Komatsu WHEEL LOADER WA900-8 Shop Manual SEN06740-04 – PDF

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Komatsu WHEEL LOADER WA900-8 Shop Manual SEN06740-04 – PDF DOWNLOAD 

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Komatsu WHEEL LOADER WA900-8 Shop Manual SEN06740-04 – PDF DOWNLOAD 

Language : English
Pages :5952
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WHEEL LOADER WA900-8 Shop Manual SEN06740-04 – PDF DOWNLOAD 

SERIAL NUMBERS 90001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in  the illustrations of this shop manual. Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA900-8 Shop Manual SEN06740-04 – PDF DOWNLOAD

SERIAL NUMBERS 90001 and up 

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 40
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 44
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 53
PRACTICAL USE OF KOMTRAX 54
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 69
HOW TO READ ELECTRICAL WIRE CODE 70
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 74
STANDARD TIGHTENING TORQUE TABLE 77
CONVERSION TABLE 84
ABBREVIATION LIST 89
01 SPECIFICATION 93
CONTENTS 94
SPECIFICATIONS 95
SPECIFICATION DRAWING 95
SPECIFICATION DRAWING: WA900-8 95
SPECIFICATIONS 97
SPECIFICATION: WA900-8 97
WEIGHT TABLE 102
WEIGHT TABLE: WA900-8 102
FUEL, COOLANT, LUBRICANT 104
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 104
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
BOOT-UP SYSTEM 114
LAYOUT DRAWING OF BOOT-UP SYSTEM 114
PRE-LUBRICATION SYSTEM 116
PRE-LUBRICATION SYSTEM DIAGRAM 116
FUNCTION OF PRE-LUBRICATION SYSTEM 116
OPERATION OF PRE-LUBRICATION SYSTEM 118
SYSTEM OPERATING LAMP SYSTEM 120
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 120
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 120
OPERATION OF SYSTEM OPERATING LAMP SYSTEM 120
BATTERY DISCONNECT SWITCH 121
FUNCTION OF BATTERY DISCONNECT SWITCH 121
OPERATION OF BATTERY DISCONNECT SWITCH 121
STARTING MOTOR DISCONNECT SWITCH 122
FUNCTION OF STARTING MOTOR DISCONNECT SWITCH 122
PREHEATING SYSTEM 123
PREHEATING SYSTEM DIAGRAM 123
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 123
OPERATION OF AUTOMATIC PREHEATING SYSTEM 124
FUNCTION OF MANUAL PREHEATING SYSTEM 124
OPERATION OF MANUAL PREHEATING SYSTEM 124
ENGINE SHUTDOWN SECONDARY SWITCH 125
FUNCTION OF ENGINE SHUTDOWN SECONDARY SWITCH 125
OPERATION OF ENGINE SHUTDOWN SECONDARY SWITCH 125
EMERGENCY ENGINE STOP SWITCH 126
FUNCTION OF EMERGENCY ENGINE STOP SWITCH 126
OPERATION OF EMERGENCY ENGINE STOP SWITCH 126
EXTERNAL POWER SUPPLY ENGINE PREHEATER 127
FUNCTION OF EXTERNAL POWER SUPPLY ENGINE PREHEATER 127
ENGINE SYSTEM 128
LAYOUT DRAWING OF ENGINE SYSTEM 128
ENGINE CONTROL SYSTEM 130
ENGINE CONTROL SYSTEM DIAGRAM 130
OPERATION OF ENGINE CONTROL SYSTEM 131
ENGINE OUTPUT TORQUE CONTROL FUNCTION 132
ENGINE AUTOMATIC WARM-UP FUNCTION 132
ENGINE POWER MODE SELECTOR SYSTEM 133
ENGINE POWER MODE SELECTOR SYSTEM DIAGRAM 133
FUNCTION OF ENGINE POWER MODE SELECTOR SYSTEM 133
OPERATION OF ENGINE POWER MODE SELECTOR SYSTEM 133
AUTOMATIC IDLE STOP SYSTEM 134
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 134
RPM SET 135
FUNCTION OF RPM SET 135
ENGINE SYSTEM 137
DAMPER 137
VGT 139
EGR SYSTEM 143
EGR VALVE 147
EGR COOLER 149
KCCV SYSTEM 150
KCCV 153
KDPF 155
COOLING SYSTEM 159
LAYOUT DRAWING OF COOLING SYSTEM 159
SPECIFICATIONS OF COOLING SYSTEM 161
COOLING FAN CONTROL SYSTEM 162
COOLING FAN CONTROL SYSTEM DIAGRAM 162
FUNCTION OF COOLING FAN CONTROL SYSTEM 163
COOLING SYSTEM 166
COOLING FAN PUMP 166
COOLING PUMP 174
COOLING FAN MOTOR 175
CONTROL SYSTEM 181
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 181
MACHINE MONITOR SYSTEM 183
MACHINE MONITOR SYSTEM DIAGRAM 183
FUNCTION OF MACHINE MONITOR SYSTEM 184
REARVIEW MONITOR SYSTEM 185
REARVIEW MONITOR SYSTEM DIAGRAM 185
FUNCTION OF REARVIEW MONITOR SYSTEM 185
KOMTRAX Plus SYSTEM 186
KOMTRAX Plus SYSTEM DIAGRAM 186
FUNCTION OF KOMTRAX Plus SYSTEM 186
LOAD METER SYSTEM 188
LOAD METER SYSTEM DIAGRAM 188
FUNCTION OF LOAD METER SYSTEM 188
MACHINE LOCK-OUT SYSTEM 194
LAYOUT DRAWING OF MACHINE LOCK-OUT SYSTEM 194
FUNCTION OF MACHINE LOCK-OUT SYSTEM 194
OPERATION OF MACHINE LOCK-OUT SYSTEM 194
CONTROL SYSTEM 196
MACHINE MONITOR 196
SWITCH PANEL 216
REARVIEW MONITOR 217
REARVIEW CAMERA 219
KOMTRAX TERMINAL 220
KOMTRAX Plus CONTROLLER 222
WIRELESS LAN UNIT 227
TRANSMISSION CONTROLLER 228
WORK EQUIPMENT CONTROLLER 232
MONITOR CONTROLLER 236
CAN TERMINATING RESISTOR 241
ENGINE CONTROLLER 242
ACCELERATOR PEDAL 255
FUEL FEED PUMP SWITCH 258
HYDRAULIC SYSTEM 259
LAYOUT DRAWING OF HYDRAULIC SYSTEM 259
CLSS 260
STRUCTURE OF CLSS 260
FUNCTION OF CLSS 261
WORK EQUIPMENT PUMP CONTROL SYSTEM 263
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP 263
PICKUP ASSISTANCE CONTROL FUNCTION OF WORK EQUIPMENT PUMP WHEN ENGINE SPEED IS LOW 263
STEERING PUMP CONTROL SYSTEM 265
SWASH PLATE CONTROL FUNCTION OF STEERING PUMP 265
PICKUP ASSISTANCE CONTROL FUNCTION OF STEERING PUMP WHEN ENGINE SPEED IS LOW 265
COMPONENT PARTS OF HYDRAULIC SYSTEM 266
HYDRAULIC TANK 266
WORK EQUIPMENT PUMP 270
STEERING PUMP 289
PILOT BRAKE CHARGE PUMP 305
PUMP ASSEMBLY (TO LUBRICATE TRANSMISSION AND TORQUE CONVERTER) 306
ACCUMULATOR CHARGE VALVE 307
CONTROL VALVE 312
POWER TRAIN SYSTEM 347
LAYOUT DRAWING OF POWER TRAIN SYSTEM 347
OPERATION OF POWER TRAIN SYSTEM 350
TRANSMISSION CONTROL SYSTEM 351
TRANSMISSION CONTROL SYSTEM DIAGRAM 351
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 353
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 353
ELECTRIC MODULATION FUNCTION 354
GEAR SHIFT DISPLAY FUNCTION 354
AUTOMATIC GEAR SHIFT FUNCTION 354
SHIFT HOLD FUNCTION 355
KICKDOWN FUNCTION 355
AUTOMATIC KICKDOWN FUNCTION 356
HUNTING PREVENTION FUNCTION 356
TRANSMISSION INITIAL LEARNING AND ECMV CURRENT ADJUSTMENT FUNCTION 356
SHIFT POINT CHANGING FUNCTION 356
3RD GEAR SPEED LIMITATION FUNCTION 357
TRANSMISSION PROTECTION FUNCTION 358
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 358
SHIFT DOWN PROTECTION FUNCTION 358
ENGINE OVERRUN PREVENTION FUNCTION 359
NEUTRALIZER FUNCTION 359
MODULATION CLUTCH FUNCTION 359
TIRE SLIP CONTROL SYSTEM 362
TIRE SLIP CONTROL SYSTEM DIAGRAM 362
FUNCTION OF TIRE SLIP CONTROL SYSTEM 362
OPERATION OF TIRE SLIP CONTROL SYSTEM 362
POWER TRAIN SYSTEM 364
DRIVE SHAFT 364
CENTER SUPPORT 366
TORQUE FLOW ASSEMBLY 367
TORQUE CONVERTER 368
VALVE ASSEMBLY (FOR MAIN RELIEF AND TORQUE CONVERTER RELIEF) 376
TORQUE CONVERTER REGULATOR VALVE 379
TRANSMISSION 381
TRANSMISSION CONTROL VALVE 399
MODULATION CLUTCH ECMV 402
F, R, 1ST, 2ND, 3RD CLUTCH ECMV 405
TRANSMISSION LUBRICATION RELIEF VALVE 410
AXLE 411
DIFFERENTIAL 414
FINAL DRIVE 417
AJSS KNOB 419
SHIFT HOLD SWITCH 420
KICKDOWN SWITCH 421
WORK EQUIPMENT SYSTEM 422
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 422
WORK EQUIPMENT SYSTEM DIAGRAM 424
WORK EQUIPMENT CONTROL SYSTEM 426
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 426
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 427
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 428
WORK EQUIPMENT LEVER OPERATION FUNCTION 428
BUCKET PRIORITY CONTROL FUNCTION 429
BOOM STOP MODULATION FUNCTION 429
WORK EQUIPMENT SHOCK REDUCTION FUNCTION 430
TILT SHOCK REDUCTION FUNCTION 430
DUMP SHOCK REDUCTION FUNCTION 431
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 433
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 433
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 433
REMOTE POSITIONER SYSTEM 435
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 435
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 435
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 436
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 436
BUCKET POSITIONER AND BOOM POSITIONER 440
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 440
AUTO-DIGGING SYSTEM 441
AUTO-DIGGING SYSTEM DIAGRAM 441
FUNCTION OF AUTO-DIGGING SYSTEM 441
SEMI-AUTO APPROACH SYSTEM 443
SEMI-AUTO APPROACH SYSTEM DIAGRAM 443
FUNCTION OF SEMI-AUTO APPROACH SYSTEM 443
SEMI-AUTO DUMP SYSTEM 444
SEMI-AUTO DUMP SYSTEM DIAGRAM 444
FUNCTION OF SEMI-AUTO DUMP SYSTEM 444
ECSS 446
ECSS DIAGRAM 446
FUNCTION OF ECSS 446
OPERATION OF ECSS 446
WALL DIGGING PREVENTION CONTROL SYSTEM 448
WALL DIGGING PREVENTION CONTROL SYSTEM DIAGRAM 448
FUNCTION OF WALL DIGGING PREVENTION CONTROL SYSTEM 448
WORK EQUIPMENT SYSTEM 450
SOLENOID VALVE (WORK EQUIPMENT LOCK) 450
PILOT CIRCUIT ACCUMULATOR 451
ECSS CIRCUIT ACCUMULATOR 452
WORK EQUIPMENT ELECTRIC LEVER 453
STEERING SYSTEM 456
LAYOUT DRAWING OF STEERING SYSTEM 456
SECONDARY STEERING SYSTEM 457
SECONDARY STEERING SYSTEM DIAGRAM 457
