Komatsu WHEEL LOADER WA600-8E0 Shop Manual SEN06766-11 PDF
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Komatsu WHEEL LOADER WA600-8E0 Shop Manual SEN06766-11 – PDF DOWNLOAD
SERIAL NUMBERS 85001 and up
Description
Komatsu WHEEL LOADER WA600-8E0 Shop Manual SEN06766-11 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WHEEL LOADER WA600-8E0 Shop Manual SEN06766-11 – PDF DOWNLOAD
Language : English
Pages :4270
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WHEEL LOADER WA600-8E0 Shop Manual SEN06766-11 – PDF DOWNLOAD
SERIAL NUMBERS 85001 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 WA600-8E0 Shop Manual SEN06766-11 – PDF DOWNLOAD
SERIAL NUMBERS 85001 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: WA600-8E0 105
Specifications 107
Specifications: WA600-8E0 107
Weight Table 112
Weight Table: WA600-8E0 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 146
DEF Mixing Tube 146
SCR Assembly 147
DEF Tank 149
DEF Pump 152
DEF Injector 153
DEF Hose 154
DEF Tank Heating Valve 155
Boot-up System 156
Layout Drawing of Boot-up System 156
Layout Drawing of Boot-up System (For Emergency Engine Stop Switch Spec) 158
System Operating Lamp System 160
System Diagram of System Operating Lamp System 160
Function of Operation Lamp System 160
Battery Disconnect Switch 162
Layout Drawing of Battery Disconnect Switch 162
Function of Battery Disconnect Switch 162
Preheating System 164
System Diagram of Preheating System 164
Function of Automatic Preheating System 164
Operation of Automatic Preheating System 165
Function of Manual Preheating System 165
Operation of Manual Preheating System 165
Engine Shutdown Secondary Switch 166
Layout Drawing of Engine Shutdown Secondary Switch 166
Function of Engine Shutdown Secondary Switch 166
Operation of Engine Shutdown Secondary Switch 167
Engine System 168
Layout Drawing of Engine System 168
Function of Engine System 169
Engine Control System 170
System Diagram of Engine Control 170
Function of Engine Control System 171
Operation of Engine Control System 172
Engine Power Mode Selector System 174
Engine Power Mode Selector System Diagram 174
Function of Engine Power Mode Selector System 174
Operation of Engine Power Mode Selector System 174
Automatic Idle Stop System 175
Function of Automatic Idle Stop System 175
RPM Set 176
Function of RPM Set 176
Component Parts of Engine System 178
Damper 178
VGT 180
EGR System 184
EGR Valve 187
EGR Cooler 189
KCCV System 190
KCCV Ventilator 192
KDPF 194
Cooling System 198
Layout Drawing of Cooling System 198
Specifications of Cooling System 199
Cooling Fan Control System 201
System Diagram of Cooling Fan Control System 201
Function of Cooling Fan Control System 201
Component Parts of Cooling System 205
Brake and Cooling Fan Pump 205
Cooling Fan Motor 215
Control System 223
Layout Drawing of Control System 223
Machine Monitor System 225
System Diagram of Machine Monitor System 225
Function of Machine Monitor System 225
Rearview Monitor System 227
System Diagram of Rearview Monitor System 227
Function of Rearview Monitor System 227
KOMTRAX Plus System 228
System Diagram of KOMTRAX Plus System 228
Function of KOMTRAX Plus System 228
Load Meter System 230
System Diagram of Load Meter 230
Function of Load Meter System 230
Component Parts of Control System 236
Machine Monitor 236
Switch Panel 255
Rearview Monitor 256
Rearview Camera 258
KOMTRAX Terminal 259
KOMTRAX Plus Controller 261
Wireless LAN Unit 266
Transmission Controller 267
Work Equipment Controller 272
Monitor Controller 277
Engine Controller 282
CAN Terminating Resistor 296
Accelerator Pedal 297
Fuel Feed Pump 299
Fuel Feed Pump Switch 300
Hydraulic System 302
Layout Drawing of Hydraulic System 302
CLSS 303
Structure of CLSS 303
Function of CLSS 304
Work Equipment Pump Control System 307
Swash Plate Control Function of Work Equipment Pump 307
Pickup Assistance Control Function When Engine Speed is Low 307
Component Parts of Hydraulic System 309
Hydraulic Tank 309
Work Equipment Pump 312
Steering Pump 331
Power Train Charge Duplex Pump 344
Control Valve 345
Power Train System 381
Layout Drawing of Power Train System 381
Operation of Power Train System 385
Transmission Control System 386
Transmission Control System Diagram 386
Transmission Gear Shift Control System 390
Electric Modulation Function System Diagram 390
Electric Modulation Function 391
Gear Shift Display Function 391
Automatic Gear Shift Function 391
Shift Hold Function 392
Kickdown Function 393
Automatic Kickdown Function 393
Torque Converter Lockup Function 394
Hunting Prevention Function 394
Transmission Initial Learning and ECMV Current Adjustment Function 394
Shift Point Changing Function 395
4th Gear Speed Limitation Function 395
Transmission Protection Function 396
Protection Function When Travel Direction is Changed 396
Shift Down Protection Function 396
Engine Overrun Prevention Function 397
Neutralizer Function 397
Modulation Clutch Control Function 398
Maximum Speed Limitation Function During Lockup 400
Component Parts of Power Train System 401
Drive Shaft 401
Torque Converter 404
Lockup Clutch ECMV 414
Modulation Clutch ECMV 417
Transmission 420
Transmission Control Valve 437
Forward and Reverse Clutch ECMV and 1st, 2nd, 3rd, 4th Clutch ECMV 440
Transfer 445
Torque Converter Regulator Valve 446
Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve 448
Transmission Lubrication Relief Valve 454
Axle 455
Differential 460
Final Drive 465
AJSS Knob 467
Combination Switch 468
Shift Hold Switch 472
Kickdown Switch 473
Work Equipment System 474
Layout Drawing of Work Equipment System 474
Work Equipment System Diagram 476
Work Equipment Control System 478
Work Equipment Speed Pattern Control Function by Work Equipment Lever Stroke 478
Work Equipment Lever Detent Position and Work Equipment Startup Current Control Function 479
Work Equipment Lever Operating Function System Diagram 480
Work Equipment Lever Operation Function 480
Bucket Priority Control Function 481
Boom Stop Modulation Function 481
Work Equipment Shock Reduction Function 482
Sub Total Switch Interlock Horn Function 485
Work Equipment Neutral Lock System 486
Work Equipment Neutral Lock System Diagram 486
Function of Work Equipment Neutral Lock System 486
Remote Positioner System 488
Remote Bucket Positioner System Diagram 488
Function of Remote Bucket Positioner System 488
Remote Boom Positioner System Diagram 489
Function of Remote Boom Positioner System 489
Bucket Positioner and Boom Positioner 493
Structure of Bucket Positioner and Boom Positioner 493
Auto-Digging System 494
Auto-Digging System Diagram 494
Function of Auto-Digging System 494
ECSS 496
ECSS Diagram 496
Function of ECSS 496
Operation of ECSS 496
Component Parts of Work Equipment System 498
Work Equipment Lock Solenoid Valve 498
Pilot Circuit Accumulator 499
ECSS Circuit Accumulator 500
Work Equipment Electric Lever 501
Steering System 504
Layout Drawing of Steering System 504
AJSS 506
Layout Drawing of AJSS 506
AJSS System Diagram 507
Function of AJSS 508
Neutralizer Function of AJSS 509
AJSS Neutral Interlock Function 510
AJSS Speed Sensing Steering Function 511
AJSS Turn Signal Pilot Lamp Control Function 512
Steering Column 514
Structure of Steering Column 514
Component Parts of Steering System 515
AJSS EPC Valve 515
Steering Lock Valve 516
Rotary Valve 517
Steering Unit 520
Stop Valve 524
Steering Valve 525
2-Way Restrictor Valve 537
Diverter Valve 539
Secondary Steering Relief Valve 545
Secondary Steering Pump 546
Brake System 547
Layout Drawing of Brake System 547
Parking Brake Control System 550
System Diagram of Parking Brake Control System 550
Operation of Parking Brake Control System 550
Component Parts of Brake System 552
Charge Valve 552
Parking Brake Solenoid Valve 557
Parking Brake Emergency Release Valve 559
Brake Circuit Accumulator 560
Brake Valve 561
Slack Adjuster 567
Brake 569
Parking Brake 571
Brake Cooling Pump 573
Undercarriage and Frame 574
Frame, Axle Mount and Center Hinge Pin 574
Structure of Frame, Axle Mount and Center Hinge Pin 574
Function of Frame, Axle Mount and Center Hinge Pin 576
Tires 577
