Komatsu WA380-8 Wheel Loader Shop Manual SEN06573-09 – PDF DOWNLOAD

Komatsu WA380-8 Wheel Loader Shop Manual SEN06573-09 – PDF DOWNLOAD

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Komatsu WA380-8 Wheel Loader Shop Manual SEN06573-09 – PDF DOWNLOAD

Language : English
Pages : 3786
Downloadable : Yes
File Type : PDF
Size: 92.6 MB

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Komatsu WA380-8 Wheel Loader Shop Manual SEN06573-09 – PDF DOWNLOAD

SERIAL NUMBERS 15001 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.

General precautions
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation
and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, always
agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator’s
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work:
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible,
insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

TABLE OF CONTENTS:

Komatsu WA380-8 Wheel Loader Shop Manual SEN06573-09 – PDF DOWNLOAD

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 25
FOREWORD, SAFETY, BASIC INFORMATION 31
HOW TO READ THE SHOP MANUAL 31
SAFETY NOTICE FOR OPERATION 33
PRECAUTIONS TO PREVENT FIRE 41
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 45
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 60
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 61
PRACTICAL USE OF KOMTRAX 62
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 77
HOW TO READ ELECTRICAL WIRE CODE 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 82
STANDARD TIGHTENING TORQUE TABLE 85
CONVERSION TABLE 92
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: WA380-8 105
SPECIFICATIONS 107
SPECIFICATIONS: WA380-8 107
WEIGHT TABLE 112
WEIGHT TABLE: WA380-8 112
TABLE OF FUEL, COOLANT, AND LUBRICANTS 114
10 STRUCTURE AND FUNCTION 117
CONTENTS 118
ABBREVIATION LIST 123
UREA SCR SYSTEM 129
LAYOUT DRAWING OF UREA SCR SYSTEM 129
UREA SCR SYSTEM DIAGRAM 133
FUNCTION OF UREA SCR SYSTEM 134
FUNCTION OF AdBlue/DEF SYSTEM 134
INDUCEMENT STRATEGY 137
COMPONENT PARTS OF UREA SCR SYSTEM 151
AdBlue/DEF MIXING TUBE 151
SCR ASSEMBLY 152
AdBlue/DEF TANK 154
AdBlue/DEF PUMP 156
AdBlue/DEF INJECTOR 157
AdBlue/DEF HOSE 158
AdBlue/DEF TANK HEATING VALVE 159
BOOT-UP SYSTEM 160
LAYOUT DRAWING OF BOOT-UP SYSTEM 160
SYSTEM OPERATING LAMP SYSTEM 161
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 161
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 161
BATTERY DISCONNECT SWITCH 162
LAYOUT DRAWING OF BATTERY DISCONNECT SWITCH 162
FUNCTION OF BATTERY DISCONNECT SWITCH 162
PREHEATING SYSTEM 164
PREHEATING SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 164
OPERATION OF AUTOMATIC PREHEATING SYSTEM 164
FUNCTION OF MANUAL PREHEATING SYSTEM 165
OPERATION OF MANUAL PREHEATING SYSTEM 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 168
FUNCTION OF ENGINE CONTROL SYSTEM 169
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 176
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 176
COMPONENT PARTS OF ENGINE SYSTEM 177
VGT 177
EGR SYSTEM 182
EGR VALVE 184
EGR COOLER 186
KCCV SYSTEM 188
KCCV VENTILATOR 190
KDPF 192
COOLING SYSTEM 196
LAYOUT DRAWING OF COOLING SYSTEM 196
SPECIFICATIONS OF COOLING SYSTEM 197
COOLING FAN CONTROL SYSTEM 199
COOLING FAN CONTROL SYSTEM DIAGRAM 199
FUNCTION OF COOLING FAN CONTROL SYSTEM 199
COMPONENT PARTS OF COOLING SYSTEM 204