FUNCTION OF SECONDARY STEERING SYSTEM 457
AJSS 458
LAYOUT DRAWING OF AJSS 458
AJSS SYSTEM DIAGRAM 459
FUNCTION OF AJSS 460
NEUTRALIZER FUNCTION OF AJSS 461
AJSS NEUTRAL INTERLOCK FUNCTION 461
AJSS SPEED SENSING STEERING FUNCTION 462
AJSS TURN SIGNAL PILOT LAMP CONTROL FUNCTION 464
STEERING LOCK SYSTEM 465
STEERING LOCK SYSTEM DIAGRAM 465
FUNCTION OF STEERING LOCK SYSTEM 465
STEERING SYSTEM 466
AJSS EPC VALVE 466
SOLENOID VALVE (FOR STEERING LOCK) 467
STEERING LOCK VALVE 468
ROTARY VALVE 469
STEERING VALVE 473
DIVERTER VALVE 487
SECONDARY STEERING RELIEF VALVE 490
SECONDARY STEERING PUMP 492
LUBRICATION FOR HINGE PIN AND STEERING 493
BRAKE SYSTEM 494
LAYOUT DRAWING OF BRAKE SYSTEM 494
PARKING BRAKE CONTROL SYSTEM 497
PARKING BRAKE CONTROL SYSTEM DIAGRAM 497
OPERATION OF PARKING BRAKE CONTROL SYSTEM 497
BRAKE SYSTEM 499
SOLENOID VALVE (PARKING BRAKE) 499
PARKING BRAKE EMERGENCY RELEASE VALVE 501
BRAKE CIRCUIT ACCUMULATOR 502
BRAKE VALVE 503
SLACK ADJUSTER 509
BRAKE 512
PARKING BRAKE 514
PARKING BRAKE CIRCUIT CHECK VALVE 517
PUMP ASSEMBLY (FOR BRAKE COOLING) 518
AUTOMATIC GREASE SYSTEM 519
LAYOUT DRAWING OF AUTOMATIC GREASE SYSTEM 519
AUTOMATIC GREASE SYSTEM DIAGRAM 522
SPECIFICATIONS OF AUTOMATIC GREASE SYSTEM 523
FUNCTION OF AUTOMATIC GREASE SYSTEM 524
AUTOMATIC GREASE SYSTEM 525
Automatic grease pump 525
AUTO-GREASING INJECTOR 527
LIFTING SYSTEM 530
POWER LADDER SYSTEM 530
LAYOUT DRAWING OF POWER LADDER SYSTEM 530
POWER LADDER SYSTEM DIAGRAM 531
FUNCTION OF POWER LADDER SYSTEM 532
OPERATION OF POWER LADDER SYSTEM 532
POWER LADDER SYSTEM 534
POWER LADDER PUMP 534
POWER LADDER RELIEF VALVE 536
SOLENOID VALVE (POWER LADDER SHOCK REDUCTION) 537
SOLENOID VALVE (POWER LADDER RAISE AND LOWER SWITCH) 538
UNDERCARRIAGE AND FRAME 539
FRAME, AXLE MOUNT AND HINGE PIN 539
STRUCTURE OF FRAME, AXLE MOUNT AND HINGE PIN 539
FUNCTION OF FRAME, AXLE MOUNT AND HINGE PIN 540
STRUCTURE OF LUBRICATION SYSTEM FOR UNDERCARRIAGE 541
SERVICE CENTER 542
SERVICE CENTER 542
SERVICE CENTER SYSTEM DIAGRAM 543
FUNCTION OF SERVICE CENTER 543
GREASE REFILL AUTOMATIC STOP SYSTEM 544
TIRE 546
STRUCTURE OF RADIAL TIRE 546
FUNCTION OF RADIAL TIRE 546
WORK EQUIPMENT 547
STRUCTURE OF WORK EQUIPMENT 547
STRUCTURE OF BUCKET 548
STRUCTURE OF LUBRICATION SYSTEM FOR WORK EQUIPMENT 549
CAB RELATED PARTS 551
ROPS 551
STRUCTURE OF ROPS 551
FUNCTION OF ROPS 551
CAB 552
STRUCTURE OF CAB 552
CAB MOUNT 553
STRUCTURE OF CAB MOUNT 553
FUNCTION OF CAB MOUNT 553
20 STANDARD VALUE TABLE 555
CONTENTS 556
STANDARD VALUE TABLE FOR ENGINE 557
STANDARD VALUE TABLE FOR ENGINE: WA900-8 557
STANDARD VALUE TABLE FOR MACHINE 561
STANDARD VALUE TABLE FOR MACHINE: WA900-8 561
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 575
30 TESTING AND ADJUSTING 579
CONTENTS 580
RELATED INFORMATION ON TESTING AND ADJUSTING 584
TOOLS FOR TESTING AND ADJUSTING 584
ENGINE AND COOLING SYSTEM 591
TEST ENGINE SPEED 591
TEST ENGINE SPEED 591
TEST BOOST PRESSURE 595
TEST BOOST PRESSURE ON MACHINE MONITOR 595
TEST BOOST PRESSURE BY TESTING TOOL 596
TEST EXHAUST GAS TEMPERATURE 599
TEST EXHAUST GAS TEMPERATURE 599
TEST EXHAUST GAS COLOR 601
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 601
TEST EXHAUST GAS COLOR BY SMOKE METER 605
CHECK AND ADJUST VALVE CLEARANCE 609
CHECK VALVE CLEARANCE 609
ADJUST VALVE CLEARANCE 611
TEST COMPRESSION PRESSURE 612
TEST COMPRESSION PRESSURE 612
TEST BLOWBY PRESSURE 616
TEST BLOWBY PRESSURE 616
TEST ENGINE OIL PRESSURE 621
TEST ENGINE OIL PRESSURE ON MACHINE MONITOR 621
TEST ENGINE OIL PRESSURE BY TESTING TOOL 622
TEST EGR VALVE AND VGT OIL PRESSURE 624
TEST EGR VALVE AND VGT OIL PRESSURE 624
TEST FUEL PRESSURE 626
TEST FUEL PRESSURE 626
TEST FUEL RETURN RATE AND LEAKAGE 628
TEST FUEL RETURN RATE AND LEAKAGE 629
BLEED AIR FROM FUEL SYSTEM 636
BLEED AIR FROM FUEL SYSTEM 636
TEST FUEL CIRCUIT FOR LEAKAGE 638
TEST FUEL CIRCUIT FOR LEAKAGE 638
TEST LOW PRESSURE CIRCUIT DEVICES 639
TEST LOW PRESSURE CIRCUIT DEVICES 639
CYLINDER CUT-OUT MODE OPERATION 644
NO-INJECTION CRANKING OPERATION 645
TEST KDPF AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 646
TEST KDPF AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 646
TEST INSTALLATION OF CYLINDER HEAD COVER AND MANIFOLDS 647
TEST INSTALLATION OF CYLINDER HEAD COVER AND MANIFOLDS 647
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 648
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 648
CLEAN FUEL DOSER 649
CLEAN FUEL DOSER 649
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 652
WRITE INJECTOR COMPENSATION VALUE 652
WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER 659
WRITE CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER 659
TEST AND ADJUST ALTERNATOR BELT TENSION 660
TEST ALTERNATOR BELT TENSION 660
ADJUST ALTERNATOR BELT TENSION 661
CHECK AND ADJUST AIR CONDITIONER COMPRESSOR BELT 662
CHECK AIR CONDITIONER COMPRESSOR BELT 662
ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 663
POWER TRAIN 664
TEST AND ADJUST POWER TRAIN OIL PRESSURE 664
TEST POWER TRAIN OIL PRESSURE 666
ADJUST POWER TRAIN OIL PRESSURE 681
TEST MODULATION CLUTCH OUTPUT SPEED SENSOR 683
TEST MODULATION CLUTCH OUTPUT SPEED SENSOR 683
TEST TRANSMISSION OUTPUT SPEED SENSOR 684
TEST TRANSMISSION OUTPUT SPEED SENSOR 684
ADJUST WHEEL SPEED SENSOR 686
ADJUST WHEEL SPEED SENSOR 686
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 687
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 687
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 690
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 690
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 693
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 693
STEERING SYSTEM 694
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 694
TEST STEERING CIRCUIT OIL PRESSURE 694
ADJUST STEERING CIRCUIT OIL PRESSURE 697
BRAKE SYSTEM 699
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 699
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 699
TEST WHEEL BRAKE OIL PRESSURE 700
TEST WHEEL BRAKE OIL PRESSURE 700
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 702
TEST BRAKE ACCUMULATOR CHARGE PRESSURE 702
ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 704
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 706
TEST ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 706
CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 710
RELEASE NITROGEN GAS WHEN YOU DISPOSE OF ACCUMULATOR 715
TEST BRAKE PERFORMANCE 716
TEST BRAKE PERFORMANCE 716
TEST BRAKE PEDAL 717
TEST BRAKE PEDAL 717
ADJUST RIGHT BRAKE PEDAL SWITCH 719
ADJUST RIGHT BRAKE PEDAL SWITCH 719
BLEED AIR FROM BRAKE CIRCUIT 721
BLEED AIR FROM BRAKE CIRCUIT 721
TEST WEAR OF WHEEL BRAKE DISC 723
TEST WEAR OF WHEEL BRAKE DISC 723
TEST PARKING BRAKE OIL PRESSURE 725
TEST PARKING BRAKE OIL PRESSURE 725
TEST PARKING BRAKE PERFORMANCE 727
TEST PARKING BRAKE PERFORMANCE 727
RELEASE PARKING BRAKE MANUALLY 728
RELEASE PARKING BRAKE MANUALLY 728
TEST WEAR AMOUNT OF PARKING BRAKE DISC 730
TEST WEAR AMOUNT OF PARKING BRAKE DISC 730
HYDRAULIC SYSTEM 732
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 732
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 732
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 734
TEST WORK EQUIPMENT OIL PRESSURE 734
ADJUST WORK EQUIPMENT OIL PRESSURE 739
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 741
TEST WORK EQUIPMENT EPC OIL PRESSURE 741
ADJUST WORK EQUIPMENT EPC OIL PRESSURE 743
BLEED AIR FROM HYDRAULIC CIRCUIT 744
BLEED AIR FROM HYDRAULIC CIRCUIT 744
TEST COOLING FAN SPEED 750
TEST COOLING FAN SPEED 750
TEST COOLING FAN CIRCUIT OIL PRESSURE 751
TEST COOLING FAN CIRCUIT OIL PRESSURE 751
TEST COOLING FAN REVERSE SOLENOID OUTLET PRESSURE 752
BLEED AIR FROM COOLING FAN CIRCUIT 755
BLEED AIR FROM COOLING PUMP 755
BLEED AIR FROM FAN MOTOR CIRCUIT 756
TEST ECSS ACCUMULATOR CHARGE PRESSURE 757
TEST ECSS ACCUMULATOR CHARGE PRESSURE 757
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 759
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE 759
CHARGE ECSS ACCUMULATOR WITH NITROGEN GAS 762
WORK EQUIPMENT 767
TEST AND ADJUST BUCKET POTENTIOMETER LEVER 767
TEST BUCKET POTENTIOMETER LEVER 767
ADJUST BUCKET POTENTIOMETER LEVER 767
TEST AND ADJUST BOOM POTENTIOMETER LEVER 769
TEST BOOM POTENTIOMETER LEVER 769
ADJUST BOOM POTENTIOMETER LEVER 769
CAB RELATED PARTS 770
TEST WORK EQUIPMENT CONTROL LEVER 770
TEST WORK EQUIPMENT CONTROL LEVER 770
TEST AJSS LEVER 772
TEST OPERATING TIME OF AJSS LEVER 772
TEST OPERATING EFFORT OF AJSS LEVER 773
TEST OPERATING EFFORT OF DIRECTIONAL SWITCH 774
TEST OPERATING EFFORT OF GEAR SPEED SWITCH 774