Features of Radial Tire When Compared with Bias Tire 577
Structure of Radial Tire 577
Function of Radial Tire 578
Structure of Bias Tire 578
Function of Bias Tire 578
Work Equipment 579
Structure of Work Equipment 579
Structure of Bucket 580
Structure of Lubrication System for Work Equipment 581
CAB Related Parts 583
ROPS CAB 583
Structure of ROPS CAB 583
Function of ROPS CAB 584
20 Standard Value Table 585
Table of Contents 586
Abbreviation List 587
Standard Value Table for Engine 593
Standard Value Table for Engine: WA600-8E0 593
Standard Value Table for Machine 596
Standard Value Table for Machine: WA600-8E0 596
Machine Posture and Procedures to Measure Performance 614
30 Testing and Adjusting 617
Table of Contents 618
Precautions Before Work 622
Abbreviation List 623
Related Information on Testing and Adjusting 629
Tools for Testing and Adjusting 629
Sketch of Tools for Testing and Adjusting 641
Engine and Cooling System 642
Examine Engine Speed 642
How to Examine Engine Speed 642
Examine Boost Pressure 646
How to Examine Boost Pressure on Machine Monitor 646
How to Examine Boost Pressure by Testing Tool 647
Examine Exhaust Gas Temperature 650
How to Examine Exhaust Gas Temperature 650
Examine Exhaust Gas Color 652
How to Examine Exhaust Gas Color with the Handy Smoke Checker 652
How to Examine Exhaust Gas Color with Smoke Meter 653
Examine Mass Air Flow and Temperature Sensor 655
How to Examine Mass Air Flow and Temperature Sensor 655
Examine and Adjust Valve Clearance 658
How to Examine Valve Clearance 658
How to Adjust Valve Clearance 659
Examine Compression Pressure 661
How to Examine Compression Pressure 661
Examine Blowby Pressure 665
How to Examine Blowby Pressure 665
Examine Engine Oil Pressure 668
How to Examine Engine Oil Pressure on Machine Monitor 668
How to Examine Engine Oil Pressure by Testing Tool 669
Examine EGR Valve and VGT Oil Pressure 671
How to Examine EGR Valve and VGT Oil Pressure 671
Examine Fuel Pressure 673
How to Examine Fuel Pressure 673
Examine Fuel Return Rate and Leakage 675
How to Examine Fuel Return Rate and Leakage 676
Bleed Air from Fuel System 679
How to Bleed Air from Fuel System 679
Examine Fuel Circuit for Leakage 681
How to Examine Fuel System for Leakage 681
Examine Supply Pump 683
How to Examine Supply Pump 683
Handle Cylinder Cut-out Mode Operation 686
Handle No-Injection Cranking Operation 687
Examine KDPF, SCR and Muffler Stack for Looseness and Damage 688
How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage 688
Examine Installed Condition of Cylinder Heads and Manifolds 689
How to Examine Installed Condition of Cylinder Heads and Manifolds 689
Examine Engine Piping for Damage and Looseness 690
How to Examine Engine Piping for Damage and Looseness 690
Clean Fuel Doser 691
How to Clean Fuel Doser 691
Write Injector Compensation Value to Engine Controller 693
How to Write Injector Compensation Value 693
Write Correction for Ash in Soot Accumulation to Engine Controller 700
How to Write Correction for Ash in Soot Accumulation to Engine Controller 700
Examine SCR Related Functions 701
Examine DEF Pump Raised Pressure 705
Examine Injection Volume from DEF Injector 712
Examine DEF Line Heater Relay 1 721
Examine DEF Line Heater Relay 2 729
Examine DEF Pump Heater Relay 736
Examine DEF Tank Heater Valve 743
Examine SCR Denitration Efficiency 747
Clean DEF Tank 752
How to Clean DEF Tank 752
Bleed Air from Coolant Circuit of DEF Tank 757
How to Bleed Air from Coolant Circuit of DEF Tank 757
Clean DEF Pump 759
How to Clean DEF Pump 759
Bleed Air from Engine Coolant Circuit 766
How to Bleed Air from Engine Coolant Circuit 766
Power Train 768
Examine and Adjust Power Train Oil Pressure 768
How to Examine Power Train Oil Pressure 770
How to Adjust Power Train Oil Pressure 783
Adjust Modulation Clutch Rotation Sensor 785
How to Adjust Modulation Clutch Rotation Sensor 785
Adjust Transmission Output Shaft Speed Sensor 786
How to Adjust Transmission Output Shaft Speed Sensor 786
Flush Torque Converter and Transmission Hydraulic Circuit 788
How to Flush Torque Converter and Transmission Hydraulic Circuit 788
Move Disabled Machine Due to Transmission Valve Failure 791
How to Move Disabled Machine Due to Transmission Valve Failure 791
Examine Drive Shaft for Looseness, Backlash, and Damage 794
How to Examine Drive Shaft for Looseness, Backlash, and Damage 794
Steering System 795
Examine Steering Wheel (For Steering Wheel Spec) 795
How to Examine Steering Wheel 795
Examine and Adjust Steering Circuit Oil Pressure 797
How to Examine Steering Circuit Oil Pressure 797
How to Adjust Steering Circuit Oil Pressure 801
Bleed Air from Steering Cylinder Circuit 802
How to Bleed Air from Steering Cylinder Circuit 802
Examine and Adjust Steering Stop Valve (For Steering Wheel Spec) 803
How to Examine Steering Stop Valve 803
How to Adjust Steering Stop Valve 803
Brake System 805
Release Remained Pressure in Brake Accumulator Circuit 805
How to Release Remained Pressure in Brake Accumulator Circuit 805
Examine Wheel Brake Oil Pressure 806
How to Examine Wheel Brake Oil Pressure 806
Examine and Adjust Brake Accumulator Charge Pressure 808
How to Examine Brake Accumulator Charge Pressure on Machine Monitor 808
How to Examine Brake Accumulator Charge Pressure by Testing Tool 809
How to Adjust Brake Accumulator Charge Pressure 810
Examine Nitrogen Gas Pressure in Brake Accumulator and Charge Gas 812
How to Examine Accumulator Nitrogen Gas Pressure for Brake 812
How to Charge Accumulator Nitrogen Gas for Brake 816
How to Release Nitrogen Gas When You Discard Accumulator 820
Bleed Air from Brake Circuit 821
How to Bleed Air from Brake Circuit 821
Examine Brake Performance 822
How to Examine Brake Performance 822
Examine Brake Pedal 823
How to Examine Brake Pedal 823
Adjust Right Brake Pedal Switch 824
How to Adjust Right Brake Pedal Switch 824
Examine Wear of Wheel Brake Disc 826
How to Examine Wear of Wheel Brake Disc 826
Examine Parking Brake Oil Pressure 828
How to Examine Parking Brake Oil Pressure 828
Examine Parking Brake Performance 832
How to Examine Parking Brake Performance 832
Release Parking Brake Manually 833
How to Release Parking Brake Manually 833
Examine Wear Volume of Parking Brake Disc 835
How to Examine Wear Quantity of Parking Brake Disc 835
Hydraulic System 837
Release Remained Pressure from Work Equipment Circuit 837
How to Release Remained Pressure from Work Equipment Circuit 837
Examine and Adjust Work Equipment Oil Pressure 839
How to Examine Work Equipment Oil Pressure 839
How to Adjust Work Equipment Oil Pressure 844
Examine and Adjust Work Equipment EPC Oil Pressure 846
How to Examine Work Equipment EPC Oil Pressure 846
How to Adjust Work Equipment EPC Oil Pressure 848
Bleed Air from Work Equipment Circuit 849
How to Bleed Air from Work Equipment Circuit 849
Examine Cooling Fan Speed 850
How to Examine Cooling Fan Speed 850
Examine Cooling Fan Circuit Oil Pressure 852
How to Examine Cooling Fan Circuit Oil Pressure 852
Bleed Air from Cooling Fan Circuit 854
How to Bleed Air from Cooling Fan Circuit 854
Examine ECSS Accumulator Charge Pressure 856
How to Examine ECSS Accumulator Charge Pressure 856
Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas 858
How to Examine ECSS Accumulator Nitrogen Gas Pressure 858
How to Charge ECSS Accumulator with Nitrogen Gas 860
Work Equipment 864
Examine and Adjust Bucket Potentiometer Lever 864
How to Examine Bucket Potentiometer Lever 864
How to Adjust Bucket Potentiometer Lever 864
Examine and Adjust Boom Potentiometer Lever 866
How to Examine Boom Potentiometer Lever 866
How to Adjust Boom Potentiometer Lever 866
CAB Related Parts 868
Examine Directional Lever (For Steering Wheel Spec) 868
How to Examine Directional Lever 868
Examine Work Equipment Control Lever 869
How to Examine Work Equipment Control Lever 869
Examine AJSS Lever (For AJSS Spec) 871
How to Examine AJSS Lever 871
Examine and Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor (AJSS Specifications) 874
How to Examine AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 874
How to Adjust AJSS Lever Angle Sensor and AJSS Frame Angle Sensor 874