BRAKE AND COOLING FAN PUMP 204
COOLING FAN MOTOR 212
CONTROL SYSTEM 218
LAYOUT DRAWING OF CONTROL SYSTEM 218
MACHINE MONITOR SYSTEM 220
MACHINE MONITOR SYSTEM DIAGRAM 220
FUNCTION OF MACHINE MONITOR SYSTEM 220
REARVIEW MONITOR SYSTEM 222
REARVIEW MONITOR SYSTEM DIAGRAM 222
FUNCTION OF REARVIEW MONITOR SYSTEM 222
KOMTRAX SYSTEM 223
KOMTRAX SYSTEM DIAGRAM 223
FUNCTION OF KOMTRAX SYSTEM 223
COMPONENT PARTS OF CONTROL SYSTEM 224
MACHINE MONITOR 224
SWITCH PANEL 244
REARVIEW MONITOR 245
REARVIEW CAMERA 247
KOMTRAX TERMINAL 248
TRANSMISSION CONTROLLER 250
WORK EQUIPMENT CONTROLLER 254
MONITOR CONTROLLER 258
CAN TERMINATING RESISTOR 263
ENGINE CONTROLLER 264
ACCELERATOR PEDAL 271
HYDRAULIC SYSTEM 273
LAYOUT DRAWING OF HYDRAULIC SYSTEM 273
CLSS 274
STRUCTURE OF CLSS 274
FUNCTION OF CLSS 275
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM 277
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP 277
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW 277
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT 277
COMPONENT PARTS OF HYDRAULIC SYSTEM 278
HYDRAULIC TANK 278
WORK EQUIPMENT PUMP 281
STEERING PUMP 295
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 308
CONTROL VALVE 309
STABILIZER VALVE 345
POWER TRAIN SYSTEM 350
LAYOUT DRAWING OF POWER TRAIN SYSTEM 350
OPERATION OF POWER TRAIN SYSTEM 353
TRANSMISSION CONTROL SYSTEM 354
TRANSMISSION CONTROL SYSTEM DIAGRAM 354
TRANSMISSION GEAR SHIFT CONTROL SYSTEM 356
ELECTRIC MODULATION FUNCTION SYSTEM DIAGRAM 356
ELECTRIC MODULATION FUNCTION 357
DISPLAY FUNCTION OF GEAR SHIFT 357
AUTOMATIC GEAR SHIFT FUNCTION 357
SHIFT HOLD FUNCTION 358
KICKDOWN FUNCTION 358
AUTOMATIC KICKDOWN FUNCTION 359
TORQUE CONVERTER LOCKUP FUNCTION 359
HUNTING PREVENTION FUNCTION 360
ADJUSTING FUNCTION OF TRANSMISSION INITIAL LEARNING AND ECMV CURRENT 360
SHIFT POINT CHANGING FUNCTION 360
4TH GEAR SPEED LIMITATION FUNCTION 361
TRANSMISSION PROTECTION FUNCTION 362
PROTECTION FUNCTION WHEN TRAVEL DIRECTION IS CHANGED 362
SHIFT DOWN PROTECTION FUNCTION 362
ENGINE OVERRUN PREVENTION FUNCTION 363
MAXIMUM SPEED LIMITATION FUNCTION 363
NEUTRALIZER FUNCTION 363
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION 365
TRANSMISSION CUT-OFF FUNCTION 367
COMPONENT PARTS OF POWER TRAIN SYSTEM 369
DRIVE SHAFT 369
TORQUE CONVERTER 371
LOCKUP CLUTCH ECMV 374
TRANSMISSION 377
TRANSMISSION CONTROL VALVE 393
FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 395
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 400
AXLE 402
CONVENTIONAL DIFFERENTIAL 405
LIMITED SLIP DIFFERENTIAL 408
FINAL DRIVE 412
COMBINATION SWITCH 414
SHIFT HOLD SWITCH 418
KICKDOWN SWITCH 419
WORK EQUIPMENT SYSTEM 420
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 420
WORK EQUIPMENT SYSTEM DIAGRAM 422
WORK EQUIPMENT CONTROL SYSTEM 424
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE 424
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION 425
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM 426
WORK EQUIPMENT LEVER OPERATION FUNCTION 427
BUCKET PRIORITY CONTROL FUNCTION 427
BOOM STOP MODULATION FUNCTION 427
WORK EQUIPMENT NEUTRAL LOCK SYSTEM 429
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM 429
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM 429
REMOTE POSITIONER SYSTEM 431
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM 431
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM 431