TEST AND ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR 775
TEST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR 775
ADJUST AJSS LEVER ANGLE SENSOR AND AJSS FRAME ANGLE SENSOR 775
TEST AND ADJUST STEERING STOPPER BOLT 777
TEST STEERING STOPPER BOLT 777
ADJUST STEERING STOPPER BOLT 777
ADJUST PLAY OF OPERATOR SEAT 778
ADJUST PLAY OF OPERATOR SEAT 778
ADJUST DOOR LOCK LINK 779
ADJUST DOOR LOCK LINK 779
ELECTRICAL SYSTEM 782
SETTING AND ADJUSTMENT OF EACH EQUIPMENT 782
SETTING AND OPERATION OF MACHINE MONITOR 786
OPERATOR MODE 790
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 790
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 790
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 791
CHECK FUNCTION OF SERVICE METER AND ODOMETER 792
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 792
SERVICE MODE 796
SERVICE MODE 796
CHECK PRE-DEFINED MONITORING INFORMATION 798
CHECK MONITORING INFORMATION 804
ABNORMALITY RECORD MENU 819
CHECK MAINTENANCE RECORD 823
MAINTENANCE MODE SETTING 825
PHONE NUMBER ENTRY SETTING 831
DEFAULT SETTING MENU 832
TESTING MENU 850
ADJUSTMENT MENU 863
NO-INJECTION CRANKING OPERATION 898
KOMTRAX SETTINGS MENU 901
DISPLAY SERVICE MESSAGE 903
SNAP SHOT 904
START UP KOMTRAX TERMINAL 907
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 912
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER 912
DEFAULT SETTING OF WIRELESS LAN MODEM 915
DEFAULT SETTING OF WIRELESS LAN MODEM 915
CHECK WIRELESS LAN MODEM COMMUNICATION 916
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 918
DOWNLOAD DATA FROM KOMTRAX Plus CONTROLLER 918
Download data from service connector 918
DOWNLOAD DATA FROM WIRELESS LAN 919
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 921
ADJUST AFTER REPLACEMENT OF KOMTRAX Plus CONTROLLER 921
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 924
ADJUST AFTER REPLACEMENT OF WIRELESS LAN MODEM 924
ADJUST REARVIEW CAMERA ANGLE 927
ADJUST REARVIEW CAMERA ANGLE 927
ENGINE CONTROLLER VOLTAGE CIRCUIT 928
BATTERY DISCONNECT SWITCH 929
TEST DIODES 930
TEST DIODES BY DIGITAL TESTER 930
TEST DIODES BY ANALOG TESTER 930
Pm-CLINIC 931
Pm-CLINIC SERVICE 931
Pm CLINIC CHECK SHEET:WA900-8 934
PERFORM QUICK PM 947
PERFORM QUICK PM 947
40 TROUBLESHOOTING 951
CONTENTS 952
RELATED INFORMATION TO TROUBLESHOOT 967
GENERAL TROUBLESHOOTING POINTS 967
TROUBLESHOOTING POINTS FOR AFTERTREATMENT SYSTEM 968
SEQUENCE OF EVENTS IN TROUBLESHOOTING 974
CHECKS BEFORE TROUBLESHOOTING 976
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 978
WALK-AROUND CHECK 978
TEST IN ACCORDANCE WITH TESTING PROCEDURE 980
CHECK FUEL LEVEL AND TYPE 980
CHECK IMPURE INGREDIENT IN FUEL 980
REPLACE FUEL PREFILTER CARTRIDGE 981
REPLACE FUEL MAIN FILTER CARTRIDGE 982
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) AND TYPE 984
CHECK COOLANT LEVEL (RESERVOIR TANK) 985
CHECK, CLEAN AND REPLACE AIR CLEANER 986
CHECK HYDRAULIC OIL LEVEL 991
CHECK HYDRAULIC OIL FILTER OR HYDRAULIC OIL STRAINER 992
CHECK OIL LEVEL IN TRANSMISSION CASE 993
CHECK OIL LEVEL IN AXLE CASE 995
BLEED AIR FROM FUEL SYSTEM 997
BLEED AIR FROM HYDRAULIC SYSTEM 997
CHECK ELECTRIC EQUIPMENT 997
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM1004
CONNECT ADAPTER TO TROUBLESHOOT WORK EQUIPMENT CONTROLLER1004
CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER1005
CONNECT ADAPTER TO TROUBLESHOOT TRANSMISSION CONTROLLER1006
CONNECT ADAPTER TO TROUBLESHOOT MONITOR CONTROLLER1007
CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL1010
CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX Plus CONTROLLER1010
CONNECT ADAPTER TO TROUBLESHOOT KomVision CONTROLLER1011
CONNECT CONNECTORS FOR ENGINE RELATED PARTS1011
DISCONNECT KomVision RADAR CONNECTOR1015
PROCEDURE FOR TROUBLESHOOTING1017
SYMPTOM AND TROUBLESHOOTING NUMBERS1019
INFORMATION DESCRIBED IN TROUBLESHOOTING1031
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE1034
CONNECTOR LAYOUT1262
CONNECTOR CONTACT IDENTIFICATION1278
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1320
FUSE LOCATION TABLE1326
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1329
PREPARATION TO TROUBLESHOOT MACHINE MONITOR1333
HARNESS CHECKER ON MACHINE MONITOR LCD UNIT1335
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883], [CB1883], [CA3135] AND [CB3135])1340
FAILURE CODES TABLE1342
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1372
FAILURE CODE [1500L0]1372
FAILURE CODE [15B0NX]1374
FAILURE CODE [15SAL1]1377
FAILURE CODE [15SALH]1380
FAILURE CODE [15SBL1]1383
FAILURE CODE [15SBLH]1386
FAILURE CODE [15SEL1]1389
FAILURE CODE [15SELH]1392
FAILURE CODE [15SFL1]1395
FAILURE CODE [15SFLH]1398
FAILURE CODE [15SGL1]1401
FAILURE CODE [15SGLH]1404
FAILURE CODE [15W0NT]1407
FAILURE CODE [2F00MA]1409
FAILURE CODE [2F00MB]1415
FAILURE CODE [2G42ZG]1420
FAILURE CODE [2G43ZG]1423
FAILURE CODE [879AKA]1426
FAILURE CODE [879AKB]1427
FAILURE CODE [879BKA]1428
FAILURE CODE [879BKB]1431
FAILURE CODE [879CKA]1434
FAILURE CODE [879CKB]1435
FAILURE CODE [879DKZ]1436
FAILURE CODE [879EMC]1440
FAILURE CODE [879FMC]1441
FAILURE CODE [879GKX]1442
FAILURE CODE [989A00]1445
FAILURE CODE [989L00]1446
FAILURE CODE [989M00]1447
FAILURE CODE [989N00]1448
FAILURE CODE [A1U0N3]1449
FAILURE CODE [A1U0N4]1453
FAILURE CODE [AA10NX]1457
FAILURE CODE [AB00KE]1460
FAILURE CODE [AB00KY]1463
FAILURE CODE [AQ10N3]1465
FAILURE CODE [B@BAZG]1468
FAILURE CODE [B@BAZK]1471
FAILURE CODE [B@BCNS]1474
FAILURE CODE [B@BCZK]1477
FAILURE CODE [B@C6NS]1480
FAILURE CODE [B@C7NS]1483
FAILURE CODE [B@CENS]1486
FAILURE CODE [B@GAZK]1489
FAILURE CODE [B@HANS]1492
FAILURE CODE [CA115]1495
FAILURE CODE [CA122]1500
FAILURE CODE [CA123]1503
FAILURE CODE [CA131]1507
FAILURE CODE [CA132]1510
FAILURE CODE [CA135]1513
FAILURE CODE [CA141]1516
FAILURE CODE [CA144]1519
FAILURE CODE [CA145]1522
FAILURE CODE [CA153]1525
FAILURE CODE [CA154]1529
FAILURE CODE [CA187]1533
FAILURE CODE [CA212]1537
FAILURE CODE [CA213]1540
FAILURE CODE [CA221]1543
FAILURE CODE [CA222]1546
FAILURE CODE [CA227]1550
FAILURE CODE [CA234]1553
FAILURE CODE [CA238]1555
FAILURE CODE [CA239]1558
FAILURE CODE [CA271]1561
FAILURE CODE [CA272]1564
FAILURE CODE [CA273]1566
FAILURE CODE [CA274]1569
FAILURE CODE [CA322]1571
FAILURE CODE [CA323]1574
FAILURE CODE [CA324]1577
FAILURE CODE [CA325]1580
FAILURE CODE [CA331]1583
FAILURE CODE [CA332]1586
FAILURE CODE [CA343]1589
FAILURE CODE [CA351]1596
FAILURE CODE [CA352]1604
FAILURE CODE [CA356]1608
FAILURE CODE [CA357]1612
FAILURE CODE [CA386]1616
FAILURE CODE [CA431]1620
FAILURE CODE [CA432]1624
FAILURE CODE [CA441]1629
FAILURE CODE [CA442]1633
FAILURE CODE [CA449]1637
FAILURE CODE [CA451]1640
FAILURE CODE [CA452]1643
FAILURE CODE [CA515]1646
FAILURE CODE [CA516]1648
FAILURE CODE [CA553]1651
FAILURE CODE [CA555]1654
FAILURE CODE [CA556]1657
FAILURE CODE [CA559]1660
FAILURE CODE [CA595]1666
FAILURE CODE [CA687]1669
FAILURE CODE [CA689]1673
FAILURE CODE [CA691]1678
FAILURE CODE [CA692]1681
FAILURE CODE [CA697]1684
FAILURE CODE [CA698]1686
FAILURE CODE [CA731]1688
FAILURE CODE [CA778]1696
FAILURE CODE [CA1117]1701
FAILURE CODE [CA1135]1706
FAILURE CODE [CA1257]1717
FAILURE CODE [CA1664]1719
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1721
FAILURE CODE [CA1691]1723
FAILURE CODE [CA1695]1728
FAILURE CODE [CA1696]1731
FAILURE CODE [CA1843]1734
FAILURE CODE [CA1844]1737
FAILURE CODE [CA1879]1740
FAILURE CODE [CA1881]1744
FAILURE CODE [CA1883]1748
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1751
FAILURE CODE [CA1921]1753
FAILURE CODE [CA1922]1761
FAILURE CODE [CA1923]1768
FAILURE CODE [CA1924]1771
Circuit diagram of fuel doser1774
FAILURE CODE [CA1925]1776
Circuit diagram of fuel doser1778
FAILURE CODE [CA1927]1780
FAILURE CODE [CA1928]1783
FAILURE CODE [CA1942]1786
FAILURE CODE [CA1963]1789
Circuit diagram of fuel doser1795
FAILURE CODE [CA1977]1797
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1800
FAILURE CODE [CA1993]1801
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1803
FAILURE CODE [CA2185]1805
FAILURE CODE [CA2186]1808
FAILURE CODE [CA2249]1811
FAILURE CODE [CA2265]1818
FAILURE CODE [CA2266]1821
FAILURE CODE [CA2271]1824
FAILURE CODE [CA2272]1827
FAILURE CODE [CA2349]1831
FAILURE CODE [CA2353]1834
FAILURE CODE [CA2357]1836
FAILURE CODE [CA2381]1841
FAILURE CODE [CA2382]1844
FAILURE CODE [CA2383]1848
FAILURE CODE [CA2386]1852
FAILURE CODE [CA2387]1854
FAILURE CODE [CA2555]1858
FAILURE CODE [CA2556]1861
FAILURE CODE [CA2637]1864
FAILURE CODE [CA2639]1871
FAILURE CODE [CA2732]1880
FAILURE CODE [CA2733]1883
FAILURE CODE [CA2741]1886
Circuit diagram of fuel doser1887
FAILURE CODE [CA2765]1889
FAILURE CODE [CA2777]1891
FAILURE CODE [CA2878]1894