Examine and Adjust Steering Stopper Bolt (For AJSS Spec) 876
How to Examine Steering Stopper Bolt 876
How to Adjust Steering Stopper Bolt 876
Adjust Play of Operator Seat 878
How to Adjust Play of Operator Seat 878
Adjust Door Lock Link 879
How to Adjust Door Lock Link 879
Electrical System 882
Set and Adjust Each Equipment 882
Set and Operate Machine Monitor 887
Operator Mode 891
Function to Show Technician Identification Status Screen 891
Function to Show Operator Identification Input Screen 891
Examine Function by LCD (Liquid Crystal Display) 892
Examine Function of Service Meter and Odometer 893
How to Set Usage Limitation and Change Maintenance Password 893
Service Mode 897
How to Operate Service Mode 897
How to See Pre-defined Monitoring Information 901
How to Examine Self-Define Monitor Information 910
Abnormality Record Menu 928
How to See Maintenance Record 933
Maintenance Mode Setting 935
How to Set Phone Number Entry 940
Default Menu 942
Diagnostic Tests Menu 958
Adjustment Menu 972
No-Injection Cranking Operation1012
KOMTRAX Settings Menu1015
How to Show Service Message1017
How to Operate Snap Shot1019
How to Start Up KOMTRAX Terminal1021
Default Setting of KOMTRAX Plus Controller1026
How to do the Default Setting of KOMTRAX Plus Controller1026
Default Setting of Wireless LAN Modem1029
Default Setting of Wireless LAN Modem1029
How to Examine Wireless LAN Modem Communication1030
Download Data from KOMTRAX Plus Controller1032
How to Download Data from KOMTRAX Plus Controller1032
Adjust After Replacement of KOMTRAX Plus Controller1036
How to Adjust After Replacement of KOMTRAX Plus Controller1036
Adjust After Replacement of Wireless LAN Modem1039
How to Adjust After Replacement of Wireless LAN Modem1039
Adjust Rearview Camera Angle1042
How to Adjust Rearview Camera Angle1042
Handle Voltage Circuit of Engine Controller1043
Handle Battery Disconnect Switch1044
Examine Diodes1045
How to Examine Diodes by Digital Tester1045
How to Examine Diodes by Analog Tester1045
Pm Clinic1046
Pm Clinic Service1046
Pm Clinic Check Sheet: WA600-8E01049
Perform Quick Pm1060
How to Perform Quick Pm1060
40 Troubleshooting1063
Table of Contents1064
Precautions Before Work1080
Abbreviation List1081
Related Information to Troubleshooting1087
General Troubleshooting Points1087
Troubleshooting Points for Urea SCR System1088
Sequence of Events in Troubleshooting1103
Checks Before Troubleshooting1105
Inspection Procedure Before Troubleshooting1107
Walk-Around Check1107
Test in Accordance with Testing Procedure1109
Examine Fuel Level and Type1109
Examine for Impure Ingredient in Fuel1109
Examine DEF Level and Type1110
Examine Fuel Prefilter1110
Examine Fuel Main Filter1112
Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type1114
Examine Coolant Level (Reservoir Tank)1116
Examine Air Cleaner Clogging1117
Clean Outer Element1118
Replace Element1120
Examine Hydraulic Oil Level1122
Examine Hydraulic Oil Strainer1123
Examine Hydraulic Oil Filter1124
Examine Oil Level in Transmission Case1125
Examine Oil Level in Axle Case1126
Bleed Air from Fuel System1127
Bleed Air from Hydraulic System1127
How to Examine Electric Equipment1127
Preparation for Troubleshooting of Electrical System1135
Procedure for Troubleshooting1145
Symptom and Troubleshooting Numbers1147
Information Shown in Troubleshooting Table1151
Connector List and Layout1153
Connector Contact Connection Table1184
T-Branch Box and T-Branch Adapter Table1224
Fuse Location Table1230
Precautions When You Clean and Replace KDPF (KCSF and KDOC)1233
Prepare Troubleshoot Machine Monitor1237
Procedure to Make Harness Checker on Machine Monitor LCD Unit1239
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135])1245
Failure Code Table1247
Troubleshooting by Failure Code (Display of Code)1278
Failure Code [1500L0]1278
Failure Code [15SAL1]1279
Failure Code [15SALH]1281
Failure Code [15SBL1]1283
Failure Code [15SBLH]1285
Failure Code [15SEL1]1287
Failure Code [15SELH]1289
Failure Code [15SFL1]1291
Failure Code [15SFLH]1293
Failure Code [15SGL1]1295
Failure Code [15SGLH]1297
Failure Code [15SHL1]1299
Failure Code [15SHLH]1301
Failure Code [15W0NT]1303
Failure Code [2F00MA]1304
Failure Code [2F00MB]1308
Failure Code [2G42ZG]1311
Failure Code [2G43ZG]1313
Failure Code [879AKA]1315
Failure Code [879AKB]1316
Failure Code [879BKA]1317
Failure Code [879BKB]1319
Failure Code [879CKA]1321
Failure Code [879CKB]1322
Failure Code [879DKZ]1323
Failure Code [879EMC]1325
Failure Code [879FMC]1326
Failure Code [879GKX]1327
Failure Code [989A00]1329
Failure Code [989L00]1330
Failure Code [989M00]1331
Failure Code [989N00]1332
Failure Code [A1U0N3]1333
Failure Code [A1U0N4]1335
Failure Code [AA10NX]1337
Failure Code [AB00KE]1339
Failure Code [AB00KY]1341
Failure Code [AQ00N3]1343
Failure Code [AQ00N4]1344
Failure Code [AQ10N3]1345
Failure Code [AS00N3]1347
Failure Code [AS00R2]1349
Failure Code [AS00R3]1350
Failure Code [AS00R4]1351
Failure Code [AS00R5]1352
Failure Code [AS00R6]1353
Failure Code [AS00ZK]1354
Failure Code [AS10NR]1355
Failure Code [B@BAZG]1356
Failure Code [B@BAZK]1357
Failure Code [B@BCNS]1359
Failure Code [B@BCQA]1360
Failure Code [B@BCZK]1362
Failure Code [B@C7NS]1364
Failure Code [B@CENS]1366
Failure Code [B@GAZK]1367
Failure Code [B@HANS]1368
Failure Code [CA115]1369
Failure Code [CA122]1373
Failure Code [CA123]1375
Failure Code [CA131]1377
Failure Code [CA132]1379
Failure Code [CA135]1381
Failure Code [CA141]1383
Failure Code [CA144]1385
Failure Code [CA145]1387
Failure Code [CA153]1389
Failure Code [CA154]1392
Failure Code [CA187]1394
Failure Code [CA212]1396
Failure Code [CA213]1398
Failure Code [CA221]1400
Failure Code [CA222]1402
Failure Code [CA227]1404
Failure Code [CA234]1406
Failure Code [CA238]1407
Failure Code [CA239]1409
Failure Code [CA249]1411
Failure Code [CA256]1413
Failure Code [CA271]1415
Failure Code [CA272]1417
Failure Code [CA273]1418
Failure Code [CA274]1420
Failure Code [CA322]1421
Failure Code [CA323]1423
Failure Code [CA324]1425
Failure Code [CA325]1427
Failure Code [CA331]1429
Failure Code [CA332]1431
Failure Code [CA343]1433
Failure Code [CA351]1435
Failure Code [CA352]1437
Failure Code [CA356]1439
Failure Code [CA357]1441
Failure Code [CA386]1443
Failure Code [CA431]1445
Failure Code [CA432]1448
Failure Code [CA441]1451
Failure Code [CA442]1453
Failure Code [CA449]1455
Failure Code [CA451]1456
Failure Code [CA452]1458
Failure Code [CA515]1460
Failure Code [CA516]1462
Failure Code [CA553]1464
Failure Code [CA555]1465
Failure Code [CA556]1467
Failure Code [CA559]1469
Failure Code [CA595]1475
Failure Code [CA687]1477
Failure Code [CA689]1479
Failure Code [CA691]1481
Failure Code [CA692]1483
Failure Code [CA697]1485
Failure Code [CA698]1486
Failure Code [CA731]1487
Failure Code [CA778]1491
Failure Code [CA1117]1494
Failure Code [CA1135]1496
Failure Code [CA1257]1498
Failure Code [CA1664]1499
Failure Code [CA1669]1503
Failure Code [CA1673]1504
Failure Code [CA1677]1505
Failure Code [CA1678]1506
Failure Code [CA1682]1507
Failure Code [CA1683]1512
Failure Code [CA1684]1514
Failure Code [CA1686]1516
Failure Code [CA1691]1517
Failure Code [CA1694]1519
Failure Code [CA1695]1521
Failure Code [CA1696]1523
Failure Code [CA1712]1525
Failure Code [CA1713]1528
Failure Code [CA1714]1530
Failure Code [CA1715]1531
Failure Code [CA1776]1532
Failure Code [CA1777]1535
Failure Code [CA1843]1538
Failure Code [CA1844]1540
Failure Code [CA1879]1542
Failure Code [CA1881]1544
Failure Code [CA1883]1546
Failure Code [CA1885]1550
Failure Code [CA1887]1552
Failure Code [CA1921]1554
Failure Code [CA1922]1557
Failure Code [CA1923]1562
Failure Code [CA1924]1564
Failure Code [CA1925]1569
Failure Code [CA1927]1573
Failure Code [CA1928]1575
Failure Code [CA1942]1577
Failure Code [CA1963]1579
Failure Code [CA1977]1586
Failure Code [CA1993]1588
Failure Code [CA2185]1591
Failure Code [CA2186]1593
Failure Code [CA2249]1595
Failure Code [CA2265]1600
Failure Code [CA2266]1602
Failure Code [CA2271]1604
Failure Code [CA2272]1606
Failure Code [CA2349]1608
Failure Code [CA2353]1610
Failure Code [CA2357]1612
Failure Code [CA2381]1615
Failure Code [CA2382]1617