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 432
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 432
BUCKET POSITIONER AND BOOM POSITIONER 436
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER 436
AUTO-DIGGING SYSTEM 437
AUTO-DIGGING SYSTEM DIAGRAM 437
FUNCTION OF AUTO-DIGGING SYSTEM 437
SEMI AUTO-DIGGING SYSTEM 439
SEMI AUTO-DIGGING SYSTEM DIAGRAM 439
FUNCTION OF SEMI AUTO-DIGGING SYSTEM 439
ECSS 441
ECSS DIAGRAM 441
FUNCTION OF ECSS 441
OPERATION OF ECSS 441
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 443
WORK EQUIPMENT LOCK SOLENOID VALVE 443
PILOT CIRCUIT ACCUMULATOR 444
ECSS CIRCUIT ACCUMULATOR 445
WORK EQUIPMENT ELECTRIC LEVER 447
MULTIFUNCTION MONO-LEVER 450
STEERING SYSTEM 451
LAYOUT DRAWING OF STEERING SYSTEM 451
SECONDARY STEERING SYSTEM 452
SECONDARY STEERING SYSTEM DIAGRAM 452
FUNCTION OF SECONDARY STEERING SYSTEM 452
STEERING COLUMN 454
STRUCTURE OF STEERING COLUMN 454
COMPONENT PARTS OF STEERING SYSTEM 455
ORBITROL VALVE 455
STOP VALVE 459
STEERING VALVE 460
SECONDARY STEERING PUMP 473
SECONDARY STEERING MOTOR 474
BRAKE SYSTEM 475
LAYOUT DRAWING OF BRAKE SYSTEM 475
LAYOUT DRAWING OF BRAKE COOLING SYSTEM 476
PARKING BRAKE CONTROL SYSTEM 477
PARKING BRAKE CONTROL SYSTEM DIAGRAM 477
OPERATION OF PARKING BRAKE CONTROL SYSTEM 477
BRAKE COOLING CONTROL SYSTEM 479
BRAKE COOLING CONTROL SYSTEM DIAGRAM 479
FUNCTION OF BRAKE COOLING CONTROL SYSTEM 479
COMPONENT PARTS OF BRAKE SYSTEM 480
CHARGE VALVE 480
PARKING BRAKE SOLENOID VALVE 485
PARKING BRAKE EMERGENCY RELEASE VALVE 487
BRAKE CIRCUIT ACCUMULATOR 488
BRAKE VALVE 490
BRAKE 494
PARKING BRAKE 497
FLOW PRIORITY VALVE 499
BRAKE COOLING MOTOR 501
BRAKE COOLING PUMP 502
BRAKE COOLING OIL COOLER 503
AUTO-GREASING SYSTEM 504
LAYOUT DRAWING OF AUTO-GREASING SYSTEM 504
SPECIFICATIONS OF AUTO-GREASING SYSTEM 505
FUNCTION OF AUTO-GREASING SYSTEM 507
COMPONENT PARTS OF AUTO-GREASING SYSTEM 508
AUTO-GREASING PUMP 508
UNDERCARRIAGE AND FRAME 509
FRAME, AXLE MOUNT AND CENTER HINGE PIN 509
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 509
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 510
TIRE 511
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE 511
STRUCTURE OF RADIAL TIRE 511
FUNCTION OF RADIAL TIRE 512
STRUCTURE OF BIAS TIRE 512
FUNCTION OF BIAS TIRE 512
WORK EQUIPMENT 513
STRUCTURE OF WORK EQUIPMENT 513
STRUCTURE OF BUCKET 514
CAB AND ITS ATTACHMENTS 515
ROPS CAB 515
STRUCTURE OF ROPS CAB 515
FUNCTION OF ROPS CAB 515
20 STANDARD VALUE TABLE 517
CONTENTS 518
ABBREVIATION LIST 519
STANDARD VALUE TABLE FOR ENGINE 525
STANDARD VALUE TABLE FOR ENGINE: WA380-8 525
STANDARD VALUE TABLE FOR MACHINE 529
STANDARD VALUE TABLE FOR MACHINE: WA380-8 529
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 548
STANDARD VALUE TABLE FOR ELECTRICAL 551
STANDARD VALUE TABLE FOR ELECTRICITY 551
30 TESTING AND ADJUSTING 573
CONTENTS 574
ABBREVIATION LIST 578
RELATED INFORMATION ON TESTING AND ADJUSTING 584
TOOLS FOR TESTING AND ADJUSTING 584
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 593
ENGINE AND COOLING SYSTEM 594
TEST ENGINE SPEED 594
METHOD FOR TESTING ENGINE SPEED 594
TEST BOOST PRESSURE 600
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 600
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 601
TEST EXHAUST GAS TEMPERATURE 604
METHOD FOR TESTING EXHAUST GAS TEMPERATURE 604