Circuit diagram of fuel doser1898
FAILURE CODE [CA2881]1900
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1904
FAILURE CODE [CA3133]1907
FAILURE CODE [CA3134]1910
FAILURE CODE [CA3135]1914
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE1917
FAILURE CODE [CA3167]1919
Reset fuel doser memory1922
FAILURE CODE [CA3313]1925
FAILURE CODE [CA3314]1928
FAILURE CODE [CA3315]1931
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION1936
FAILURE CODE [CA3316]1938
FAILURE CODE [CA3317]1941
FAILURE CODE [CA3318]1944
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION1949
FAILURE CODE [CA3319]1951
FAILURE CODE [CA3321]1954
FAILURE CODE [CA3322]1957
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION1962
FAILURE CODE [CA3419]1964
FAILURE CODE [CA3421]1966
FAILURE CODE [CA4151]1969
FAILURE CODE [CA4158]1977
FAILURE CODE [CA4161]1980
FAILURE CODE [CA4162]1983
FAILURE CODE [CA4163]1986
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION1988
FAILURE CODE [CA4259]1989
FAILURE CODE [CA4952]1992
FAILURE CODE [CA5383]1995
FAILURE CODE [CB115]1997
FAILURE CODE [CB122]2002
FAILURE CODE [CB123]2005
FAILURE CODE [CB153]2009
FAILURE CODE [CB154]2013
FAILURE CODE [CB187]2017
FAILURE CODE [CB227]2021
FAILURE CODE [CB238]2024
FAILURE CODE [CB239]2027
FAILURE CODE [CB271]2030
FAILURE CODE [CB272]2033
FAILURE CODE [CB273]2035
FAILURE CODE [CB274]2038
FAILURE CODE [CB343]2040
FAILURE CODE [CB351]2047
FAILURE CODE [CB352]2055
FAILURE CODE [CB356]2059
FAILURE CODE [CB357]2063
FAILURE CODE [CB386]2067
FAILURE CODE [CB441]2070
FAILURE CODE [CB442]2074
FAILURE CODE [CB449]2078
FAILURE CODE [CB451]2081
FAILURE CODE [CB452]2084
FAILURE CODE [CB515]2087
FAILURE CODE [CB516]2089
FAILURE CODE [CB553]2092
FAILURE CODE [CB555]2095
FAILURE CODE [CB556]2098
FAILURE CODE [CB559]2101
FAILURE CODE [CB595]2107
FAILURE CODE [CB687]2110
FAILURE CODE [CB689]2114
FAILURE CODE [CB691]2119
FAILURE CODE [CB692]2122
FAILURE CODE [CB697]2125
FAILURE CODE [CB698]2127
FAILURE CODE [CB731]2129
FAILURE CODE [CB778]2138
FAILURE CODE [CB1117]2143
FAILURE CODE [CB1257]2148
FAILURE CODE [CB1548]2150
FAILURE CODE [CB1549]2153
FAILURE CODE [CB1551]2156
FAILURE CODE [CB1552]2159
FAILURE CODE [CB1553]2162
FAILURE CODE [CB1622]2165
FAILURE CODE [CB1664]2168
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2171
FAILURE CODE [CB1691]2172
FAILURE CODE [CB1695]2177
FAILURE CODE [CB1696]2180
FAILURE CODE [CB1843]2183
FAILURE CODE [CB1844]2186
FAILURE CODE [CB1879]2189
FAILURE CODE [CB1881]2193
FAILURE CODE [CB1883]2197
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2200
FAILURE CODE [CB1921]2202
FAILURE CODE [CB1922]2210
FAILURE CODE [CB1923]2217
FAILURE CODE [CB1924]2220
Circuit diagram of fuel doser2223
FAILURE CODE [CB1925]2225
Circuit diagram of fuel doser2227
FAILURE CODE [CB1927]2229
FAILURE CODE [CB1928]2232
FAILURE CODE [CB1942]2236
FAILURE CODE [CB1963]2239
Circuit diagram of fuel doser2245
FAILURE CODE [CB1977]2247
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2250
FAILURE CODE [CB1993]2251
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2253
FAILURE CODE [CB2249]2255
FAILURE CODE [CB2265]2261
FAILURE CODE [CB2266]2264
FAILURE CODE [CB2271]2267
FAILURE CODE [CB2272]2270
FAILURE CODE [CB2349]2274
FAILURE CODE [CB2353]2277
FAILURE CODE [CB2357]2279
FAILURE CODE [CB2381]2284
FAILURE CODE [CB2382]2287
FAILURE CODE [CB2383]2291
FAILURE CODE [CB2386]2295
FAILURE CODE [CB2387]2297
FAILURE CODE [CB2637]2301
FAILURE CODE [CB2639]2308
FAILURE CODE [CB2732]2317
FAILURE CODE [CB2733]2320
FAILURE CODE [CB2741]2323
Circuit diagram of fuel doser2324
FAILURE CODE [CB2765]2326
FAILURE CODE [CB2777]2328
FAILURE CODE [CB2878]2331
Circuit diagram of fuel doser2335
FAILURE CODE [CB2881]2337
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2341
FAILURE CODE [CB3133]2344
FAILURE CODE [CB3134]2347
FAILURE CODE [CB3135]2351
LOADED DIAGNOSTICS OPERATION TO CLEAR FAILURE CODE2354
FAILURE CODE [CB3167]2356
Reset fuel doser memory2359
FAILURE CODE [CB3313]2362
FAILURE CODE [CB3314]2365
FAILURE CODE [CB3315]2368
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION2373
FAILURE CODE [CB3316]2374
FAILURE CODE [CB3317]2377
FAILURE CODE [CB3318]2380
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION2385
FAILURE CODE [CB3319]2387
FAILURE CODE [CB3321]2390
FAILURE CODE [CB3322]2393
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION2398
FAILURE CODE [CB3419]2400
FAILURE CODE [CB3421]2402
FAILURE CODE [CB4151]2405
FAILURE CODE [CB4158]2413
FAILURE CODE [CB4161]2416
FAILURE CODE [CB4162]2419
FAILURE CODE [CB4163]2422
LOADED DIAGNOSTICS OPERATION TO CONFIRM FAILURE CORRECTION2424
FAILURE CODE [CB4259]2425
FAILURE CODE [CB4952]2428
FAILURE CODE [CB5383]2431
FAILURE CODE [D110L4]2433
FAILURE CODE [D162KA]2436
FAILURE CODE [D162KB]2437
FAILURE CODE [D162KY]2438
FAILURE CODE [D180KA]2439
FAILURE CODE [D180KB]2442
FAILURE CODE [D180KY]2445
FAILURE CODE [D191KA]2447
FAILURE CODE [D191KB]2450
FAILURE CODE [D191KY]2453
FAILURE CODE [D192KA]2455
FAILURE CODE [D192KB]2458
FAILURE CODE [D192KY]2461
FAILURE CODE [D19JKZ]2463
FAILURE CODE [D19LKA]2468
FAILURE CODE [D19LKB]2471
FAILURE CODE [D19LKY]2474
FAILURE CODE [D1E6KA]2476
FAILURE CODE [D1E6KB]2479
FAILURE CODE [D1E6KY]2482
FAILURE CODE [D1EFKA]2484
FAILURE CODE [D1EFKB]2487
FAILURE CODE [D1EFKY]2490
FAILURE CODE [D1J0KB]2493
FAILURE CODE [D5ZHKA]2496
FAILURE CODE [D5ZHKB]2499
FAILURE CODE [D5ZHKZ]2502
FAILURE CODE [D5ZHL6]2506
FAILURE CODE [D862KA]2509
FAILURE CODE [DA80KY]2512
FAILURE CODE [DA80L4]2515
FAILURE CODE [DAF0KT]2519
FAILURE CODE [DAF0MB]2520
FAILURE CODE [DAF0MC]2521
FAILURE CODE [DAF3KK]2522
FAILURE CODE [DAF8KB]2526
FAILURE CODE [DAFDKB]2529
FAILURE CODE [DAFGMC]2532
FAILURE CODE [DAFLKA]2533
FAILURE CODE [DAFLKB]2536
FAILURE CODE [DAFQKR]2539
FAILURE CODE [DAQ0KK]2550
FAILURE CODE [DAQ0KT]2555
FAILURE CODE [DAQ0MC]2556
FAILURE CODE [DAQ1KA]2557
FAILURE CODE [DAQ2KK]2560
FAILURE CODE [DAQ4KB]2564
FAILURE CODE [DAQ9KQ]2567
FAILURE CODE [DAQLKA]2569
FAILURE CODE [DAQLKB]2572
FAILURE CODE [DAQQKR]2575
FAILURE CODE [DAQRKR]2590
FAILURE CODE [DAQRMA]2604
FAILURE CODE [DAZ9KQ]2605
FAILURE CODE [DAZQKR]2607
FAILURE CODE [DB2QKR]2618
FAILURE CODE [DB2RKR]2636
FAILURE CODE [DB90KK]2654
FAILURE CODE [DB90KT]2659
FAILURE CODE [DB90MC]2660
FAILURE CODE [DB91KA]2661
FAILURE CODE [DB92KK]2664
FAILURE CODE [DB95KX]2669
FAILURE CODE [DB96KX]2672
FAILURE CODE [DB97KX]2677
FAILURE CODE [DB99KQ]2680
FAILURE CODE [DB9LKA]2682
FAILURE CODE [DB9LKB]2685
FAILURE CODE [DB9QKR]2688
FAILURE CODE [DB9RKR]2704
FAILURE CODE [DB9RMA]2720
FAILURE CODE [DBE5KX]2722
FAILURE CODE [DBE6KX]2725
FAILURE CODE [DBE7KX]2728
FAILURE CODE [DBP0KM]2732
FAILURE CODE [DBP0KT]2734
FAILURE CODE [DBP0NR]2735
FAILURE CODE [DBP5KP]2736
FAILURE CODE [DBPLKA]2740
FAILURE CODE [DBPLKB]2744
FAILURE CODE [DBPQKR]2747
FAILURE CODE [DBPRKR]2761
FAILURE CODE [DBPRMA]2774
FAILURE CODE [DBPUKR]2775
FAILURE CODE [DBPVKR]2785
FAILURE CODE [DBPWKR]2793
FAILURE CODE [DBPXKR]2795
FAILURE CODE [DBV0MC]2797
FAILURE CODE [DBV1KK]2798
FAILURE CODE [DBV5KX]2803
FAILURE CODE [DBV6KX]2807
FAILURE CODE [DBV7KX]2811
FAILURE CODE [DBV8KX]2812
FAILURE CODE [DBVLKA]2813
FAILURE CODE [DBVLKB]2817
FAILURE CODE [DBVQK4]2820
FAILURE CODE [DBVQKR]2834
FAILURE CODE [DBVRKR]2848
FAILURE CODE [DBVVKR]2862
FAILURE CODE [DBVWKR]2863
FAILURE CODE [DD1ALD]2865
FAILURE CODE [DDA8KB]2868
FAILURE CODE [DDA9KB]2871
FAILURE CODE [DDAAL6]2874
FAILURE CODE [DDACKA]2878
FAILURE CODE [DDACKY]2883
FAILURE CODE [DDADKA]2887
FAILURE CODE [DDADKY]2891
FAILURE CODE [DDB6L4]2893
FAILURE CODE [DDD1LD]2897
FAILURE CODE [DDDBKA]2900
FAILURE CODE [DDDBKY]2904
FAILURE CODE [DDE2KB]2907
FAILURE CODE [DDE2L6]2910
FAILURE CODE [DDE5KA]2912
FAILURE CODE [DDK4KA]2915
FAILURE CODE [DDK4KB]2919
FAILURE CODE [DDK5L4]2923
FAILURE CODE [DDNRKY]2926
FAILURE CODE [DDNTKY]2929
FAILURE CODE [DDNUKY]2932
FAILURE CODE [DDNWKY]2935
FAILURE CODE [DDNYKB]2937
FAILURE CODE [DDP5KA]2940
FAILURE CODE [DDP6KA]2943
FAILURE CODE [DDP6KY]2946
FAILURE CODE [DDP6NR]2949
FAILURE CODE [DDW9LD]2951
FAILURE CODE [DDWLLD]2954
FAILURE CODE [DF10KA]2957
FAILURE CODE [DF10KB]2958
FAILURE CODE [DGE5KA]2959
FAILURE CODE [DGE5KB]2962
FAILURE CODE [DGF1KA]2965
FAILURE CODE [DGF1KB]2968
FAILURE CODE [DGH2KX]2971
FAILURE CODE [DGR2KB]2974
FAILURE CODE [DGR2KZ]2978
FAILURE CODE [DGR4KB]2982
FAILURE CODE [DGR4KZ]2986
FAILURE CODE [DGT1KA]2990
FAILURE CODE [DGT1KB]2993
FAILURE CODE [DGT5KA]2996
FAILURE CODE [DGT5KY]3001
FAILURE CODE [DGT6KA]3005
FAILURE CODE [DGT6KY]3010
FAILURE CODE [DH21KA]3014
FAILURE CODE [DH21KY]3018
FAILURE CODE [DHA4KA]3021
FAILURE CODE [DHAAMA]3024