Failure Code [CA2383]1619
Failure Code [CA2386]1621
Failure Code [CA2387]1623
Troubleshooting Flowchart1627
Failure Code [CA2555]1628
Failure Code [CA2556]1630
Failure Code [CA2637]1632
Failure Code [CA2639]1634
Failure Code [CA2732]1637
Failure Code [CA2733]1639
Failure Code [CA2741]1641
Failure Code [CA2765]1645
Failure Code [CA2771]1646
Failure Code [CA2777]1652
Failure Code [CA2878]1655
Failure Code [CA2881]1661
Failure Code [CA2976]1667
Failure Code [CA3133]1669
Failure Code [CA3134]1671
Failure Code [CA3135]1673
Failure Code [CA3142]1677
Failure Code [CA3143]1678
Failure Code [CA3144]1679
Failure Code [CA3146]1682
Failure Code [CA3147]1683
Failure Code [CA3148]1684
Failure Code [CA3151]1687
Failure Code [CA3165]1692
Failure Code [CA3167]1694
Failure Code [CA3229]1700
Failure Code [CA3231]1703
Failure Code [CA3232]1706
Failure Code [CA3235]1711
Failure Code [CA3239]1713
Failure Code [CA3241]1716
Failure Code [CA3242]1719
Failure Code [CA3251]1722
Failure Code [CA3253]1725
Failure Code [CA3254]1730
Failure Code [CA3255]1734
Failure Code [CA3256]1737
Failure Code [CA3311]1740
Failure Code [CA3312]1743
Failure Code [CA3313]1746
Failure Code [CA3314]1747
Failure Code [CA3315]1748
Failure Code [CA3316]1752
Failure Code [CA3317]1753
Failure Code [CA3318]1754
Failure Code [CA3319]1758
Failure Code [CA3321]1759
Failure Code [CA3322]1760
Failure Code [CA3419]1764
Failure Code [CA3421]1766
Failure Code [CA3497]1768
Failure Code [CA3498]1769
Failure Code [CA3543]1770
Failure Code [CA3545]1775
Failure Code [CA3547]1777
Failure Code [CA3558]1778
Failure Code [CA3559]1780
Failure Code [CA3562]1782
Failure Code [CA3563]1784
Failure Code [CA3567]1787
Failure Code [CA3568]1791
Failure Code [CA3571]1798
Failure Code [CA3572]1800
Failure Code [CA3574]1802
Failure Code [CA3575]1805
Failure Code [CA3577]1806
Failure Code [CA3578]1808
Failure Code [CA3582]1810
Failure Code [CA3583]1818
Failure Code [CA3596]1820
Failure Code [CA3649]1824
Failure Code [CA3681]1827
Failure Code [CA3682]1832
Failure Code [CA3713]1838
Failure Code [CA3717]1841
Failure Code [CA3718]1842
Failure Code [CA3725]1843
Failure Code [CA3748]1846
Failure Code [CA3751]1848
Failure Code [CA3755]1850
Failure Code [CA3866]1852
Failure Code [CA3867]1856
Failure Code [CA3868]1859
Failure Code [CA3899]1863
Failure Code [CA3911]1865
Failure Code [CA3912]1869
Failure Code [CA3932]1871
Failure Code [CA3933]1873
Failure Code [CA3934]1875
Failure Code [CA3935]1878
Failure Code [CA3936]1880
Failure Code [CA4151]1882
Failure Code [CA4152]1886
Failure Code [CA4155]1890
Failure Code [CA4156]1893
Failure Code [CA4157]1896
Failure Code [CA4158]1898
Failure Code [CA4159]1899
Failure Code [CA4161]1900
Failure Code [CA4162]1903
Failure Code [CA4163]1906
Failure Code [CA4164]1908
Failure Code [CA4165]1911
Failure Code [CA4166]1914
Failure Code [CA4168]1916
Failure Code [CA4169]1920
Failure Code [CA4171]1925
Failure Code [CA4249]1930
Failure Code [CA4251]1934
Failure Code [CA4259]1937
Failure Code [CA4261]1941
Failure Code [CA4277]1944
Failure Code [CA4281]1947
Failure Code [CA4459]1951
Failure Code [CA4461]1953
Failure Code [CA4658]1956
Failure Code [CA4731]1960
Failure Code [CA4732]1961
Failure Code [CA4739]1962
Failure Code [CA4768]1963
Failure Code [CA4769]1965
Failure Code [CA4842]1968
Failure Code [CA4952]1972
Failure Code [CA5115]1974
Failure Code [CA5179]1977
Failure Code [CA5181]1979
Failure Code [CA5383]1981
Failure Code [CB115]1983
Failure Code [CB187]1986
Failure Code [CB227]1988
Failure Code [CB238]1989
Failure Code [CB239]1991
Failure Code [CB271]1993
Failure Code [CB272]1995
Failure Code [CB273]1996
Failure Code [CB274]1998
Failure Code [CB343]1999
Failure Code [CB352]2001
Failure Code [CB386]2003
Failure Code [CB441]2005
Failure Code [CB442]2007
Failure Code [CB689]2009
Failure Code [CB697]2011
Failure Code [CB698]2012
Failure Code [CB731]2013
Failure Code [CB778]2016
Failure Code [CB1117]2018
Failure Code [CB1257]2020
Failure Code [CB1664]2021
Failure Code [CB1682]2024
Failure Code [CB1691]2029
Failure Code [CB1694]2031
Failure Code [CB1695]2033
Failure Code [CB1696]2035
Failure Code [CB1776]2037
Failure Code [CB1777]2040
Failure Code [CB1879]2043
Failure Code [CB1881]2045
Failure Code [CB1883]2047
Failure Code [CB1887]2052
Failure Code [CB1921]2054
Failure Code [CB1922]2057
Failure Code [CB1923]2062
Failure Code [CB1924]2064
Failure Code [CB1925]2069
Failure Code [CB1927]2073
Failure Code [CB1928]2075
Failure Code [CB1963]2077
Failure Code [CB1977]2084
Failure Code [CB1993]2086
Failure Code [CB2265]2089
Failure Code [CB2266]2091
Failure Code [CB2637]2093
Failure Code [CB2639]2095
Failure Code [CB2732]2098
Failure Code [CB2733]2100
Failure Code [CB2741]2102
Failure Code [CB2771]2106
Failure Code [CB2777]2112
Failure Code [CB2878]2115
Failure Code [CB2881]2121
Failure Code [CB2976]2127
Failure Code [CB3133]2129
Failure Code [CB3134]2131
Failure Code [CB3135]2133
Failure Code [CB3142]2138
Failure Code [CB3143]2139
Failure Code [CB3144]2140
Failure Code [CB3146]2143
Failure Code [CB3147]2144
Failure Code [CB3148]2145
Failure Code [CB3151]2148
Failure Code [CB3165]2153
Failure Code [CB3167]2155
Failure Code [CB3229]2161
Failure Code [CB3231]2164
Failure Code [CB3235]2167
Failure Code [CB3239]2169
Failure Code [CB3241]2172
Failure Code [CB3251]2175
Failure Code [CB3253]2178
Failure Code [CB3254]2183
Failure Code [CB3255]2187
Failure Code [CB3256]2190
Failure Code [CB3311]2193
Failure Code [CB3312]2196
Failure Code [CB3313]2199
Failure Code [CB3314]2200
Failure Code [CB3315]2201
Failure Code [CB3316]2205
Failure Code [CB3317]2206
Failure Code [CB3318]2207
Failure Code [CB3319]2211
Failure Code [CB3321]2212
Failure Code [CB3322]2213
Failure Code [CB3545]2217
Failure Code [CB3558]2219
Failure Code [CB3559]2221
Failure Code [CB3562]2223
Failure Code [CB3563]2225
Failure Code [CB3567]2228
Failure Code [CB3568]2232
Failure Code [CB3571]2239
Failure Code [CB3572]2241
Failure Code [CB3574]2243
Failure Code [CB3575]2246
Failure Code [CB3577]2248
Failure Code [CB3578]2250
Failure Code [CB3582]2252
Failure Code [CB3583]2260
Failure Code [CB3596]2262
Failure Code [CB3681]2266
Failure Code [CB3713]2271
Failure Code [CB3717]2274
Failure Code [CB3751]2275
Failure Code [CB3755]2277
Failure Code [CB3899]2279
Failure Code [CB3911]2281
Failure Code [CB3912]2285
Failure Code [CB3932]2287
Failure Code [CB3933]2289
Failure Code [CB3934]2291
Failure Code [CB3935]2293
Failure Code [CB3936]2295
Failure Code [CB4151]2297
Failure Code [CB4152]2301
Failure Code [CB4155]2305
Failure Code [CB4156]2308
Failure Code [CB4157]2311
Failure Code [CB4158]2313
Failure Code [CB4159]2314
Failure Code [CB4161]2315
Failure Code [CB4162]2318
Failure Code [CB4163]2321
Failure Code [CB4164]2323
Failure Code [CB4165]2326
Failure Code [CB4166]2329
Failure Code [CB4168]2331
Failure Code [CB4169]2334
Failure Code [CB4171]2337
Failure Code [CB4249]2341
Failure Code [CB4251]2344
Failure Code [CB4259]2347
Failure Code [CB4261]2350
Failure Code [CB4459]2353
Failure Code [CB4461]2355
Failure Code [CB4658]2358
Failure Code [CB4952]2362
Failure Code [CB5115]2364
Failure Code [CB5383]2367
Failure Code [D162KA]2369
Failure Code [D162KA]2371
Failure Code [D162KB]2373
Failure Code [D162KB]2375
Failure Code [D162KY]2377
Failure Code [D162KY]2379
Failure Code [D191KA]2381
Failure Code [D191KB]2384
Failure Code [D191KY]2387
Failure Code [D192KA]2389
Failure Code [D192KB]2391
Failure Code [D192KY]2393
Failure Code [D19JKZ]2394
Failure Code [D1E6KA]2396
Failure Code [D1E6KB]2398
Failure Code [D1E6KY]2400
Failure Code [D5ZHKA]2402
Failure Code [D5ZHKB]2404
Failure Code [D5ZHKZ]2406
Failure Code [D5ZHL6]2409
Failure Code [D5ZMLD]2411
Failure Code [D862KA]2413
Failure Code [DA80L4]2414
Failure Code [DAF0KT]2416
Failure Code [DAF0MB]2417
Failure Code [DAF0MC]2418
Failure Code [DAF3KK]2419
Failure Code [DAF8KB]2421
Failure Code [DAFDKB]2422
Failure Code [DAFGMC]2424
Failure Code [DAFLKA]2425
Failure Code [DAFLKB]2427
Failure Code [DAFQKR]2429
Failure Code [DAQ0KK]2430
Failure Code [DAQ0KT]2433
Failure Code [DAQ0MC]2434
Failure Code [DAQ1KA]2435
Failure Code [DAQ2KK]2438
Failure Code [DAQ4KB]2441
