Tilts Back and Forth While You Carry Load (Work Equipment Valve in Hold)3130
H-32 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move3131
H-33 When Operating Work Equipment Engine Speed Drops Largely or Engine Stops3132
H-34 Large Shocks are Made When Work Equipment Starts to Move and Stops3133
H-35 When Some Work Equipment Stalls Hydraulically, Other Work Equipment Moves3135
H-36 ECSS (Travel Damper) Does Not Work and Machine Pitches and Bounces3136
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)3137
H-38 Unusual Noise is Heard from Around Fan3138
Troubleshooting of Engine (S-Mode)3139
Information Shown in Troubleshooting Table (S-Mode)3139
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position3140
S-2 Engine Cranks but No Exhaust Smoke Comes Out3141
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)3142
S-4 Engine Startability is Unsatisfactory3143
S-5 Engine Does Not Pick Up Smoothly3145
S-6 Engine Stops During Operation3147
S-7 Engine Runs Rough or is Not Stable3149
S-8 Engine Lacks Power3150
S-9 KDPF Becomes Clogged in a Short Time3152
S-10 Engine Oil Consumption is Excessive3154
S-11 Oil Becomes Dirty Quickly3155
S-12 Fuel Consumption is Excessive3156
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant3157
S-14 Oil Pressure Drops3158
S-15 Fuel Mixes Into Engine Oil3160
S-16 Water Mixes Into Engine Oil (Milky)3161
S-17 Coolant Temperature Increases Too High (Overheating)3162
S-18 Unusual Noise is Heard3163
S-19 Vibration is Excessive3164
S-20 Air Cannot be Bled from Fuel Circuit3165
S-21 Active Regeneration is Done Frequently3166
S-22 Active Regeneration Continues Long3168
S-23 White Smoke is Exhausted During Active Regeneration3169
S-24 DEF Consumption is Excessive3170
S-25 There is Unusual Smell (Irritating Odor)3172
S-26 Foreign Materials Enter DEF (DEF Increases)3173
50 Disassembly and Assembly3175
Table of Contents3176
Precautions Before Work3181
Abbreviation List3182
Related Information on Disassembly and Assembly3188
How to Read This Manual3188
Coating Materials List3189
Special Tool List3194
Sketches of Special Tools3211
Engine and Cooling System3219
Remove and Install Supply Pump Assembly3219
How to Remove Supply Pump Assembly3219
How to Install Supply Pump Assembly3231
Remove and Install Injector Assembly3244
How to Remove Injector Assembly3245
How to Install Injector Assembly3256
Remove and Install Fuel Doser Assembly3269
How to Remove Fuel Doser Assembly3269
How to Install Fuel Doser Assembly3270
Remove and Install Cylinder Head Assembly3273
How to Remove Cylinder Head Assembly3274
How to Install Cylinder Head Assembly3321
Remove and Install EGR Valve Assembly3378
How to Remove EGR Valve Assembly3378
How to Install EGR Valve Assembly3379
Remove and Install EGR Cooler Assembly3380
How to Remove EGR Cooler Assembly3380
How to Install EGR Cooler Assembly3389
Remove and Install Starter Assembly3398
How to Remove Starting Motor Assembly3398
How to Install Starting Motor Assembly3399
Remove and Install Alternator Belt3400
How to Remove Alternator Belt3400
How to Install Alternator Belt3401
Remove and Install Radiator Assembly3403
How to Remove Radiator Assembly3403
How to Install Radiator Assembly3405
Remove and Install Cooling Fan and Fan Motor Assembly3408
How to Remove Cooling Fan and Fan Motor Assembly3408
How to Install Cooling Fan and Fan Motor Assembly3409
Remove and Install Hydraulic Oil Cooler Assembly3412
How to Remove Hydraulic Oil Cooler Assembly3412
How to Install Hydraulic Oil Cooler Assembly3413
Remove and Install Aftercooler Assembly3415
How to Remove Aftercooler Assembly3415
How to Install Aftercooler Assembly3417
Remove and Install Power Train Oil Cooler Assembly3419
How to Remove Power Train Oil Cooler Assembly3419
How to Install Power Train Oil Cooler Assembly3421
Remove and Install Engine Assembly3424
How to Remove Engine Assembly3424
How to Install Engine Assembly3437
Remove and Install Engine Front Oil Seal3451
How to Remove Engine Front Oil Seal3451
How to Install Engine Front Oil Seal3454
Remove and Install Engine Rear Oil Seal3458
How to Remove Engine Rear Oil Seal3458
How to Install Engine Rear Oil Seal3459
Remove and Install Engine Hood Assembly3464
How to Remove Engine Hood Assembly3464
How to Install Engine Hood Assembly3466