FAILURE CODE [DHABMA]3026
FAILURE CODE [DHACMA]3028
FAILURE CODE [DHADMA]3030
FAILURE CODE [DHPAKA]3032
FAILURE CODE [DHPAKY]3036
FAILURE CODE [DHPCKA]3039
FAILURE CODE [DHPCKY]3043
FAILURE CODE [DHPDKA]3046
FAILURE CODE [DHPDKY]3050
FAILURE CODE [DHPSKA]3053
FAILURE CODE [DHPSKY]3057
FAILURE CODE [DHT2L6]3060
FAILURE CODE [DHT3KX]3063
FAILURE CODE [DHT5KX]3067
FAILURE CODE [DHT7KX]3071
FAILURE CODE [DHT8KA]3075
FAILURE CODE [DHT8KY]3078
FAILURE CODE [DHTAKX]3080
FAILURE CODE [DHTBKA]3084
FAILURE CODE [DHTBKY]3088
FAILURE CODE [DHU2KA]3091
FAILURE CODE [DHU2KY]3094
FAILURE CODE [DHU3KA]3097
FAILURE CODE [DHU3KY]3100
FAILURE CODE [DJF1KA]3103
FAILURE CODE [DK30KA]3106
FAILURE CODE [DK30KY]3110
FAILURE CODE [DK55KA]3113
FAILURE CODE [DK55KY]3114
FAILURE CODE [DK55L5]3115
FAILURE CODE [DK59KA]3116
FAILURE CODE [DK59KY]3120
FAILURE CODE [DK59L8]3123
FAILURE CODE [DK5AKA]3128
FAILURE CODE [DK5AKY]3132
FAILURE CODE [DK5BKA]3135
FAILURE CODE [DK5BKY]3139
FAILURE CODE [DK5BL8]3142
FAILURE CODE [DK5CKA]3146
FAILURE CODE [DK5CKY]3150
FAILURE CODE [DKA0KA]3153
FAILURE CODE [DKA0KY]3157
FAILURE CODE [DKA0L0]3160
FAILURE CODE [DKA1KA]3163
FAILURE CODE [DKA1KY]3167
FAILURE CODE [DKD0KA]3170
FAILURE CODE [DKD0KY]3173
FAILURE CODE [DKD0L8]3175
FAILURE CODE [DKR2KX]3177
FAILURE CODE [DKR2NX]3181
FAILURE CODE [DKR3KX]3184
FAILURE CODE [DKR3NX]3188
FAILURE CODE [DLFAKA]3191
FAILURE CODE [DLFALC]3194
FAILURE CODE [DLFFLC]3197
FAILURE CODE [DLM3KA]3201
FAILURE CODE [DLM3LC]3204
FAILURE CODE [DLT3KA]3207
FAILURE CODE [DLT3LC]3210
FAILURE CODE [DLT4KB]3213
FAILURE CODE [DLT4KX]3216
FAILURE CODE [DNDBL4]3219
FAILURE CODE [DPQ1KR]3222
FAILURE CODE [DPQ1LD]3228
FAILURE CODE [DPQ2KR]3234
FAILURE CODE [DPQ3KR]3241
FAILURE CODE [DPQ4KB]3247
FAILURE CODE [DQ11KQ]3249
SENSOR ADDRESSES LIST3253
FAILURE CODE [DQ11KR]3254
FAILURE CODE [DQ11KT]3257
FAILURE CODE [DQ11MA]3260
FAILURE CODE [DQ11NR]3264
FAILURE CODE [DQ12KQ]3267
SENSOR ADDRESSES LIST3271
FAILURE CODE [DQ12KR]3272
FAILURE CODE [DQ12KT]3275
FAILURE CODE [DQ12MA]3278
FAILURE CODE [DQ12NR]3282
FAILURE CODE [DQ13KQ]3285
SENSOR ADDRESSES LIST3289
FAILURE CODE [DQ13KR]3290
FAILURE CODE [DQ13KT]3293
FAILURE CODE [DQ13MA]3296
FAILURE CODE [DQ13NR]3300
FAILURE CODE [DQ14KQ]3303
SENSOR ADDRESSES LIST3307
FAILURE CODE [DQ14KR]3308
FAILURE CODE [DQ14KT]3311
FAILURE CODE [DQ14MA]3314
FAILURE CODE [DQ14NR]3319
FAILURE CODE [DR10KA]3322
FAILURE CODE [DR20KA]3326
FAILURE CODE [DR30KA]3330
FAILURE CODE [DR40KA]3334
FAILURE CODE [DR50KA]3338
FAILURE CODE [DR60KA]3342
FAILURE CODE [DSJ0KR]3346
FAILURE CODE [DT22KB]3356
FAILURE CODE [DUMBKB]3359
FAILURE CODE [DV00KB]3362
FAILURE CODE [DV01KB]3365
FAILURE CODE [DW4PKA]3368
FAILURE CODE [DW4PKB]3371
FAILURE CODE [DW4PKY]3374
FAILURE CODE [DW4QKA]3377
FAILURE CODE [DW4QKB]3380
FAILURE CODE [DW4QKY]3383
FAILURE CODE [DW4RKA]3386
FAILURE CODE [DW4RKB]3389
FAILURE CODE [DW4RKY]3392
FAILURE CODE [DW4SKA]3395
FAILURE CODE [DW4SKB]3398
FAILURE CODE [DW4SKY]3401
FAILURE CODE [DW5PKA]3404
FAILURE CODE [DW5PKB]3407
FAILURE CODE [DW5PKY]3410
FAILURE CODE [DW5QKA]3413
FAILURE CODE [DW5QKB]3416
FAILURE CODE [DW5QKY]3419
FAILURE CODE [DW5RKA]3422
FAILURE CODE [DW5RKB]3425
FAILURE CODE [DW5RKY]3428
FAILURE CODE [DW5SKA]3431
FAILURE CODE [DW5SKB]3434
FAILURE CODE [DW5SKY]3437
FAILURE CODE [DW7BKA]3440
FAILURE CODE [DW7BKB]3443
FAILURE CODE [DW7BKY]3446
FAILURE CODE [DWM1KA]3448
FAILURE CODE [DWM1KB]3451
FAILURE CODE [DWM1KY]3454
FAILURE CODE [DWN6KA]3456
FAILURE CODE [DWN6KB]3459
FAILURE CODE [DWN6KY]3462
FAILURE CODE [DWN8KA]3465
FAILURE CODE [DWN8KB]3468
FAILURE CODE [DWN8KY]3471
FAILURE CODE [DWNFKA]3474
FAILURE CODE [DWNFKB]3477
FAILURE CODE [DWNFKY]3480
FAILURE CODE [DWNVKA]3482
FAILURE CODE [DWNVKB]3485
FAILURE CODE [DWNVKY]3488
FAILURE CODE [DX16KA]3490
FAILURE CODE [DX16KB]3493
FAILURE CODE [DX16KY]3496
FAILURE CODE [DXA1KA]3498
FAILURE CODE [DXA1KB]3501
FAILURE CODE [DXA1KY]3504
FAILURE CODE [DXA8KA]3506
FAILURE CODE [DXA8KB]3509
FAILURE CODE [DXA8KY]3512
FAILURE CODE [DXANKA]3514
FAILURE CODE [DXANKB]3517
FAILURE CODE [DXANKY]3520
FAILURE CODE [DXF0KA]3522
FAILURE CODE [DXF0KB]3525
FAILURE CODE [DXF0KY]3528
FAILURE CODE [DXF5KA]3530
FAILURE CODE [DXF5KB]3533
FAILURE CODE [DXF5KY]3536
FAILURE CODE [DXF6KA]3538
FAILURE CODE [DXF6KB]3541
FAILURE CODE [DXF6KY]3544
FAILURE CODE [DXH4KA]3546
FAILURE CODE [DXH4KB]3549
FAILURE CODE [DXH4KY]3552
FAILURE CODE [DXH5KA]3554
FAILURE CODE [DXH5KB]3557
FAILURE CODE [DXH5KY]3560
FAILURE CODE [DXH6KA]3562
FAILURE CODE [DXH6KB]3565
FAILURE CODE [DXH6KY]3568
FAILURE CODE [DXH7KA]3570
FAILURE CODE [DXH7KB]3573
FAILURE CODE [DXH7KY]3576
FAILURE CODE [DXH8KA]3578
FAILURE CODE [DXH8KB]3581
FAILURE CODE [DXH8KY]3584
FAILURE CODE [DXHPKA]3586
FAILURE CODE [DXHPKB]3589
FAILURE CODE [DXHPKY]3592
FAILURE CODE [DXHPMA]3595
FAILURE CODE [DXHPMB]3598
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)3601
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)3601
MANUAL PREHEATING SYSTEM DOES NOT WORK3616
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK (FOR MACHINES WITHOUT PRE-LUBRICATION SYSTEM)3624
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK (FOR MACHINES WITH PRE-LUBRICATION SYSTEM)3631
WHILE PREHEATING IS IN OPERATION, PREHEATING DISPLAY DOES NOT LIGHT UP3638
NONE OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY ANYTHING3642
LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING3652
BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL (BACKLIGHT GOES OFF OR FLICKERS)3655
LCD UNIT ON MACHINE MONITOR IS ABNORMAL3658
METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL3661
NIGHT MODE LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL3666
LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL3670
NIGHT MODE LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCHES DOES NOT OPERATE PROPERLY3675
TWO SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION3680
SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL3685
SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY3690
REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS3691
REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY3696
REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED3702
NIGHT MODE LAMP OF REARVIEW MONITOR IS ABNORMAL3708
AIR CLEANER CLOGGING CAUTION LAMP DOES NOT LIGHT UP3712
RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP3715
PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN PARKING BRAKE IS ON (PARKING) POSITION3718
BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE IS LOW3727
BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE IS LOW3731
FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL3735
TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT RISE OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP3738
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT RISE OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP3740
SEATBELT CAUTION LAMP DOES NOT INDICATE NORMALLY3742
ALARM BUZZER DOES NOT SOUND3745
ALARM BUZZER DOES NOT STOP3747
KICKDOWN DOES NOT OPERATE WHEN KICKDOWN SWITCH IS ON POSITION3749
HOLD DOES NOT OPERATE WHEN HOLD SWITCH IS ON POSITION3752
PARKING BRAKE DOES NOT OPERATE EVEN IF IT IS APPLIED, OR THE BRAKE DRAGS IN FORWARD OR REVERSE TRAVEL WHEN PARKING BRAKE IS RELEASED3755
LOADER PUMP1 OR LOADER PUMP 2 IS FIXED TO THE MINIMUM FLOW3763
ECSS DOES NOT OPERATE OR CANNOT BE DEACTIVATED3766
HORN DOES NOT SOUND3769
HORN DOES NOT STOP3774
NONE OF HEADLAMP, CLEARANCE LAMP, OR TAIL LAMP LIGHTS UP3777
CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OFF3781
HEADLAMP DO NOT LIGHT UP OR GO OFF3787
SIDE WORKING LAMP DOES NOT LIGHT UP OR GO OFF3793
FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OFF3798
REAR WORKING LAMP DOES NOT LIGHT UP OR GO OFF3805
NONE OF TURN SIGNAL LAMP OR HAZARD LAMP LIGHTS UP OR GO OFF3812
TURN SIGNAL LAMP DOES NOT LIGHT UP OR GO OFF3818
HAZARD LAMP DOES NOT LIGHT UP OR GO OFF3825
BRAKE LAMP DOES NOT LIGHT UP OR STAYS LIT3831
BACKUP LAMP DOES NOT LIGHT UP OR STAYS LIT3836
STAIRCASE LIGHT DOES NOT LIGHT UP OR GO OFF3840
ENGINE ROOM LAMP DOES NOT LIGHT UP OR GO OFF3846
FOG LAMP DOES NOT LIGHT UP OR GO OFF3851
YELLOW REVOLVING LAMP DOES NOT LIGHT UP OR GO OFF3856
BACKUP BUZZER DOES NOT SOUND OR DOES NOT STOP3861
FRONT WIPER DOES NOT OPERATE3865
REAR WIPER DOES NOT OPERATE3870
SIDE WIPER DOES NOT OPERATE3875
FUEL FEED PUMP DOES NOT OPERATE OR DOES NOT STOP AUTOMATICALLY3880
FRONT WINDOW WASHER DOES NOT OPERATE3888
REAR WINDOW WASHER DOES NOT OPERATE3892
SIDE WINDOW WASHER DOES NOT OPERATE3896
POWER LADDER DOES NOT OPERATE3900
SHOCK IS LARGE WHEN POWER LADDER STOPS3907