Failure Code [DAQ9KQ]2443
Failure Code [DAQLKA]2444
Failure Code [DAQLKB]2446
Failure Code [DAQQKR]2448
Failure Code [DAQRKR]2449
Failure Code [DAQRMA]2450
Failure Code [DAZ9KQ]2451
Failure Code [DAZQKR]2452
Failure Code [DB2QKR]2453
Failure Code [DB2RKR]2461
Failure Code [DB90KK]2466
Failure Code [DB90KT]2469
Failure Code [DB90MC]2470
Failure Code [DB91KA]2471
Failure Code [DB92KK]2474
Failure Code [DB95KX]2477
Failure Code [DB96KX]2479
Failure Code [DB97KX]2482
Failure Code [DB99KQ]2483
Failure Code [DB9LKA]2484
Failure Code [DB9LKB]2486
Failure Code [DB9QKR]2488
Failure Code [DB9RKR]2489
Failure Code [DB9RMA]2490
Failure Code [DBE5KX]2491
Failure Code [DBE6KX]2493
Failure Code [DBV0MC]2495
Failure Code [DBV1KK]2496
Failure Code [DBV5KX]2498
Failure Code [DBV6KX]2500
Failure Code [DBV7KX]2502
Failure Code [DBV8KX]2503
Failure Code [DBVLKA]2504
Failure Code [DBVLKB]2506
Failure Code [DBVQK4]2508
Failure Code [DBVQKR]2509
Failure Code [DBVRKR]2510
Failure Code [DBVVKR]2511
Failure Code [DBVWKR]2512
Failure Code [DD1ALD]2513
Failure Code [DDA8KB]2515
Failure Code [DDA9KB]2517
Failure Code [DDAAL6]2519
Failure Code [DDAAL6]2521
Failure Code [DDB6L4]2524
Failure Code [DDD1LD]2527
Failure Code [DDDBKA]2529
Failure Code [DDDBKB]2531
Failure Code [DDE5KA]2533
Failure Code [DDK4KA]2534
Failure Code [DDK4KB]2537
Failure Code [DDK5L4]2539
Failure Code [DDK6KA]2541
Failure Code [DDK6KB]2544
Failure Code [DDNRKY]2547
Failure Code [DDP5KA]2549
Failure Code [DDW9LD]2551
Failure Code [DDWLLD]2553
Failure Code [DF10KA]2555
Failure Code [DF10KB]2559
Failure Code [DGE5KA]2562
Failure Code [DGE5KB]2564
Failure Code [DGF1KA]2566
Failure Code [DGF1KB]2568
Failure Code [DGH2KX]2570
Failure Code [DGR2KB]2572
Failure Code [DGR2KZ]2574
Failure Code [DGR4KB]2576
Failure Code [DGR4KZ]2578
Failure Code [DGT1KA]2580
Failure Code [DGT1KB]2582
Failure Code [DGT4KA]2584
Failure Code [DGT4KY]2586
Failure Code [DH21KA]2588
Failure Code [DH21KY]2591
Failure Code [DHA4KA]2593
Failure Code [DHAAMA]2595
Failure Code [DHABMA]2596
Failure Code [DHACMA]2597
Failure Code [DHADMA]2598
Failure Code [DHPCKA]2599
Failure Code [DHPCKY]2601
Failure Code [DHPDKA]2603
Failure Code [DHPDKY]2605
Failure Code [DHQ2KX]2607
Failure Code [DHT2L6]2609
Failure Code [DHT5KX]2610
Failure Code [DHT7KX]2613
Failure Code [DHT8KA]2616
Failure Code [DHT8KY]2619
Failure Code [DHTBKA]2621
Failure Code [DHTBKB]2623
Failure Code [DHU2KA]2625
Failure Code [DHU2KY]2627
Failure Code [DHU3KA]2629
Failure Code [DHU3KY]2631
Failure Code [DJF1KA]2633
Failure Code [DK30KA]2635
Failure Code [DK30KY]2637
Failure Code [DK55KA]2639
Failure Code [DK55KY]2642
Failure Code [DK55L5]2644
Failure Code [DK59KA]2645
Failure Code [DK59KY]2650
Failure Code [DK59L8]2654
Failure Code [DK5AKA]2659
Failure Code [DK5AKY]2663
Failure Code [DK5BKA]2667
Failure Code [DK5BKY]2671
Failure Code [DK5BL8]2675
Failure Code [DK5CKA]2680
Failure Code [DK5CKY]2684
Failure Code [DK5DKA]2688
Failure Code [DK5DKY]2691
Failure Code [DK5DL8]2694
Failure Code [DK5EKA]2699
Failure Code [DK5EKY]2702
Failure Code [DKA0KA]2705
Failure Code [DKA0KY]2708
Failure Code [DKA0L0]2711
Failure Code [DKA1KA]2714
Failure Code [DKA1KY]2717
Failure Code [DKD0KA]2719
Failure Code [DKD0KY]2721
Failure Code [DKD0L8]2723
Failure Code [DLFAKA]2724
Failure Code [DLFALC]2726
Failure Code [DLM3KA]2728
Failure Code [DLM3LC]2730
Failure Code [DLT3KA]2732
Failure Code [DLT3LC]2734
Failure Code [DLT4KB]2736
Failure Code [DLT4KX]2738
Failure Code [DPQ1KR]2740
Failure Code [DPQ2KR]2743
Failure Code [DPQ3KR]2746
Failure Code [DSJ0KR]2750
Failure Code [DT22KB]2754
Failure Code [DV00KB]2756
Failure Code [DW2BKA]2758
Failure Code [DW2BKB]2760
Failure Code [DW2BKY]2762
Failure Code [DW2BL1]2764
Failure Code [DW2BLH]2766
Failure Code [DW4PKA]2767
Failure Code [DW4PKB]2769
Failure Code [DW4PKY]2771
Failure Code [DW4QKA]2773
Failure Code [DW4QKB]2775
Failure Code [DW4QKY]2777
Failure Code [DW4RKA]2779
Failure Code [DW4RKB]2781
Failure Code [DW4RKY]2783
Failure Code [DW4SKA]2785
Failure Code [DW4SKB]2787
Failure Code [DW4SKY]2789
Failure Code [DW7BKA]2791
Failure Code [DW7BKB]2793
Failure Code [DW7BKY]2795
Failure Code [DWM1KA]2797
Failure Code [DWM1KB]2799
Failure Code [DWM1KY]2801
Failure Code [DWN6KA]2803
Failure Code [DWN6KB]2805
Failure Code [DWN6KY]2807
Failure Code [DWN8KA]2809
Failure Code [DWN8KB]2811
Failure Code [DWN8KY]2813
Failure Code [DWNFKA]2815
Failure Code [DWNFKB]2817
Failure Code [DWNFKY]2819
Failure Code [DX16KA]2821
Failure Code [DX16KB]2823
Failure Code [DX16KY]2825
Failure Code [DXA1KA]2827
Failure Code [DXA1KB]2829
Failure Code [DXA1KY]2831
Failure Code [DXF0KA]2832
Failure Code [DXF0KB]2834
Failure Code [DXF0KY]2836
Failure Code [DXH1KA]2838
Failure Code [DXH1KB]2840
Failure Code [DXH1KY]2842
Failure Code [DXH4KA]2844
Failure Code [DXH4KB]2846
Failure Code [DXH4KY]2848
Failure Code [DXH5KA]2850
Failure Code [DXH5KB]2852
Failure Code [DXH5KY]2854
Failure Code [DXH6KA]2856
Failure Code [DXH6KB]2858
Failure Code [DXH6KY]2860
Failure Code [DXH7KA]2862
Failure Code [DXH7KB]2864
Failure Code [DXH7KY]2866
Failure Code [DXH8KA]2868
Failure Code [DXH8KB]2870
Failure Code [DXH8KY]2872
Failure Code [DXHHKA]2874
Failure Code [DXHHKB]2876
Failure Code [DXHHKY]2878
Failure Code [DXHJKA]2880
Failure Code [DXHJKB]2882
Failure Code [DXHJKY]2884
Failure Code [DXHKKA]2886
Failure Code [DXHKKB]2888
Failure Code [DXHKKY]2890
Failure Code [DXHPKA]2892
Failure Code [DXHPKB]2894
Failure Code [DXHPKY]2896
Failure Code [DXHPMA]2898
Failure Code [DXHPMB]2900
Troubleshooting of Electrical System (E-Mode)2902
E-1 Engine Does Not Start (Engine Does Not Crank)2902
E-2 Manual Preheating System Does Not Operate2911
E-3 Automatic Preheating System Does Not Operate2914
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On2917
E-5 All of LCD Unit, LED Unit, and Meter Unit on Machine Monitor Display Nothing2919
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)2922
E-7 LCD Unit on Machine Monitor Displays Nothing2925
E-8 Backlight of LCD Unit on Machine Monitor is Abnormal, (Backlight Goes Out or Flickers)2927
E-9 LCD on Machine Monitor Does Not Show Correctly2929
E-10 Meter Unit Display on Machine Monitor is Abnormal2931
E-11 Night Lighting Lamp of Meter Unit on Machine Monitor is Abnormal2934
E-12 LED Unit Lamp on Machine Monitor is Abnormal2937
E-13 Night Lighting Lamp of Switch Panel on Machine Monitor is Abnormal or Switch Does Not Operate Correctly2939
E-14 2 Switches Operation of Switch Panel on Machine Monitor Does Not Function2942
E-15 Switch Panel Buzzer of Machine Monitor is Abnormal2945
E-16 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Correctly2948
E-17 Rearview Monitor Does Not Come On or Backlight Flickers2949
E-18 Rearview Monitor Images are Not Shown Clearly2952
E-19 Rearview Monitor Brightness Cannot be Adjusted2955
E-20 Night Lighting Lamp of Rearview Monitor is Abnormal2958
E-21 Air Cleaner Clogging Indicator Lamp Does Not Come On2960
E-22 Radiator Coolant Level Caution Lamp Does Not Come On2962
E-23 Parking Brake Indicator Lamp Does Not Light When the Parking Brake is Set to ON (Parking) Position2964
E-24 When Front Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On2968
E-25 When Rear Brake Accumulator Oil Pressure Drops, the Brake Oil Pressure Caution Lamp Does Not Come On2970
E-26 Fuel Level Gauge Does Not Show Correct Level2972
E-27 Torque Converter Oil Temperature Gauge Does Not Increase, or Torque Converter Oil Temperature Caution Lamp Does Not Come On2974
E-28 Indication of Hydraulic Oil Temperature Gauge Does Not Increase, or Hydraulic Oil Temperature Caution Lamp Does Not Light2975
E-29 Seat Belt Caution Lamp Indication is Abnormal2977
E-30 Alarm Buzzer Does Not Sound2978
E-31 Alarm Buzzer Does Not Stop2980
E-32 Kickdown Does Not Work When Kickdown Switch is Turned ON2981
E-33 Hold Switch Does Not Work When It is Pushed2983
E-34 Brake Does Not Work When Parking Brake is Applied or Brake Drags in Forward or Reverse Travel When Parking Brake is Released2985
E-35 Engine Mode Selector Function Does Not Operate Normally When Engine Power Mode Selector Switch is Operated2989