TEST EXHAUST GAS COLOR 606
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 606
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 607
TEST AND ADJUST VALVE CLEARANCE 609
METHOD FOR TESTING VALVE CLEARANCE 609
METHOD FOR ADJUSTING VALVE CLEARANCE 610
TEST COMPRESSION PRESSURE 612
METHOD FOR TESTING COMPRESSION PRESSURE 612
TEST BLOWBY PRESSURE 618
METHOD FOR TESTING BLOWBY PRESSURE 618
TEST ENGINE OIL PRESSURE 621
METHOD FOR TESTING ENGINE OIL PRESSURE 621
TEST EGR VALVE AND VGT OIL PRESSURE 623
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 623
TEST FUEL PRESSURE 625
METHOD FOR TESTING FUEL PRESSURE 626
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 631
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 632
BLEED AIR FROM FUEL SYSTEM 638
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 638
TEST FUEL CIRCUIT FOR LEAKAGE 640
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 640
HANDLE CYLINDER CUT-OUT MODE OPERATION 642
HANDLE NO-INJECTION CRANKING OPERATION 643
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 644
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 644
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 645
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS 645
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 646
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 646
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 647
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 647
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 647
TEST ALTERNATOR BELT 649
METHOD FOR TESTING ALTERNATOR BELT 649
TEST AUTOMATIC TENSIONER 651
METHOD FOR TESTING AUTOMATIC TENSIONER 651
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 654
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 654
TEST SCR RELATED FUNCTIONS 655
TEST AdBlue/DEF PUMP RAISED PRESSURE 659
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 662
TEST AdBlue/DEF LINE HEATER RELAY 1 667
TEST AdBlue/DEF LINE HEATER RELAY 2 671
TEST AdBlue/DEF PUMP HEATER RELAY 675
TEST AdBlue/DEF TANK HEATER VALVE 679
TEST SCR NOx REMOVAL EFFICIENCY 683
CLEAN AdBlue/DEF TANK 687
METHOD FOR CLEANING AdBlue/DEF TANK 687
POWER TRAIN 691
TEST AND ADJUST POWER TRAIN OIL PRESSURE 691
METHOD FOR TESTING POWER TRAIN OIL PRESSURE 694
METHOD FOR ADJUSTING POWER TRAIN OIL PRESSURE 708
ADJUST TRANSMISSION INPUT SPEED SENSOR 710
METHOD FOR ADJUSTING TRANSMISSION INPUT SPEED SENSOR 710
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 711
METHOD FOR ADJUSTING TRANSMISSION OUTPUT SHAFT SPEED SENSOR 711
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 712
METHOD FOR FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 712
MOVE DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 714
METHOD FOR MOVING DISABLED MACHINE DUE TO TRANSMISSION VALVE FAILURE 714
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 716
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE 716
STEERING SYSTEM 717
TEST STEERING WHEEL 717
METHOD FOR TESTING STEERING WHEEL 717
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 719
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE 719
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE 721
BLEED AIR FROM STEERING CYLINDER CIRCUIT 723
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT 723
TEST AND ADJUST STEERING STOP VALVE 724
METHOD FOR TESTING STEERING STOP VALVE 724