Remove and Install Fuel Tank Assembly3469
How to Remove Fuel Tank Assembly3469
How to Install Fuel Tank Assembly3472
Remove and Install DEF Tank Assembly3475
How to Remove DEF Tank Assembly3475
How to Install DEF Tank Assembly3480
Remove and Install DEF Tank Sensor Flange Assembly3485
How to Remove DEF Tank Sensor Flange Assembly3485
How to Install DEF Tank Sensor Flange Assembly3490
Remove and Install DEF Tank Sensor3495
How to Remove DEF Tank Sensor3495
How to Install DEF Tank Sensor3495
Remove and Install DEF Tank Strainer3497
How to Remove DEF Tank Strainer3497
How to Install DEF Tank Strainer3497
Remove and Install KDPF Assembly3498
How to Remove KDPF Assembly3499
How to Install KDPF Assembly3501
Disassemble and Assemble KDPF Assembly3504
How to Disassemble KDPF Assembly3504
How to Assemble KDPF Assembly3509
Remove and Install SCR Assembly3515
How to Remove SCR Assembly3515
How to Install SCR Assembly3517
Remove and Install KDPF and SCR Assembly3520
How to Remove KDPF and SCR Assembly3520
How to Install KDPF and SCR Assembly3526
Remove and Install KCCV Assembly3531
How to Remove KCCV Assembly3531
How to Install KCCV Assembly3532
Remove and Install VGT Assembly3534
How to Remove VGT Assembly3534
How to Install VGT Assembly3538
Remove and Install DEF Mixing Tube3543
How to Remove DEF Mixing Tube3543
How to Install DEF Mixing Tube3546
Remove and Install DEF Injector3551
How to Remove DEF Injector3551
How to Install DEF Injector3554
Remove and Install DEF Pump3559
How to Remove DEF Pump3559
How to Install DEF Pump3562
Remove and Install DEF Hose3565
How to Remove DEF Hose3565
How to Install DEF Hose3574
Remove and Install Air Cleaner Assembly3584
How to Remove Air Cleaner Assembly3584
How to Install Air Cleaner Assembly3585
Remove and Install Air Conditioner Compressor Assembly3587
How to Remove Air Conditioner Compressor Assembly3587
How to Install Air Conditioner Compressor Assembly3588
Remove and Install Air Conditioner Condenser Assembly3590
How to Remove Air Conditioner Condenser Assembly3590
How to Install Air Conditioner Condenser Assembly3591
Power Train3593
Remove and Install Damper Assembly3593
How to Remove Damper Assembly3593
How to Install Damper Assembly3594
Disassemble and Assemble Damper Assembly3596
How to Disassemble Damper Assembly3596
How to Assemble Damper Assembly3598
Remove and Install Torque Converter and Transmission Assembly3601
How to Remove Torque Converter and Transmission Assembly3601
How to Install Torque Converter and Transmission Assembly3608
Disassemble and Assemble Torque Converter Assembly3615
How to Disassemble Torque Converter Assembly3616
How to Assemble Torque Converter Assembly3630
Disassemble and Assemble Transmission Assembly3650
How to Disassemble Transmission Assembly3651
How to Assemble Transmission Assembly3666
Disassemble and Assemble Transfer Assembly3687
How to Disassemble Transfer Assembly3687
How to Assemble Transfer Assembly3696
Remove and Install Parking Brake Assembly3709
How to Remove Parking Brake Assembly3709
How to Install Parking Brake Assembly3710
Disassemble and Assemble Parking Brake Assembly3712
How to Disassemble Parking Brake Assembly3712
How to Assemble Parking Brake Assembly3716
Remove and Install Front Axle Assembly3722
How to Remove Front Axle Assembly3722
How to Install Front Axle Assembly3724
Remove and Install Rear Axle Assembly3726
How to Remove Rear Axle Assembly3726
How to Install Rear Axle Assembly3728
Remove and Install Center Support Assembly3731
How to Remove Center Support Assembly3731
How to Install Center Support Assembly3732
Disassemble and Assemble Center Support Assembly3734
How to Disassemble Center Support Assembly3734
How to Assemble Center Support Assembly3735
Disassemble and Assemble Differential Assembly3738
How to Disassemble Differential Assembly3739
How to Assemble Differential Assembly3746
Disassemble and Assemble Final Drive Assembly3758
How to Disassemble Final Drive Assembly3758
How to Assemble Final Drive Assembly3761
Remove and Install Final Drive Carrier Assembly3767
How to Remove Final Drive Carrier Assembly3767
How to Install Final Drive Carrier Assembly3769
Disassemble and Assemble Final Drive Carrier Assembly3771
How to Disassemble Final Drive Carrier Assembly3771