E-36 Flow of Loader Pump Does Not Increase from the Minimum Rate2991
E-37 ECSS Function Cannot be Selected or Cannot be Released2992
E-38 Horn Does Not Sound2994
E-39 Horn Does Not Stop2997
E-40 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light2999
E-41 Clearance Lamp and Tail Lamp Do Not Come On or Go Out3001
E-42 Both High and Low Beams of Headlamp Do Not Come On or Go Out3005
E-43 Low Beam of Headlamp Does Not Come On or Go Out3009
E-44 High Beam of Headlamp Does Not Come On or Go Out3011
E-45 Front Working Lamp Does Not Come On or Go Out3013
E-46 Rear Working Lamp Does Not Come On or Go Out3017
E-47 All of Turn Signal Lamps and Hazard Lamps Do Not Come On or Go Out3021
E-48 Turn Signal Lamps Do Not Come On or Go Out3024
E-49 Hazard Lamp Does Not Come On or Go Out3028
E-50 Brake Lamp Does Not Light or Stays Lighted3030
E-51 Backup Lamp Does Not Come On or Does Not Go Out3033
E-52 Backup Buzzer Does Not Sound or Continues to Sound3035
E-53 Front Wiper Does Not Operate3037
E-54 Rear Wiper Does Not Operate3041
E-55 Fuel Feed Pump Does Not Operate or Stop Automatically3044
E-56 Window Washer Does Not Operate3049
E-57 KOMTRAX Plus System Does Not Operate Normally3052
Troubleshooting for Hydraulic and Mechanical Systems (H Mode)3053
Failure Mode and Cause Table3053
H-1 Machine Does Not Start3075
H-2 Lockup is Not Released3078
H-3 Torque Converter Lockup Clutch Does Not Engage3079
H-4 Travel Speed is Slow, Bucket Thrust Force is Weak, Gradability is Low, or Gear Speed Does Not Shift3080
H-5 Large Shock is Made When Machine Moves Off or Gear is Shifted3083
H-6 Large Time Lag is Monitored When Machine Starts and Gear is Shifted3086
H-7 Oil Temperature of Torque Converter is High3089
H-8 Machine Does Not Turn (For Steering Wheel Spec)3091
H-9 Machine Does Not Turn (AJSS Specification)3093
H-10 Turning Response is Unsatisfactory (For Steering Wheel Spec)3095
H-11 Turning Response is Unsatisfactory (AJSS Specification)3097
H-12 Steering Wheel is Heavy to Operate3099
H-13 Machine Sways or Large Shocks are Made While Machine Turns (For Steering Wheel Spec)3100
H-14 Machine Sways or Large Shocks are Made While Machine Turns (AJSS Specification)3102
H-15 Turning Radius is Different Between Right and Left Turns3104
H-16 Wheel Brakes Do Not Work or are Weak3105
H-17 Wheel Brakes are Not Released or Drag3107
H-18 Parking Brake Does Not Work or It is Weak3108
H-19 Parking Brake is Not Released or Drags3109
H-20 Boom Does Not Rise3111
H-21 Boom Moves Slow or Boom Lacks Lifting Force3113
H-22 Rising Boom Slows Down at Some Height3115
H-23 Lift Cylinders Can Not Hold Bucket on Ground3116
H-24 Hydraulic Drift of Boom is Large3117
H-25 Boom Moves Up and Down During Operation3118
H-26 Bucket Does Not Tilt Back3119
H-27 Bucket Moves Slow or Lacks Tilt-Back Force3121
H-28 Bucket Decreases Speed During Tilt-Back Operation3123
H-29 Bucket Cylinder Does Not Hold Bucket on Ground3124
H-30 Hydraulic Drift of Bucket is Large3125
H-31 Bucket Tilts Back and Forth While You Carry Load (Work Equipment Valve in Hold)3126
H-32 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move3127
H-33 When Operating Work Equipment Engine Speed Drops Largely or Engine Stops3128
H-34 Large Shocks are Made When Work Equipment Starts to Move and Stops3129
H-35 When Some Work Equipment Stalls Hydraulically, Other Work Equipment Moves3131
H-36 ECSS (Travel Damper) Does Not Work and Machine Pitches and Bounces3132
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)3133
H-38 Unusual Noise is Heard from Around Fan3134
Troubleshooting of Engine (S-Mode)3135
Information Shown in Troubleshooting Table (S-Mode)3135
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position3136
S-2 Engine Cranks but No Exhaust Smoke Comes Out3137
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)3138
S-4 Engine Startability is Unsatisfactory3139
S-5 Engine Does Not Pick Up Smoothly3141
S-6 Engine Stops During Operation3143
S-7 Engine Runs Rough or is Not Stable3145
S-8 Engine Lacks Power3146
S-9 KDPF Becomes Clogged in a Short Time3148
S-10 Engine Oil Consumption is Excessive3150
S-11 Oil Becomes Dirty Quickly3151
S-12 Fuel Consumption is Excessive3152
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant3153
S-14 Oil Pressure Drops3154
S-15 Fuel Mixes Into Engine Oil3156
S-16 Water Mixes Into Engine Oil (Milky)3157
S-17 Coolant Temperature Increases Too High (Overheating)3158
S-18 Unusual Noise is Heard3159
S-19 Vibration is Excessive3160
S-20 Air Cannot be Bled from Fuel Circuit3161
S-21 Active Regeneration is Done Frequently3162
S-22 Active Regeneration Continues Long3164
S-23 White Smoke is Exhausted During Active Regeneration3165
S-24 DEF Consumption is Excessive3166
S-25 There is Unusual Smell (Irritating Odor)3168
S-26 Foreign Materials Enter DEF (DEF Increases)3169
50 Disassembly and Assembly3171
Table of Contents3172
Precautions Before Work3177
Abbreviation List3178
Related Information on Disassembly and Assembly3184
How to Read This Manual3184
Coating Materials List3185
Special Tool List3190
Sketches of Special Tools3207
Engine and Cooling System3215
Remove and Install Supply Pump Assembly3215
How to Remove Supply Pump Assembly3215
How to Install Supply Pump Assembly3227
Remove and Install Injector Assembly3240
How to Remove Injector Assembly3241
How to Install Injector Assembly3252
Remove and Install Fuel Doser Assembly3265
How to Remove Fuel Doser Assembly3265
How to Install Fuel Doser Assembly3266
Remove and Install Cylinder Head Assembly3269
How to Remove Cylinder Head Assembly3270
How to Install Cylinder Head Assembly3317
Remove and Install EGR Valve Assembly3374
How to Remove EGR Valve Assembly3374
How to Install EGR Valve Assembly3375
Remove and Install EGR Cooler Assembly3376
How to Remove EGR Cooler Assembly3376
How to Install EGR Cooler Assembly3385
Remove and Install Starter Assembly3394
How to Remove Starting Motor Assembly3394
How to Install Starting Motor Assembly3395
Remove and Install Alternator Belt3396
How to Remove Alternator Belt3396
How to Install Alternator Belt3397
Remove and Install Radiator Assembly3399
How to Remove Radiator Assembly3399
How to Install Radiator Assembly3401
Remove and Install Cooling Fan and Fan Motor Assembly3404
How to Remove Cooling Fan and Fan Motor Assembly3404
How to Install Cooling Fan and Fan Motor Assembly3405
Remove and Install Hydraulic Oil Cooler Assembly3408
How to Remove Hydraulic Oil Cooler Assembly3408
How to Install Hydraulic Oil Cooler Assembly3409
Remove and Install Aftercooler Assembly3411
How to Remove Aftercooler Assembly3411
How to Install Aftercooler Assembly3413
Remove and Install Power Train Oil Cooler Assembly3415
How to Remove Power Train Oil Cooler Assembly3415
How to Install Power Train Oil Cooler Assembly3417
Remove and Install Engine Assembly3420
How to Remove Engine Assembly3420
How to Install Engine Assembly3433
Remove and Install Engine Front Oil Seal3447
How to Remove Engine Front Oil Seal3447
How to Install Engine Front Oil Seal3450
Remove and Install Engine Rear Oil Seal3454
How to Remove Engine Rear Oil Seal3454
How to Install Engine Rear Oil Seal3455
Remove and Install Engine Hood Assembly3460
How to Remove Engine Hood Assembly3460
How to Install Engine Hood Assembly3462
Remove and Install Fuel Tank Assembly3465
How to Remove Fuel Tank Assembly3465
How to Install Fuel Tank Assembly3468
Remove and Install DEF Tank Assembly3471
How to Remove DEF Tank Assembly3471
How to Install DEF Tank Assembly3476
Remove and Install DEF Tank Sensor Flange Assembly3481
How to Remove DEF Tank Sensor Flange Assembly3481
How to Install DEF Tank Sensor Flange Assembly3486
Remove and Install DEF Tank Sensor3491
How to Remove DEF Tank Sensor3491
How to Install DEF Tank Sensor3491
Remove and Install DEF Tank Strainer3493
How to Remove DEF Tank Strainer3493
How to Install DEF Tank Strainer3493
Remove and Install KDPF Assembly3494
How to Remove KDPF Assembly3495
How to Install KDPF Assembly3497
Disassemble and Assemble KDPF Assembly3500
How to Disassemble KDPF Assembly3500
How to Assemble KDPF Assembly3505
Remove and Install SCR Assembly3511
How to Remove SCR Assembly3511