PARKING STATUS CANNOT BE CANCELLED WHILE POWER LADDER IS STORED3911
AUTO-DIGGING FUNCTION DOES NOT OPERATE3914
SEMI-AUTO APPROACH FUNCTION DOES NOT OPERATE3918
SEMI-AUTO DUMP FUNCTION DOES NOT OPERATE3922
KOMTRAX Plus SYSTEM DOES NOT OPERATE NORMALLY3927
DATA DOWNLOAD WITH WIRELESS LAN DOES NOT OPERATE3930
KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS3931
KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY3936
KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED3944
NIGHT MODE LAMP OF KomVision MONITOR IS ABNORMAL3950
KomVision MONITOR DOES NOT DISPLAY CAMERA IMAGE PARTIALLY3954
KomVision MONITOR DOES NOT DISPLAY NORMALLY AFTER CALIBRATION3956
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)3958
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE)3958
FAILURE MODE AND CAUSE TABLE3959
MACHINE DOES NOT MOVE3973
ECMV OPERATION TABLE3981
TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADEABILITY IS LOW, OR GEAR DOES NOT SHIFT3982
ECMV OPERATION TABLE3989
STRONG SHOCKS ARE MADE WHEN YOU START MACHINE OR SHIFT GEARS3990
ECMV OPERATION TABLE3995
TIME LAG IS LARGE WHEN YOU START MACHINE OR SHIFT GEARS3996
ECMV OPERATION TABLE4001
TORQUE CONVERTER OIL TEMPERATURE IS HIGH4002
MACHINE DOES NOT TURN4008
TURNING RESPONSE IS POOR4014
MACHINE SWAYS OR STRONG SHOCKS ARE MADE WHILE MACHINE TURNS4020
WHEEL BRAKES DO NOT WORK OR ARE WEAK4025
WHEEL BRAKES ARE NOT RELEASED OR DRAG4029
PARKING BRAKE DOES NOT WORK OR IS WEAK4031
PARKING BRAKE IS NOT RELEASED OR DRAGS4033
BOOM DOES NOT RISE4037
BOOM MOVES SLOW OR LACKS LIFTING FORCE4043
RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT4049
LIFT CYLINDER DOES NOT HOLD BUCKET ON GROUND4050
HYDRAULIC DRIFT OF BOOM IS LARGE4054
BOOM MOVES UP AND DOWN DURING OPERATION4056
BUCKET DOES NOT TILT BACK4058
BUCKET MOVES SLOW OR LACKS TILT BACK FORCE4065
BUCKET SLOWS DOWN DURING TILT BACK OPERATION4072
BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND4073
HYDRAULIC DRIFT OF BUCKET IS LARGE4077
BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD4079
BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE4081
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS WHEN YOU OPERATE WORK EQUIPMENT4083
STRONG SHOCKS ARE MADE WHEN YOU MOVE OR STOP WORK EQUIPMENT4087
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES4094
ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES4095
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)4098
UNUSUAL NOISE IS HEARD FROM AROUND FAN4102
TROUBLESHOOTING OF ENGINE (S-MODE)4103
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (S MODE)4103
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION4104
ENGINE CRANKS BUT DOES NOT START4106
FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)4111
ENGINE STARTABILITY IS POOR4118
ENGINE DOES NOT PICK UP SMOOTHLY4125
ENGINE STOPS DURING OPERATION4132
ENGINE RUNS ROUGH OR IS UNSTABLE4139
ENGINE LACKS POWER4145
KDPF GETS CLOGGED IN A SHORT TIME4152
ENGINE OIL CONSUMPTION IS EXCESSIVE4158
OIL BECOMES CONTAMINATED QUICKLY4162
FUEL CONSUMPTION IS EXCESSIVE4166
OIL MIXES INTO COOLANT (OR COOLANT SPURTS BACK AND COOLANT LEVEL DOES DOWN)4170
ENGINE OIL PRESSURE DROPS4172
FUEL MIXES INTO ENGINE OIL4176
WATER MIXES INTO ENGINE OIL (MILKY)4178
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)4181
UNUSUAL NOISE IS HEARD4186
VIBRATION IS EXCESSIVE4190
AIR CANNOT BE BLED FROM FUEL CIRCUIT4193
ACTIVE REGENERATION IS EXECUTED FREQUENTLY4197
ACTIVE REGENERATION TAKES LONG4204
WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION4209
50 DISASSEMBLY AND ASSEMBLY4211
CONTENTS4212
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY4217
HOW TO READ THIS MANUAL4217
COATING MATERIALS LIST4219
SPECIAL TOOLS LIST4223
SKETCHES OF SPECIAL TOOLS4240
ENGINE AND COOLING SYSTEM4253
REMOVE AND INSTALL COOLING ASSEMBLY4253
REMOVE COOLING ASSEMBLY4255
INSTALL COOLING ASSEMBLY4271
REMOVE AND INSTALL RADIATOR CORE4289
REMOVE RADIATOR CORE4290
INSTALL RADIATOR CORE4297
REMOVE AND INSTALL RADIATOR RESERVOIR TANK ASSEMBLY4304
REMOVE RADIATOR RESERVOIR TANK ASSEMBLY4304
INSTALL RADIATOR RESERVOIR TANK ASSEMBLY4306
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY4308
REMOVE COOLING FAN AND FAN MOTOR ASSEMBLY4309
INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY4313
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY4317
REMOVE HYDRAULIC COOLER ASSEMBLY4317
INSTALL HYDRAULIC COOLER ASSEMBLY4319
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY4321
REMOVE AFTER COOLER ASSEMBLY4322
INSTALL AFTER COOLER ASSEMBLY4327
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY4332
REMOVE POWER TRAIN OIL COOLER ASSEMBLY4333
INSTALL POWER TRAIN OIL COOLER ASSEMBLY4334
REMOVE AND INSTALL BRAKE COOLER4337
REMOVE BRAKE COOLER4337
INSTALL BRAKE COOLER4338
REMOVE AND INSTALL ENGINE ASSEMBLY4340
REMOVE ENGINE ASSEMBLY4342
INSTALL ENGINE ASSEMBLY4356
REMOVE AND INSTALL UPPER PORTION OF ENGINE4371
REMOVE UPPER PORTION OF ENGINE4372
INSTALL UPPER PORTION OF ENGINE4377
REMOVE AND INSTALL TOP HOOD ASSEMBLY4382
REMOVE TOP HOOD ASSEMBLY4382
INSTALL TOP HOOD ASSEMBLY4384
REMOVE AND INSTALL FUEL TANK ASSEMBLY4387
REMOVE FUEL TANK ASSEMBLY4388
INSTALL FUEL TANK ASSEMBLY4394
REMOVE AND INSTALL KDPF ASSEMBLY4399
REMOVE KDPF ASSEMBLY4400
INSTALL KDPF ASSEMBLY4406
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY4414
DISASSEMBLE KDPF ASSEMBLY4415
ASSEMBLE KDPF ASSEMBLY4421
REMOVE AND INSTALL AIR CLEANER ASSEMBLY4430
REMOVE AIR CLEANER ASSEMBLY4431
INSTALL AIR CLEANER ASSEMBLY4432
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY4435
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY4436
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY4438
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY4441
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY4442
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY4444
DRAIN AND ADD COOLANT4447
DRAIN COOLANT4447
ADD COOLANT4449
POWER TRAIN4451
REMOVE AND INSTALL DAMPER ASSEMBLY4451
REMOVE DAMPER ASSEMBLY4453
INSTALL DAMPER ASSEMBLY4455
DISASSEMBLE AND ASSEMBLE DAMPER ASSEMBLY4458
DISASSEMBLE DAMPER ASSEMBLY4459
ASSEMBLE DAMPER ASSEMBLY4460
REMOVE AND INSTALL TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4466
REMOVE TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4470
INSTALL TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4495
DISCONNECT AND CONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4521
DISCONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4522
CONNECT TRANSMISSION, TRANSFER ASSEMBLY AND TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4527
DISCONNECT AND CONNECT TORQUE CONVERTER, INPUT TRANSFER AND PTO ASSEMBLY4535
DISCONNECT TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4536
CONNECT TORQUE CONVERTER, INPUT TRANSFER, PTO ASSEMBLY4538
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY4541
DISASSEMBLE TORQUE CONVERTER ASSEMBLY4542
ASSEMBLE TORQUE CONVERTER ASSEMBLY4544
DISASSEMBLE AND ASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY4549
DISASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY4551
ASSEMBLE INPUT TRANSFER AND PTO ASSEMBLY4562
DISCONNECT AND CONNECT TRANSMISSION AND TRANSFER ASSEMBLY4584
DISCONNECT TRANSMISSION AND TRANSFER ASSEMBLY4584
CONNECT TRANSMISSION AND TRANSFER ASSEMBLY4585
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY4587
DISASSEMBLE TRANSMISSION ASSEMBLY4589
ASSEMBLE TRANSMISSION ASSEMBLY4602
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY4617
DISASSEMBLE TRANSFER ASSEMBLY4619
ASSEMBLE TRANSFER ASSEMBLY4627
REMOVE AND INSTALL PARKING BRAKE ASSEMBLY4641
REMOVE PARKING BRAKE ASSEMBLY4642
INSTALL PARKING BRAKE ASSEMBLY4646
DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY4649
DISASSEMBLE PARKING BRAKE ASSEMBLY4650
ASSEMBLE PARKING BRAKE ASSEMBLY4652
DRAIN AND ADD TRANSMISSION OIL4656
DRAIN TRANSMISSION OIL4656
ADD TRANSMISSION OIL4657
REMOVE AND INSTALL FRONT AXLE ASSEMBLY4658
REMOVE FRONT AXLE ASSEMBLY4660
INSTALL FRONT AXLE ASSEMBLY4667
REMOVE AND INSTALL REAR AXLE ASSEMBLY4673
REMOVE REAR AXLE ASSEMBLY4675
INSTALL REAR AXLE ASSEMBLY4683
REMOVE AND INSTALL CENTER SUPPORT ASSEMBLY4691
REMOVE CENTER SUPPORT ASSEMBLY4692
INSTALL CENTER SUPPORT ASSEMBLY4694
DISASSEMBLE AND ASSEMBLE CENTER SUPPORT ASSEMBLY4698
DISASSEMBLE CENTER SUPPORT ASSEMBLY4698
ASSEMBLE CENTER SUPPORT ASSEMBLY4700
REMOVE AND INSTALL DIFFERENTIAL ASSEMBLY4705
REMOVE DIFFERENTIAL ASSEMBLY4706
INSTALL DIFFERENTIAL ASSEMBLY4709
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY4713
DISASSEMBLE DIFFERENTIAL ASSEMBLY4715
ASSEMBLE DIFFERENTIAL ASSEMBLY4725
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY4747