How to Assemble Final Drive Carrier Assembly3771
Remove and Install Front Final Drive and Brake Assembly3773
How to Remove Front Final Drive and Brake Assembly3773
How to Install Front Final Drive and Brake Assembly3774
Steering System3776
Remove and Install Steering Valve Assembly3776
How to Remove Steering Valve Assembly3776
How to Install Steering Valve Assembly3777
Brake System3780
Disassemble and Assemble Brake Assembly3780
How to Disassemble Brake Assembly3780
How to Assemble Brake Assembly3783
Undercarriage and Frame3788
Remove and Install Center Hinge Pin3788
How to Remove Center Hinge Pin3789
How to Install Center Hinge Pin3792
Remove and Install Counterweight Assembly3798
How to Remove Counterweight Assembly3798
How to Install Counterweight Assembly3799
Hydraulic System3801
Remove and Install Hydraulic Tank Assembly3801
How to Remove Hydraulic Tank Assembly3801
How to Install Hydraulic Tank Assembly3804
Remove and Install Work Equipment Pump Assembly3808
How to Remove Work Equipment Pump Assembly3808
How to Install Work Equipment Pump Assembly3810
Remove and Install Power Train Pump Assembly3813
How to Remove Power Train Pump Assembly3813
How to Install Power Train Pump Assembly3815
Remove and Install Steering Pump and Cooling Fan Pump Assembly3817
How to Remove Steering Pump and Cooling Fan Pump Assembly3817
How to Install Steering Pump and Cooling Fan Pump Assembly3820
Remove and Install Control Valve Assembly3823
How to Remove Control Valve Assembly3823
How to Install Control Valve Assembly3826
Work Equipment3829
Remove and Install Work Equipment Assembly3829
How to Remove Work Equipment Assembly3829
How to Install Work Equipment Assembly3833
Disassemble and Assemble Hydraulic Cylinder Assembly3841
How to Disassemble Hydraulic Cylinder Assembly3842
How to Assemble Hydraulic Cylinder Assembly3844
CAB Related Parts3849
Remove and Install Operator Cab Assembly3849
How to Remove Operator Cab Assembly3849
How to Install Operator Cab Assembly3857
Remove and Install Operator Cab Glass (Adhered Glass)3866
How to Remove Operator Cab Glass (Adhered Glass)3866
How to Install Operator Cab Glass (Adhered Glass)3867
Remove and Install Floor Frame Assembly3876
How to Remove Floor Frame Assembly3876
How to Install Floor Frame Assembly3880
Remove and Install Air Conditioner Unit Assembly3884
How to Remove Air Conditioner Unit Assembly3884
How to Install Air Conditioner Unit Assembly3888
Remove and Install Operator Seat Assembly3892
How to Remove Operator Seat Assembly3892
How to Install Operator Seat Assembly3894
Remove and Install Switch Assembly of AJSS Lever3897
How to Remove Switch Assembly of AJSS Lever3897
How to Install Switch Assembly of AJSS Lever3899
Remove and Install Work Equipment Control Lever3903
How to Remove Work Equipment Control Lever3903
How to Install Work Equipment Control Lever3905
How to Remove and Install Seat Belt3908
How to Remove Seat Belt3908
How to Install Seatbelt3908
Electrical System3910
Remove and Install Engine Controller Assembly3910
How to Remove Engine Controller Assembly3910
How to Install Engine Controller Assembly3911
Remove and Install Work Equipment Controller Assembly3915
How to Remove Work Equipment Controller Assembly3915
How to Install Work Equipment Controller Assembly3916
Remove and Install Transmission Controller Assembly3919
How to Remove Transmission Controller Assembly3919
How to Install Transmission Controller Assembly3920
Remove and Install Monitor Controller Assembly3923
How to Remove Monitor Controller Assembly3923
How to Install Monitor Controller Assembly3924
Remove and Install Machine Monitor Assembly3927
How to Remove Machine Monitor Assembly3927
How to Install Machine Monitor Assembly3928
Remove and Install Mass Air Flow and Temperature Sensor3930
How to Remove Mass Air Flow and Temperature Sensor3930
How to Install Mass Air Flow and Temperature Sensor3930
Remove and Install KCCV Crankcase Pressure Sensor3931
How to Remove KCCV Crankcase Pressure Sensor3931
How to Install KCCV Crankcase Pressure Sensor3932
Remove and Install SCR Temperature Sensor3934
How to Remove SCR Temperature Sensor3934
How to Install SCR Temperature Sensor3936
Remove And Install KOMTRAX Plus Controller Assembly3938
How to Remove KOMTRAX Plus Controller Assembly3938