How to Install SCR Assembly3513
Remove and Install KDPF and SCR Assembly3516
How to Remove KDPF and SCR Assembly3516
How to Install KDPF and SCR Assembly3522
Remove and Install KCCV Assembly3527
How to Remove KCCV Assembly3527
How to Install KCCV Assembly3528
Remove and Install VGT Assembly3530
How to Remove VGT Assembly3530
How to Install VGT Assembly3534
Remove and Install DEF Mixing Tube3539
How to Remove DEF Mixing Tube3539
How to Install DEF Mixing Tube3542
Remove and Install DEF Injector3547
How to Remove DEF Injector3547
How to Install DEF Injector3550
Remove and Install DEF Pump3555
How to Remove DEF Pump3555
How to Install DEF Pump3558
Remove and Install DEF Hose3561
How to Remove DEF Hose3561
How to Install DEF Hose3570
Remove and Install Air Cleaner Assembly3580
How to Remove Air Cleaner Assembly3580
How to Install Air Cleaner Assembly3581
Remove and Install Air Conditioner Compressor Assembly3583
How to Remove Air Conditioner Compressor Assembly3583
How to Install Air Conditioner Compressor Assembly3584
Remove and Install Air Conditioner Condenser Assembly3586
How to Remove Air Conditioner Condenser Assembly3586
How to Install Air Conditioner Condenser Assembly3587
Power Train3589
Remove and Install Damper Assembly3589
How to Remove Damper Assembly3589
How to Install Damper Assembly3590
Disassemble and Assemble Damper Assembly3592
How to Disassemble Damper Assembly3592
How to Assemble Damper Assembly3594
Remove and Install Torque Converter and Transmission Assembly3597
How to Remove Torque Converter and Transmission Assembly3597
How to Install Torque Converter and Transmission Assembly3604
Disassemble and Assemble Torque Converter Assembly3611
How to Disassemble Torque Converter Assembly3612
How to Assemble Torque Converter Assembly3626
Disassemble and Assemble Transmission Assembly3646
How to Disassemble Transmission Assembly3647
How to Assemble Transmission Assembly3662
Disassemble and Assemble Transfer Assembly3683
How to Disassemble Transfer Assembly3683
How to Assemble Transfer Assembly3692
Remove and Install Parking Brake Assembly3705
How to Remove Parking Brake Assembly3705
How to Install Parking Brake Assembly3706
Disassemble and Assemble Parking Brake Assembly3708
How to Disassemble Parking Brake Assembly3708
How to Assemble Parking Brake Assembly3712
Remove and Install Front Axle Assembly3718
How to Remove Front Axle Assembly3718
How to Install Front Axle Assembly3720
Remove and Install Rear Axle Assembly3722
How to Remove Rear Axle Assembly3722
How to Install Rear Axle Assembly3724
Remove and Install Center Support Assembly3727
How to Remove Center Support Assembly3727
How to Install Center Support Assembly3728
Disassemble and Assemble Center Support Assembly3730
How to Disassemble Center Support Assembly3730
How to Assemble Center Support Assembly3731
Disassemble and Assemble Differential Assembly3734
How to Disassemble Differential Assembly3735
How to Assemble Differential Assembly3742
Disassemble and Assemble Final Drive Assembly3754
How to Disassemble Final Drive Assembly3754
How to Assemble Final Drive Assembly3757
Remove and Install Final Drive Carrier Assembly3763
How to Remove Final Drive Carrier Assembly3763
How to Install Final Drive Carrier Assembly3765
Disassemble and Assemble Final Drive Carrier Assembly3767
How to Disassemble Final Drive Carrier Assembly3767
How to Assemble Final Drive Carrier Assembly3767
Remove and Install Front Final Drive and Brake Assembly3769
How to Remove Front Final Drive and Brake Assembly3769
How to Install Front Final Drive and Brake Assembly3770
Steering System3772
Remove and Install Steering Valve Assembly3772
How to Remove Steering Valve Assembly3772
How to Install Steering Valve Assembly3773
Brake System3776
Disassemble and Assemble Brake Assembly3776
How to Disassemble Brake Assembly3776
How to Assemble Brake Assembly3779
Undercarriage and Frame3784
Remove and Install Center Hinge Pin3784
How to Remove Center Hinge Pin3785
How to Install Center Hinge Pin3788
Remove and Install Counterweight Assembly3794
How to Remove Counterweight Assembly3794
How to Install Counterweight Assembly3795
Hydraulic System3797
Remove and Install Hydraulic Tank Assembly3797
How to Remove Hydraulic Tank Assembly3797
How to Install Hydraulic Tank Assembly3800
Remove and Install Work Equipment Pump Assembly3804
How to Remove Work Equipment Pump Assembly3804
How to Install Work Equipment Pump Assembly3806
Remove and Install Power Train Pump Assembly3809
How to Remove Power Train Pump Assembly3809
How to Install Power Train Pump Assembly3811
Remove and Install Steering Pump and Cooling Fan Pump Assembly3813
How to Remove Steering Pump and Cooling Fan Pump Assembly3813
How to Install Steering Pump and Cooling Fan Pump Assembly3816
Remove and Install Control Valve Assembly3819
How to Remove Control Valve Assembly3819
How to Install Control Valve Assembly3822
Work Equipment3825
Remove and Install Work Equipment Assembly3825
How to Remove Work Equipment Assembly3825
How to Install Work Equipment Assembly3829
Disassemble and Assemble Hydraulic Cylinder Assembly3837
How to Disassemble Hydraulic Cylinder Assembly3838
How to Assemble Hydraulic Cylinder Assembly3840
CAB Related Parts3845
Remove and Install Operator Cab Assembly3845
How to Remove Operator Cab Assembly3845
How to Install Operator Cab Assembly3853
Remove and Install Operator Cab Glass (Adhered Glass)3862
How to Remove Operator Cab Glass (Adhered Glass)3862
How to Install Operator Cab Glass (Adhered Glass)3863
Remove and Install Floor Frame Assembly3872
How to Remove Floor Frame Assembly3872
How to Install Floor Frame Assembly3876
Remove and Install Air Conditioner Unit Assembly3880
How to Remove Air Conditioner Unit Assembly3880
How to Install Air Conditioner Unit Assembly3884
Remove and Install Operator Seat Assembly3888
How to Remove Operator Seat Assembly3888
How to Install Operator Seat Assembly3890
Remove and Install Switch Assembly of AJSS Lever3893
How to Remove Switch Assembly of AJSS Lever3893
How to Install Switch Assembly of AJSS Lever3895
Remove and Install Work Equipment Control Lever3899
How to Remove Work Equipment Control Lever3899
How to Install Work Equipment Control Lever3901
How to Remove and Install Seat Belt3904
How to Remove Seat Belt3904
How to Install Seatbelt3904
Electrical System3906
Remove and Install Engine Controller Assembly3906
How to Remove Engine Controller Assembly3906
How to Install Engine Controller Assembly3907
Remove and Install Work Equipment Controller Assembly3911
How to Remove Work Equipment Controller Assembly3911
How to Install Work Equipment Controller Assembly3912
Remove and Install Transmission Controller Assembly3915
How to Remove Transmission Controller Assembly3915
How to Install Transmission Controller Assembly3916
Remove and Install Monitor Controller Assembly3919
How to Remove Monitor Controller Assembly3919
How to Install Monitor Controller Assembly3920
Remove and Install Machine Monitor Assembly3923
How to Remove Machine Monitor Assembly3923
How to Install Machine Monitor Assembly3924
Remove and Install Mass Air Flow and Temperature Sensor3926
How to Remove Mass Air Flow and Temperature Sensor3926
How to Install Mass Air Flow and Temperature Sensor3926
Remove and Install KCCV Crankcase Pressure Sensor3927
How to Remove KCCV Crankcase Pressure Sensor3927
How to Install KCCV Crankcase Pressure Sensor3928
Remove and Install SCR Temperature Sensor3930
How to Remove SCR Temperature Sensor3930
How to Install SCR Temperature Sensor3932
Remove And Install KOMTRAX Plus Controller Assembly3934
How to Remove KOMTRAX Plus Controller Assembly3934
How to Install KOMTRAX Plus Controller Assembly3935
Remove and Install KOMTRAX Terminal Assembly3936
How to Remove KOMTRAX Terminal Assembly3936
How to Install KOMTRAX Terminal Assembly3936
Remove and Install Wireless LAN Unit Assembly3938
How to Remove Wireless LAN Unit Assembly3938
How to Install Wireless LAN Unit Assembly3939
60 Maintenance Standard3941
Table of Contents3942
Abbreviation List3943
Engine and Cooling System3949
Maintenance Standard for Engine Mount3949
Maintenance Standard for Damper3950