METHOD FOR ADJUSTING STEERING STOP VALVE 724
BRAKE SYSTEM 725
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 725
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 725
TEST WHEEL BRAKE OIL PRESSURE 726
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 726
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 728
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE 728
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE 729
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 730
METHOD FOR TESTING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 730
METHOD FOR CHARGING ACCUMULATOR NITROGEN GAS PRESSURE FOR BRAKE 732
BLEED AIR FROM BRAKE CIRCUIT 735
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT 735
TEST BRAKING PERFORMANCE 736
METHOD FOR TESTING BRAKING PERFORMANCE 736
TEST BRAKE PEDAL 737
METHOD FOR TESTING BRAKE PEDAL 737
TEST AND ADJUST BRAKE PEDAL AND LINKAGE 738
METHOD FOR TESTING BRAKE PEDAL AND LINKAGE 738
METHOD FOR ADJUSTING BRAKE PEDAL AND LINKAGE 738
TEST LOWERING OF WHEEL BRAKE PRESSURE 739
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 740
TEST WEAR OF WHEEL BRAKE DISC 742
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 742
TEST PARKING BRAKE OIL PRESSURE 744
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 744
TEST PARKING BRAKE PERFORMANCE 746
METHOD FOR TESTING PARKING BRAKE PERFORMANCE 746
RELEASE PARKING BRAKE MANUALLY 747
METHOD FOR RELEASING PARKING BRAKE MANUALLY 747
TEST WEAR AMOUNT OF PARKING BRAKE DISC 749
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC 749
HYDRAULIC SYSTEM 751
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 751
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 751
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 753
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE 753
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE 757
TEST AND ADJUST WORK EQUIPMENT EPC OIL PRESSURE 759
METHOD FOR TESTING WORK EQUIPMENT EPC OIL PRESSURE 759
METHOD FOR ADJUSTING WORK EQUIPMENT EPC OIL PRESSURE 761
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 762
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 762
TEST COOLING FAN SPEED 763
METHOD FOR TESTING COOLING FAN SPEED 763
TEST COOLING FAN CIRCUIT OIL PRESSURE 765
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 765
BLEED AIR FROM COOLING FAN CIRCUIT 768
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT 768
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS 770
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 770
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS 772
WORK EQUIPMENT 776
TEST AND ADJUST BUCKET POSITIONER DETECTION LEVER 776
METHOD FOR TESTING BUCKET POTENTIOMETER LEVER 776
METHOD FOR ADJUSTING BUCKET POTENTIOMETER LEVER 776
TEST AND ADJUST BOOM POTENTIOMETER LEVER 778
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 778
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 778
CAB AND ITS ATTACHMENTS 779
TEST DIRECTIONAL LEVER 779
METHOD FOR TESTING DIRECTIONAL LEVER 779
TEST WORK EQUIPMENT CONTROL LEVER 780
METHOD FOR TESTING WORK EQUIPMENT CONTROL LEVER 780
ELECTRICAL SYSTEM 783
SET AND ADJUST EACH EQUIPMENT 783
SET AND OPERATE MACHINE MONITOR 787
OPERATOR MODE 791
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 791
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 791