How to Install KOMTRAX Plus Controller Assembly3939
Remove and Install KOMTRAX Terminal Assembly3940
How to Remove KOMTRAX Terminal Assembly3940
How to Install KOMTRAX Terminal Assembly3940
Remove and Install Wireless LAN Unit Assembly3942
How to Remove Wireless LAN Unit Assembly3942
How to Install Wireless LAN Unit Assembly3943
60 Maintenance Standard3945
Table of Contents3946
Abbreviation List3947
Engine and Cooling System3953
Maintenance Standard for Engine Mount3953
Maintenance Standard for Damper3954
Maintenance Standard for Brake and Cooling Fan Pump3956
Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump3958
Maintenance Standard for Cooling Fan Motor3959
Power Train3962
Maintenance Standard for Drive Shaft3962
Maintenance Standard for Center Support3963
Maintenance Standard for Transmission Mount3965
Maintenance Standard for Torque Converter3966
Maintenance Standard for Lockup Clutch ECMV3972
Maintenance Standard for Modulation Clutch ECMV3973
Maintenance Standard for Transmission3974
Maintenance Standard for Transmission Control Valve3982
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd, 3rd, 4th Clutch ECMV3984
Maintenance Standard for Torque Converter Regulator Valve3985
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve3986
Maintenance Standard for Transmission Lubrication Relief Valve3989
Maintenance Standard for Front Axle3990
Maintenance Standard for Rear Axle3994
Maintenance Standard for Front Differential3998
Maintenance Standard for Rear Differential4002
Maintenance Standard for Final Drive4006
Steering System4008
Maintenance Standard for Steering Column4008
Maintenance Standard for Steering Pump4009
Maintenance Standard for Steering Valve4011
Maintenance Standard for Steering Cylinder4012
Maintenance Standard for Diverter Valve4014
Maintenance Standard for Secondary Steering Pump4015
Brake System4016
Maintenance Standard for Brake Valve4016
Maintenance Standard for Slack Adjuster4020
Maintenance Standard for Brake4021
Maintenance Standard for Parking Brake4023
Maintenance Standard for Parking Brake Solenoid Valve4025
Maintenance Standard for Brake Cooling Pump4026
Undercarriage and Frame4027
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin4027
Hydraulic System4032
Maintenance Standard for Hydraulic Tank4032
Maintenance Standard for Work Equipment Pump4033
Maintenance Standard for Power Train Charge Duplex Pump4036
Maintenance Standard for Control Valve4037
Work Equipment4050
Maintenance Standard for Work Equipment Linkage4050
Maintenance Standard for Bucket4054
Maintenance Standard for Lift Cylinder4056
Maintenance Standard for Bucket Cylinder4057
80 Appendix4059
Table of Contents4060
Precautions Before Work4062
Abbreviation List4063
Air Conditioner System4069
Precautions for Refrigerant4069
Air Conditioner Component4070
Specifications of Air Conditioner4072
Structure and Function of Refrigeration Cycle4073
Outline of Refrigeration Cycle4074
Component Parts of Air Conditioner System4076
Air Conditioner Unit4076
Configuration Diagram of Air Conditioner Unit4076
Function of Air Conditioner Unit4078
Component Parts of Air Conditioner Unit4080
Function of Evaporator as Air Conditioner Unit Component4081
Function of Heater Core as Air Conditioner Unit Component4081
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component4081
Function of Servo Motor as Air Conditioner Unit Component4081
Structure of Expansion Valve as Air Conditioner Unit Component4082
Function of Expansion Valve as Air Conditioner Unit Component4082
Operate Expansion Valve as Air Conditioner Unit Component4082
Function of Dual Pressure Switch4083
Air Conditioner Controller4084
Structure of Air Conditioner Controller4084
Compressor4085
Structure of Compressor4085
Specifications of Compressor4085
Function of Compressor4086
Condenser4087
Structure of Condenser4087
Specifications of Condenser4087
Function of Condenser4087
Air Conditioner Related Sensors4089
Structure of Sunlight Sensor4089
Function of Sunlight Sensor4089
Structure of Outside Temperature Sensor4089
Function of Outside Air Temperature Sensor4089
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4091
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4093
System Diagram of Air Conditioner4095