Maintenance Standard for Brake and Cooling Fan Pump3952
Maintenance Standard for Servo Valve of Brake and Cooling Fan Pump3954
Maintenance Standard for Cooling Fan Motor3955
Power Train3958
Maintenance Standard for Drive Shaft3958
Maintenance Standard for Center Support3959
Maintenance Standard for Transmission Mount3961
Maintenance Standard for Torque Converter3962
Maintenance Standard for Lockup Clutch ECMV3968
Maintenance Standard for Modulation Clutch ECMV3969
Maintenance Standard for Transmission3970
Maintenance Standard for Transmission Control Valve3978
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd, 3rd, 4th Clutch ECMV3980
Maintenance Standard for Torque Converter Regulator Valve3981
Maintenance Standard for Main Relief Valve, Torque Converter Relief Valve, and Main Flow Selector Valve3982
Maintenance Standard for Transmission Lubrication Relief Valve3985
Maintenance Standard for Front Axle3986
Maintenance Standard for Rear Axle3990
Maintenance Standard for Front Differential3994
Maintenance Standard for Rear Differential3998
Maintenance Standard for Final Drive4002
Steering System4004
Maintenance Standard for Steering Column4004
Maintenance Standard for Steering Pump4005
Maintenance Standard for Steering Valve4007
Maintenance Standard for Steering Cylinder4008
Maintenance Standard for Diverter Valve4010
Maintenance Standard for Secondary Steering Pump4011
Brake System4012
Maintenance Standard for Brake Valve4012
Maintenance Standard for Slack Adjuster4016
Maintenance Standard for Brake4017
Maintenance Standard for Parking Brake4019
Maintenance Standard for Parking Brake Solenoid Valve4021
Maintenance Standard for Brake Cooling Pump4022
Undercarriage and Frame4023
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin4023
Hydraulic System4028
Maintenance Standard for Hydraulic Tank4028
Maintenance Standard for Work Equipment Pump4029
Maintenance Standard for Power Train Charge Duplex Pump4032
Maintenance Standard for Control Valve4033
Work Equipment4046
Maintenance Standard for Work Equipment Linkage4046
Maintenance Standard for Bucket4050
Maintenance Standard for Lift Cylinder4052
Maintenance Standard for Bucket Cylinder4053
80 Appendix4055
Table of Contents4056
Precautions Before Work4058
Abbreviation List4059
Air Conditioner System4065
Precautions for Refrigerant4065
Air Conditioner Component4066
Specifications of Air Conditioner4068
Structure and Function of Refrigeration Cycle4069
Outline of Refrigeration Cycle4070
Component Parts of Air Conditioner System4072
Air Conditioner Unit4072
Configuration Diagram of Air Conditioner Unit4072
Function of Air Conditioner Unit4074
Component Parts of Air Conditioner Unit4076
Function of Evaporator as Air Conditioner Unit Component4077
Function of Heater Core as Air Conditioner Unit Component4077
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component4077
Function of Servo Motor as Air Conditioner Unit Component4077
Structure of Expansion Valve as Air Conditioner Unit Component4078
Function of Expansion Valve as Air Conditioner Unit Component4078
Operate Expansion Valve as Air Conditioner Unit Component4078
Function of Dual Pressure Switch4079
Air Conditioner Controller4080
Structure of Air Conditioner Controller4080
Compressor4081
Structure of Compressor4081
Specifications of Compressor4081
Function of Compressor4082
Condenser4083
Structure of Condenser4083
Specifications of Condenser4083
Function of Condenser4083
Air Conditioner Related Sensors4085
Structure of Sunlight Sensor4085
Function of Sunlight Sensor4085
Structure of Outside Temperature Sensor4085
Function of Outside Air Temperature Sensor4085
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner4087
Circuit Diagram and Configuration of Connector Pins of Air Conditioner4089
System Diagram of Air Conditioner4091
Input and Output Signals of Air Conditioner Controller4091
Function of Air Conditioner Controller4093
Locations of Air Conditioner Parts and Layout of Connectors4094
Examine Air Leakage (Duct)4098
How to Examine Air Leakage (Duct)4098
Examine Air Conditioner with Self-Diagnosis Function4100
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor4101
Examine Vent (Mode) Changeover4102
How to Examine Vent (Mode) Changeover4102
Examine Fresh/Recirc Air Changeover4103
How to Examine Fresh/Recirc Air Changeover4103
Examine Sunlight Sensor4104
How to Examine Sunlight Sensor4104
Examine Refrigerant (Dual) Pressure Switch4105
How to Examine Refrigerant (Dual) Pressure Switch4105
Examine Relay4106
How to Examine Relay4106
Air Conditioner Troubleshooting Chart 14107
Air Conditioner Troubleshooting Chart 24108
Information Shown in Troubleshooting Table4111
Failure Code [879AKA]4112
Failure Code [879AKB]4113
Failure Code [879BKA]4114
Failure Code [879BKB]4116
Failure Code [879CKA]4118
Failure Code [879CKB]4119
Failure Code [879DKZ]4120
Failure Code [879EMC]4122
Failure Code [879FMC]4123
Failure Code [879GKX]4124
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)4126
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)4128
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)4131
A-4 Troubleshooting for Fresh/Recirc Air Changeover4133
Troubleshooting by Gauge Pressure4135
Connect Service Tool4137
How to Connect Service Tool4137
Precautions for Disconnection and Connection of Air Conditioner Piping4138
Handle Compressor Oil4140
How to Replace Desiccant4142
90 Circuit Diagrams4145
Table of Contents4146
Abbreviation List4147
Hydraulic Circuit Diagram4153
Symbols Used in Hydraulic Circuit Diagram4153
Hydraulic Circuit Diagram (For AJSS Spec)4157
Hydraulic Circuit Diagram (For Steering Wheel Spec)4159
Power Train Hydraulic Circuit Diagram4161
Electrical Circuit Diagram4163
Symbols Used in Electric Circuit Diagram4163
Electrical Circuit Diagram of Machine (1/8)4167
Electrical Circuit Diagram of Machine (2/8)4169
Electrical Circuit Diagram of Machine (3/8)4171
Electrical Circuit Diagram of Machine (4/8)4173
Electrical Circuit Diagram of Machine (5/8)4175
Electrical Circuit Diagram of Machine (6/8)4177
Electrical Circuit Diagram of Machine (7/8)4179
Electrical Circuit Diagram of Machine (8/8)4181
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (1/8)4183
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (2/8)4185
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (3/8)4187
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (4/8)4189
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (5/8)4191
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (6/8)4193
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (7/8)4195
Electrical Circuit Diagram of Machine (For Emergency Engine Stop Switch Spec) (8/8)4197
Electrical Circuit Diagram of Floor (For AJSS Spec) (1/7)4199
Electrical Circuit Diagram of Floor (For AJSS Spec) (2/7)4201
Electrical Circuit Diagram of Floor (For AJSS Spec) (3/7)4203
Electrical Circuit Diagram of Floor (For AJSS Spec) (4/7)4205
Electrical Circuit Diagram of Floor (For AJSS Spec) (5/7)4207
Electrical Circuit Diagram of Floor (For AJSS Spec) (6/7)4209
Electrical Circuit Diagram of Floor (For AJSS Spec) (7/7)4211
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (1/7)4213
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (2/7)4215
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (3/7)4217
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (4/7)4219
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (5/7)4221
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (6/7)4223
Electrical Circuit Diagram of Floor (For Steering Wheel Spec) (7/7)4225
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (1/7)4227
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (2/7)4229
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (3/7)4231
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (4/7)4233
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (5/7)4235
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (6/7)4237
Electrical Circuit Diagram of Floor (For Emergency Engine Stop Switch Spec) (7/7)4239
Electrical Circuit Diagram of Engine (1/2)4241
Electrical Circuit Diagram of Engine (2/2)4243
Index4245
S.M 29/12/24