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 792
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 793
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 793
SERVICE MODE 797
METHOD FOR OPERATING SERVICE MODE 797
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 800
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 807
ABNORMALITY RECORD MENU 822
METHOD FOR CONFIRMING MAINTENANCE RECORD 827
METHOD FOR OPERATING MAINTENANCE MODE SETTING 829
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 834
DEFAULT MENU 836
DIAGNOSTIC TESTS MENU 851
ADJUSTMENT MENU 863
METHOD FOR PERFORMING NO-INJECTION CRANKING 911
KOMTRAX SETTINGS MENU 913
METHOD FOR DISPLAYING SERVICE MESSAGE 915
METHOD FOR STARTING UP KOMTRAX TERMINAL 917
ADJUST REARVIEW CAMERA ANGLE 922
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 922
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 924
HANDLE BATTERY DISCONNECT SWITCH 925
TEST DIODES 926
METHOD FOR TESTING DIODE USING DIGITAL TESTER 926
METHOD FOR TESTING DIODE USING ANALOG TESTER 926
AUTO-GREASING DEVICE 927
BLEED THE AIR OF AUTO-GREASING SYSTEM 927
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 927
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 930
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 931
Pm CLINIC 933
Pm CLINIC SERVICE 933
Pm CLINIC CHECK SHEET: WA380-8 936
40 TROUBLESHOOTING 947
CONTENTS 948
ABBREVIATION LIST 961
RELATED INFORMATION ON TROUBLESHOOTING 967
GENERAL TROUBLESHOOTING POINTS 967
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 968
SEQUENCE OF EVENTS IN TROUBLESHOOTING 980
CHECKS BEFORE TROUBLESHOOTING 982
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 984
WALK-AROUND CHECK 984
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 986
CHECK FUEL LEVEL AND TYPE 986
FUEL – CHECK FOR FOREIGN MATERIAL 986
CHECK AdBule/DEF LEVEL AND TYPE 987
CHECK FUEL PREFILTER 987
CHECK MAIN FILTER 989
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 990
CHECK COOLANT LEVEL (RESERVOIR TANK) 991
CHECK CLOGGING OF AIR CLEANER 992
OUTER ELEMENT – CLEAN 992
REPLACE ELEMENT 994
CHECK HYDRAULIC OIL LEVEL 995
CHECK HYDRAULIC OIL STRAINER 996
CHECK HYDRAULIC FILTER 997
CHECK OIL LEVEL IN TRANSMISSION CASE 999
CHECK OIL LEVEL IN FRONT AXLE CASE 1000
CHECK OIL LEVEL IN REAR AXLE CASE 1001
BLEED AIR FROM FUEL SYSTEM 1002
BLEED AIR FROM HYDRAULIC SYSTEM 1002
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 1002
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1008
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1020
SYMPTOM AND TROUBLESHOOTING NUMBERS 1022
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1027
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1029
CONNECTORS LIST AND LAYOUT 1032
CONNECTOR CONTACT IDENTIFICATION 1159
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1199
FUSE LOCATION TABLE 1205
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1209
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 1213
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 1215
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1221
FAILURE CODES TABLE 1223
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1247
FAILURE CODE [1500L0] 1247
FAILURE CODE [15SAL1] 1248
FAILURE CODE [15SALH] 1250
FAILURE CODE [15SBL1] 1252
FAILURE CODE [15SBLH] 1254
FAILURE CODE [15SEL1] 1256
FAILURE CODE [15SELH] 1258