Input and Output Signals of Air Conditioner Controller4095
Function of Air Conditioner Controller4097
Locations of Air Conditioner Parts and Layout of Connectors4098
Examine Air Leakage (Duct)4102
How to Examine Air Leakage (Duct)4102
Examine Air Conditioner with Self-Diagnosis Function4104
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor4105
Examine Vent (Mode) Changeover4106
How to Examine Vent (Mode) Changeover4106
Examine Fresh/Recirc Air Changeover4107
How to Examine Fresh/Recirc Air Changeover4107
Examine Sunlight Sensor4108
How to Examine Sunlight Sensor4108
Examine Refrigerant (Dual) Pressure Switch4109
How to Examine Refrigerant (Dual) Pressure Switch4109
Examine Relay4110
How to Examine Relay4110
Air Conditioner Troubleshooting Chart 14111
Air Conditioner Troubleshooting Chart 24112
Information Shown in Troubleshooting Table4115
Failure Code [879AKA]4116
Failure Code [879AKB]4117
Failure Code [879BKA]4118
Failure Code [879BKB]4120
Failure Code [879CKA]4122
Failure Code [879CKB]4123
Failure Code [879DKZ]4124
Failure Code [879EMC]4126
Failure Code [879FMC]4127
Failure Code [879GKX]4128
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4130
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4132
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4135
A-4 Troubleshooting for Fresh/Recirc Air Changeover4137
Troubleshooting by Gauge Pressure4139
Connect Service Tool4141
How to Connect Service Tool4141
Precautions for Disconnection and Connection of Air Conditioner Piping4142
Handle Compressor Oil4144
How to Replace Desiccant4146
90 Circuit Diagrams4149
Table of Contents4150
Abbreviation List4151
Hydraulic Circuit Diagram4157
Symbols Used in Hydraulic Circuit Diagram4157
Hydraulic Circuit Diagram (For AJSS Spec)4161
Hydraulic Circuit Diagram (For Steering Wheel Spec)4163
Power Train Hydraulic Circuit Diagram4165
Electrical Circuit Diagram4167
Symbols Used in Electric Circuit Diagram4167
Electrical Circuit Diagram of Machine (1/8)4171
Electrical Circuit Diagram of Machine (2/8)4173
Electrical Circuit Diagram of Machine (3/8)4175
Electrical Circuit Diagram of Machine (4/8)4177
Electrical Circuit Diagram of Machine (5/8)4179
Electrical Circuit Diagram of Machine (6/8)4181
Electrical Circuit Diagram of Machine (7/8)4183
Electrical Circuit Diagram of Machine (8/8)4185
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (1/8)4187
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (2/8)4189
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (3/8)4191
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (4/8)4193
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (5/8)4195
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (6/8)4197
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (7/8)4199
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (8/8)4201
Electrical Circuit Diagram of Floor (For AJSS Spec) (1/7)4203
Electrical Circuit Diagram of Floor (For AJSS Spec) (2/7)4205
Electrical Circuit Diagram of Floor (For AJSS Spec) (3/7)4207
Electrical Circuit Diagram of Floor (For AJSS Spec) (4/7)4209
Electrical Circuit Diagram of Floor (For AJSS Spec) (5/7)4211
Electrical Circuit Diagram of Floor (For AJSS Spec) (6/7)4213
Electrical Circuit Diagram of Floor (For AJSS Spec) (7/7)4215
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (1/7)4217
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (2/7)4219
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (3/7)4221
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (4/7)4223
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (5/7)4225
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (6/7)4227
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (7/7)4229
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (1/7)4231
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (2/7)4233
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (3/7)4235
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (4/7)4237
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (5/7)4239
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (6/7)4241
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (7/7)4243
Electrical Circuit Diagram of Engine (1/2)4245
Electrical Circuit Diagram of Engine (2/2)4247
Index4249
S.M 29/12/24