REMOVE FINAL DRIVE CARRIER ASSEMBLY4748
INSTALL FINAL DRIVE CARRIER ASSEMBLY4749
DISASSEMBLE AND ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY4752
DISASSEMBLE FINAL DRIVE CARRIER ASSEMBLY4752
ASSEMBLE FINAL DRIVE CARRIER ASSEMBLY4754
REMOVE AND INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY4757
REMOVE FRONT FINAL DRIVE AND BRAKE ASSEMBLY4757
INSTALL FRONT FINAL DRIVE AND BRAKE ASSEMBLY4761
DISASSEMBLE AND ASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY4765
DISASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY4767
ASSEMBLE FINAL DRIVE AND BRAKE ASSEMBLY4776
STEERING SYSTEM4793
REMOVE AND INSTALL STEERING VALVE ASSEMBLY4793
REMOVE STEERING VALVE ASSEMBLY4794
INSTALL STEERING VALVE ASSEMBLY4802
REMOVE AND INSTALL ROTARY VALVE ASSEMBLY4811
REMOVE ROTARY VALVE ASSEMBLY4812
INSTALL ROTARY VALVE ASSEMBLY4814
BRAKE SYSTEM4817
REMOVE AND INSTALL RIGHT BRAKE VALVE ASSEMBLY4817
REMOVE RIGHT BRAKE VALVE ASSEMBLY4818
INSTALL RIGHT BRAKE VALVE ASSEMBLY4821
REMOVE AND INSTALL LEFT BRAKE VALVE ASSEMBLY4826
REMOVE LEFT BRAKE VALVE ASSEMBLY4827
INSTALL LEFT BRAKE VALVE ASSEMBLY4829
REMOVE AND INSTALL BRAKE ACCUMULATOR ASSEMBLY4833
REMOVE BRAKE ACCUMULATOR ASSEMBLY4834
INSTALL BRAKE ACCUMULATOR ASSEMBLY4837
UNDERCARRIAGE AND FRAME4840
REMOVE AND INSTALL CENTER HINGE PIN4840
REMOVE CENTER HINGE PIN4844
INSTALL CENTER HINGE PIN4855
REMOVE AND INSTALL BUMPER ASSEMBLY4873
REMOVE BUMPER ASSEMBLY4874
INSTALL BUMPER ASSEMBLY4877
HYDRAULIC SYSTEM4880
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY4880
REMOVE HYDRAULIC TANK ASSEMBLY4881
INSTALL HYDRAULIC TANK ASSEMBLY4889
REMOVE AND INSTALL WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY4896
REMOVE WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY4897
INSTALL WORK EQUIPMENT PUMP, PILOT AND BRAKE CHARGE PUMP ASSEMBLY4902
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY4906
REMOVE WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY4907
INSTALL WORK EQUIPMENT PUMP AND BRAKE COOLING DUPLEX PUMP ASSEMBLY4911
REMOVE AND INSTALL SECONDARY STEERING PUMP ASSEMBLY4915
REMOVE SECONDARY STEERING PUMP ASSEMBLY4916
INSTALL SECONDARY STEERING PUMP ASSEMBLY4917
REMOVE AND INSTALL STEERING PUMP ASSEMBLY4919
REMOVE STEERING PUMP ASSEMBLY4920
INSTALL STEERING PUMP ASSEMBLY4926
REMOVE AND INSTALL COOLING PUMP AND COOLING FAN PUMP ASSEMBLY4931
REMOVE COOLING PUMP AND COOLING FAN PUMP ASSEMBLY4932
INSTALL COOLING PUMP AND COOLING FAN PUMP ASSEMBLY4937
REMOVE AND INSTALL TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY4943
REMOVE TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY4944
INSTALL TRANSMISSION AND TORQUE CONVERTER LUBRICATION TRIPLEX PUMP ASSEMBLY4946
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY4948
REMOVE CONTROL VALVE ASSEMBLY4949
INSTALL CONTROL VALVE ASSEMBLY4961
REMOVE AND INSTALL DIVERTER VALVE ASSEMBLY4973
REMOVE DIVERTER VALVE ASSEMBLY4974
INSTALL DIVERTER VALVE ASSEMBLY4977
DRAIN AND ADD HYDRAULIC OIL4980
DRAIN HYDRAULIC OIL4980
ADD HYDRAULIC OIL4982
WORK EQUIPMENT4983
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY4983
REMOVE WORK EQUIPMENT ASSEMBLY4984
INSTALL WORK EQUIPMENT ASSEMBLY4991
DISASSEMBLE AND ASSEMBLE STEERING CYLINDER ASSEMBLY4999
DISASSEMBLE STEERING CYLINDER ASSEMBLY5000
ASSEMBLE STEERING CYLINDER ASSEMBLY5002
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY5006
DISASSEMBLE BUCKET CYLINDER ASSEMBLY5007
ASSEMBLE BUCKET CYLINDER ASSEMBLY5009
DISASSEMBLE AND ASSEMBLE LIFT CYLINDER ASSEMBLY5013
DISASSEMBLE LIFT CYLINDER ASSEMBLY5014
ASSEMBLE LIFT CYLINDER ASSEMBLY5016
REMOVE AND INSTALL BOOM END (BUCKET HINGE) BUSHING5020
REMOVE BOOM END (BUCKET HINGE) BUSHING5020
INSTALL BOOM END (BUCKET HINGE) BUSHING5021
CAB RELATED PARTS5022
REMOVE AND INSTALL ROPS ASSEMBLY5022
REMOVE ROPS ASSEMBLY5023
INSTALL ROPS ASSEMBLY5027
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY5032
REMOVE OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY5034
INSTALL OPERATOR CAB ASSEMBLY AND FLOOR FRAME ASSEMBLY5044
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY5055
REMOVE OPERATOR CAB ASSEMBLY5056
INSTALL OPERATOR CAB ASSEMBLY5070
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)5084
REMOVE OPERATOR CAB GLASS (ADHERED GLASS)5084
INSTALL OPERATOR CAB GLASS (ADHERED GLASS)5085
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY5094
REMOVE AIR CONDITIONER UNIT ASSEMBLY5095
INSTALL AIR CONDITIONER UNIT ASSEMBLY5101
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY5109
REMOVE OPERATOR SEAT ASSEMBLY5109
INSTALL OPERATOR SEAT ASSEMBLY5112
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER5116
REMOVE WORK EQUIPMENT CONTROL LEVER5116
INSTALL WORK EQUIPMENT CONTROL LEVER5120
REMOVE AND INSTALL SEATBELT5124
REMOVE SEATBELT5124
INSTALL SEATBELT5125
REMOVE AND INSTALL AJSS LEVER SWITCH ASSEMBLY5127
REMOVE AJSS LEVER SWITCH ASSEMBLY5128
INSTALL AJSS LEVER SWITCH ASSEMBLY5132
ELECTRICAL SYSTEM5138
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY5138
REMOVE ENGINE CONTROLLER ASSEMBLY5138
INSTALL ENGINE CONTROLLER ASSEMBLY5142
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY5148
REMOVE WORK EQUIPMENT CONTROLLER ASSEMBLY5148
INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY5151
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY5154
REMOVE TRANSMISSION CONTROLLER ASSEMBLY5154
INSTALL TRANSMISSION CONTROLLER ASSEMBLY5157
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY5160
REMOVE MONITOR CONTROLLER ASSEMBLY5160
INSTALL MONITOR CONTROLLER ASSEMBLY5163
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY5166
REMOVE MACHINE MONITOR ASSEMBLY5166
INSTALL MACHINE MONITOR ASSEMBLY5168
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR5171
REMOVE MASS AIR FLOW AND TEMPERATURE SENSOR5171
INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR5172
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR5173
REMOVE KCCV CRANKCASE PRESSURE SENSOR5173
INSTALL KCCV CRANKCASE PRESSURE SENSOR5176
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR5180
REMOVE KDPF TEMPERATURE SENSOR5180
INSTALL KDPF TEMPERATURE SENSOR5187
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR5192
REMOVE KDPF DIFFERENTIAL PRESSURE SENSOR5192
INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR5195
REMOVE AND INSTALL KomVision CAMERA ASSEMBLY5199
REMOVE KomVision CAMERA ASSEMBLY5201
INSTALL KomVision CAMERA ASSEMBLY5211
REMOVE AND INSTALL KomVision RADAR ASSEMBLY5222
REMOVE KomVision RADAR ASSEMBLY5224
INSTALL KomVision RADAR ASSEMBLY5227
REMOVE AND INSTALL KomVision CONTROLLER5230
REMOVE KomVision CONTROLLER5230
INSTALL KomVision CONTROLLER5231
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY5233
REMOVE KOMTRAX Plus CONTROLLER ASSEMBLY5233
INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY5235
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY5237
REMOVE WIRELESS LAN UNIT ASSEMBLY5237
INSTALL WIRELESS LAN UNIT ASSEMBLY5239
60 MAINTENANCE STANDARD5241
CONTENTS5242
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD5243
ENGINE AND COOLING SYSTEM5245
MAINTENANCE STANDARD OF ENGINE MOUNT5245
MAINTENANCE STANDARD OF DAMPER5246
MAINTENANCE STANDARD OF COOLING FAN PUMP5248
SERVO VALVE OF COOLING FAN PUMP5250
MAINTENANCE STANDARD OF COOLING FAN MOTOR5251
POWER TRAIN5254
MAINTENANCE STANDARD OF DRIVE SHAFT5254
MAINTENANCE STANDARD OF CENTER SUPPORT5255
MAINTENANCE STANDARD OF TRANSMISSION MOUNT5257
MAINTENANCE STANDARD OF TORQUE FLOW ASSEMBLY5259
MAINTENANCE STANDARD OF TORQUE CONVERTER5261
MAINTENANCE STANDARD OF MODULATION CLUTCH5268
MAINTENANCE STANDARD OF VALVE ASSEMBLY (FOR MAIN RELIEF AND TORQUE CONVERTER RELIEF)5270
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE5272
MAINTENANCE STANDARD OF TRANSMISSION5274
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE5282
MAINTENANCE STANDARD OF F, R, 1ST, 2ND, 3RD CLUTCH ECMV5283
MAINTENANCE STANDARD OF MODULATION CLUTCH ECMV5285
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION RELIEF VALVE5287
MAINTENANCE STANDARD OF FRONT AXLE5288
MAINTENANCE STANDARD OF REAR AXLE5290
MAINTENANCE STANDARD OF FRONT DIFFERENTIAL5292
MAINTENANCE STANDARD OF REAR DIFFERENTIAL5296
MAINTENANCE STANDARD OF FINAL DRIVE5300
STEERING SYSTEM5302
MAINTENANCE STANDARD OF STEERING PUMP5302
MAINTENANCE STANDARD OF STEERING CYLINDER5305
BRAKE SYSTEM5307
MAINTENANCE STANDARD OF BRAKE5307
MAINTENANCE STANDARD OF PARKING BRAKE5309
MAINTENANCE STANDARD OF PARKING BRAKE CIRCUIT CHECK VALVE5311
UNDERCARRIAGE AND FRAME5312
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN5312
HYDRAULIC SYSTEM5319
MAINTENANCE STANDARD OF HYDRAULIC TANK5319
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP5321
MAINTENANCE STANDARD OF CONTROL VALVE5324
WORK EQUIPMENT5337
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE5337
MAINTENANCE STANDARD OF BUCKET5341
MAINTENANCE STANDARD OF LIFT CYLINDER5342
MAINTENANCE STANDARD OF BUCKET CYLINDER5343
CAB RELATED PARTS5344
MAINTENANCE STANDARD OF CAB MOUNT5344
80 OTHERS5345
CONTENTS5346
AIR CONDITIONER SYSTEM5348
PRECAUTIONS FOR REFRIGERANT5348
AIR CONDITIONER5349
SPECIFICATIONS OF AIR CONDITIONER5351
STRUCTURE AND FUNCTION OF REFRIGERATION CYCLE5352
OUTLINE OF REFRIGERATION CYCLE5353
COMPONENT PARTS OF AIR CONDITIONER SYSTEM5355
AIR CONDITIONER UNIT5355
AIR CONDITIONER UNIT5358
FUNCTION OF EVAPORATOR5358
FUNCTION OF HEATER CORE5358
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR5358
FUNCTION OF SERVOMOTOR5358
STRUCTURE OF EXPANSION VALVE5359
FUNCTION OF EXPANSION VALVE5359
OPERATION OF EXPANSION VALVE5359
FUNCTION OF TRIPLE PRESSURE SWITCH5360
AIR CONDITIONER CONTROLLER5362
STRUCTURE OF AIR CONDITIONER CONTROLLER5362
COMPRESSOR5363
STRUCTURE OF COMPRESSOR5363
SPECIFICATIONS OF COMPRESSOR5363
FUNCTION OF COMPRESSOR5363
CONDENSER5365
STRUCTURE OF CONDENSER5365
SPECIFICATIONS OF CONDENSER5365
FUNCTION OF CONDENSER5365
RECEIVER DRIER5367
STRUCTURE OF RECEIVER DRIER5367
SPECIFICATIONS OF RECEIVER DRIER5367
FUNCTION OF RECEIVER DRIER5367
AIR CONDITIONER RELATED SENSORS5368
STRUCTURE OF SUNLIGHT SENSOR5368
FUNCTION OF SUNLIGHT SENSOR5368
STRUCTURE OF AMBIENT TEMPERATURE SENSOR5368
FUNCTION OF AMBIENT TEMPERATURE SENSOR5368
PROCEDURE FOR TESTING AND TROUBLESHOOTING AIR CONDITIONER5369
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER5371
AIR CONDITIONER SYSTEM DIAGRAM5373
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER5374
FUNCTION OF AIR CONDITIONER CONTROLLER5375
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS5376
TEST AIR LEAKAGE (DUCT)5380
TEST AIR LEAKAGE (DUCT)5380
TEST AIR CONDITIONER WITH SELF-DIAGNOSIS FUNCTION5382
OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF MACHINE MONITOR5383
TEST VENT (MODE) CHANGEOVER5384
TEST VENT (MODE) CHANGEOVER5384
TEST FRESH/RECIRC AIR CHANGEOVER5385
TEST FRESH/RECIRC AIR CHANGEOVER5385
TEST SUNLIGHT SENSOR5386
TEST SUNLIGHT SENSOR5386
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT5387
METHOD FOR TESTING (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT5387
TEST RELAYS5389
TEST RELAYS5389
AIR CONDITIONER TROUBLESHOOTING CHART 15390
AIR CONDITIONER TROUBLESHOOTING CHART 25392
INFORMATION DESCRIBED IN TROUBLESHOOTING5395
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)5398
FAILURE CODE [879AKA]5398
FAILURE CODE [879AKB]5399
FAILURE CODE [879BKA]5400
FAILURE CODE [879BKB]5403
FAILURE CODE [879CKA]5406
FAILURE CODE [879CKB]5407
FAILURE CODE [879DKZ]5408
FAILURE CODE [879EMC]5412
FAILURE CODE [879FMC]5413
FAILURE CODE [879GKX]5414
TROUBLESHOOTING OF AIR CONDITIONER SYSTEM (A-MODE)5417
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)5417
TROUBLESHOOTING FOR CONDENSER5422
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)5429
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)5434
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER5438
TROUBLESHOOTING BY GAUGE PRESSURE5441
CONNECT SERVICE TOOL5445
CONNECT SERVICE TOOL5445
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPINGS5446
COMPRESSOR OIL5447
KomVision SYSTEM5449
STRUCTURE AND OPERATION OF KomVision SYSTEM5449
PRECAUTIONS FOR KomVision SYSTEM5449
LAYOUT DRAWING OF KomVision SYSTEM5450
KomVision SYSTEM5456
TEST AND ADJUST KomVision SYSTEM5469
SETTING AND OPERATION OF KomVision MONITOR5469
CAMERA CALIBRATION5489
5 CAMERA CALIBRATION5490
1 CAMERA CALIBRATION5515
ADJUST RADAR (FOR MACHINE WITH RADAR)5522
SET DEFAULT RADAR SETTING5522
ADJUST RADAR5524
TROUBLESHOOTING FOR KomVision SYSTEM5529
RELATED INFORMATION TO TROUBLESHOOT5529
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)5547
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)5726
90 CIRCUIT DIAGRAMS5753
CONTENTS5754
HOW TO READ THE CODES FOR ELECTRIC CABLE5756
HYDRAULIC CIRCUIT DIAGRAM5760
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM5760
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT5765
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM5767
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT (COMBINATION OF FORWARD 1ST TRAVEL, BOOM RAISE AND BUCKET TILT OPERATION 1/2)5769
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN (COMBINATION OF FORWARD 1ST TRAVEL, BOOM RAISE AND BUCKET TILT OPERATION 2/2)5771
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT(COMBINATION OF BOOM LOWER, REVERSE 2ND TRAVEL, STEER LEFT, AND LEFT BRAKE OPERATION 1/2)5773
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN(COMBINATION OF BOOM LOWER, REVERSE 2ND TRAVEL, STEER LEFT, AND LEFT BRAKE OPERATION 2/2)5775
ELECTRICAL CIRCUIT DIAGRAM5777
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM5777
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8)5781
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8)5783
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8)5785
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8)5787
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8)5789
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8)5791
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8)5793
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8)5795
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/8)5797
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/8)5799
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/8)5801
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/8)5803
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/8)5805
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/8)5807
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/8)5809
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/8)5811
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (1/2)5813
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE (2/2)5815
CONNECTOR AND WIRING HARNESS CHART5817
CONNECTOR AND WIRING HARNESS CHART (1/53)5819
CONNECTOR AND WIRING HARNESS CHART (2/53)5821
CONNECTOR AND WIRING HARNESS CHART (3/53)5823
CONNECTOR AND WIRING HARNESS CHART (4/53)5825
CONNECTOR AND WIRING HARNESS CHART (5/53)5827
CONNECTOR AND WIRING HARNESS CHART (6/53)5829
CONNECTOR AND WIRING HARNESS CHART (7/53)5831
CONNECTOR AND WIRING HARNESS CHART (8/53)5833
CONNECTOR AND WIRING HARNESS CHART (9/53)5835
CONNECTOR AND WIRING HARNESS CHART (10/53)5837
CONNECTOR AND WIRING HARNESS CHART (11/53)5839
CONNECTOR AND WIRING HARNESS CHART (12/53)5841
CONNECTOR AND WIRING HARNESS CHART (13/53)5843
CONNECTOR AND WIRING HARNESS CHART (14/53)5845
CONNECTOR AND WIRING HARNESS CHART (15/53)5847
CONNECTOR AND WIRING HARNESS CHART (16/53)5849
CONNECTOR AND WIRING HARNESS CHART (17/53)5851
CONNECTOR AND WIRING HARNESS CHART (18/53)5853
CONNECTOR AND WIRING HARNESS CHART (19/53)5855
CONNECTOR AND WIRING HARNESS CHART (20/53)5857
CONNECTOR AND WIRING HARNESS CHART (21/53)5859
CONNECTOR AND WIRING HARNESS CHART (22/53)5861
CONNECTOR AND WIRING HARNESS CHART (23/53)5863
CONNECTOR AND WIRING HARNESS CHART (24/53)5865
CONNECTOR AND WIRING HARNESS CHART (25/53)5867
CONNECTOR AND WIRING HARNESS CHART (26/53)5869
CONNECTOR AND WIRING HARNESS CHART (27/53)5871
CONNECTOR AND WIRING HARNESS CHART (28/53)5873
CONNECTOR AND WIRING HARNESS CHART (29/53)5875
CONNECTOR AND WIRING HARNESS CHART (30/53)5877
CONNECTOR AND WIRING HARNESS CHART (31/53)5879
CONNECTOR AND WIRING HARNESS CHART (32/53)5881
CONNECTOR AND WIRING HARNESS CHART (33/53)5883
CONNECTOR AND WIRING HARNESS CHART (33/53)5885
CONNECTOR AND WIRING HARNESS CHART (34/53)5887
CONNECTOR AND WIRING HARNESS CHART (35/53)5889
CONNECTOR AND WIRING HARNESS CHART (36/53)5891
CONNECTOR AND WIRING HARNESS CHART (37/53)5893
CONNECTOR AND WIRING HARNESS CHART (38/53)5895
CONNECTOR AND WIRING HARNESS CHART (39/53)5897
CONNECTOR AND WIRING HARNESS CHART (40/53)5899
CONNECTOR AND WIRING HARNESS CHART (41/53)5901
CONNECTOR AND WIRING HARNESS CHART (42/53)5903
CONNECTOR AND WIRING HARNESS CHART (43/53)5905
CONNECTOR AND WIRING HARNESS CHART (44/53)5907
CONNECTOR AND WIRING HARNESS CHART (45/53)5909
CONNECTOR AND WIRING HARNESS CHART (46/53)5911
CONNECTOR AND WIRING HARNESS CHART (47/53)5913
CONNECTOR AND WIRING HARNESS CHART (48/53)5915
CONNECTOR AND WIRING HARNESS CHART (49/53)5917
CONNECTOR AND WIRING HARNESS CHART (50/53)5919
CONNECTOR AND WIRING HARNESS CHART (51/53)5921
CONNECTOR AND WIRING HARNESS CHART (52/53)5923
CONNECTOR AND WIRING HARNESS CHART (53/53)5925
INDEX5927

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24