FAILURE CODE [15SFL1] 1260
FAILURE CODE [15SFLH] 1262
FAILURE CODE [15SGL1] 1264
FAILURE CODE [15SGLH] 1266
FAILURE CODE [15SHL1] 1268
FAILURE CODE [15SHLH] 1270
FAILURE CODE [2F00MA] 1273
FAILURE CODE [2F00MB] 1277
FAILURE CODE [2G42ZG] 1280
FAILURE CODE [2G43ZG] 1282
FAILURE CODE [879AKA] 1284
FAILURE CODE [879AKB] 1286
FAILURE CODE [879BKA] 1288
FAILURE CODE [879BKB] 1290
FAILURE CODE [879CKA] 1292
FAILURE CODE [879CKB] 1294
FAILURE CODE [879DKZ] 1296
FAILURE CODE [879EMC] 1298
FAILURE CODE [879FMC] 1301
FAILURE CODE [989A00] 1304
FAILURE CODE [989L00] 1305
FAILURE CODE [989M00] 1306
FAILURE CODE [989N00] 1307
FAILURE CODE [A1U0N3] 1308
FAILURE CODE [A1U0N4] 1310
FAILURE CODE [AA10NX] 1312
FAILURE CODE [AB00KE] 1314
FAILURE CODE [AB00KY] 1316
FAILURE CODE [AQ10N3] 1318
FAILURE CODE [AS00N3] 1320
FAILURE CODE [AS00R2] 1322
FAILURE CODE [AS00R3] 1323
FAILURE CODE [AS00R4] 1324
FAILURE CODE [AS00R5] 1325
FAILURE CODE [AS00R6] 1326
FAILURE CODE [AS00ZK] 1327
FAILURE CODE [AS10KM] 1328
FAILURE CODE [AS10NR] 1329
FAILURE CODE [AS10NT] 1330
FAILURE CODE [B@BAZG] 1331
FAILURE CODE [B@BAZK] 1332
FAILURE CODE [B@BCNS] 1334
FAILURE CODE [B@BCZK] 1335
FAILURE CODE [B@C7NS] 1337
FAILURE CODE [B@CENS] 1339
FAILURE CODE [B@HANS] 1340
FAILURE CODE [CA115] 1341
FAILURE CODE [CA122] 1342
FAILURE CODE [CA123] 1344
FAILURE CODE [CA131] 1346
FAILURE CODE [CA132] 1348
FAILURE CODE [CA144] 1351
FAILURE CODE [CA145] 1353
FAILURE CODE [CA153] 1355
FAILURE CODE [CA154] 1358
FAILURE CODE [CA187] 1360
FAILURE CODE [CA221] 1362
FAILURE CODE [CA222] 1364
FAILURE CODE [CA227] 1366
FAILURE CODE [CA234] 1367
FAILURE CODE [CA238] 1368
FAILURE CODE [CA239] 1370
FAILURE CODE [CA249] 1372
FAILURE CODE [CA256] 1374
FAILURE CODE [CA271] 1376
FAILURE CODE [CA272] 1378
FAILURE CODE [CA322] 1380
FAILURE CODE [CA323] 1382
FAILURE CODE [CA324] 1384
FAILURE CODE [CA325] 1386
FAILURE CODE [CA331] 1388
FAILURE CODE [CA332] 1390
FAILURE CODE [CA343] 1392
FAILURE CODE [CA351] 1393
FAILURE CODE [CA352] 1394
FAILURE CODE [CA356] 1397
FAILURE CODE [CA357] 1399
FAILURE CODE [CA386] 1402
FAILURE CODE [CA428] 1403
FAILURE CODE [CA429] 1405
FAILURE CODE [CA431] 1407
FAILURE CODE [CA432] 1410
FAILURE CODE [CA435] 1414
FAILURE CODE [CA441] 1416
FAILURE CODE [CA442] 1418
FAILURE CODE [CA449] 1419
FAILURE CODE [CA451] 1420
FAILURE CODE [CA452] 1422
FAILURE CODE [CA488] 1424
FAILURE CODE [CA515] 1425
FAILURE CODE [CA516] 1427
FAILURE CODE [CA553] 1429
FAILURE CODE [CA555] 1430
FAILURE CODE [CA556] 1431
FAILURE CODE [CA559] 1432
FAILURE CODE [CA595] 1435
FAILURE CODE [CA687] 1436
FAILURE CODE [CA689] 1438
FAILURE CODE [CA691] 1441
FAILURE CODE [CA692] 1443
FAILURE CODE [CA697] 1445
FAILURE CODE [CA698] 1446
FAILURE CODE [CA731] 1447
FAILURE CODE [CA778] 1449
FAILURE CODE [CA1117] 1454
FAILURE CODE [CA1664] 1455
FAILURE CODE [CA1669] 1458
FAILURE CODE [CA1673] 1459
FAILURE CODE [CA1677] 1460
FAILURE CODE [CA1678] 1461
FAILURE CODE [CA1682] 1462
FAILURE CODE [CA1683] 1466
FAILURE CODE [CA1684] 1468
FAILURE CODE [CA1686] 1470
FAILURE CODE [CA1691] 1471
FAILURE CODE [CA1694] 1474
FAILURE CODE [CA1695] 1477
FAILURE CODE [CA1696] 1478
FAILURE CODE [CA1712] 1480
FAILURE CODE [CA1713] 1483
FAILURE CODE [CA1714] 1485
FAILURE CODE [CA1715] 1486
FAILURE CODE [CA1776] 1487
FAILURE CODE [CA1777] 1490
FAILURE CODE [CA1843] 1493
FAILURE CODE [CA1844] 1495
FAILURE CODE [CA1879] 1498
FAILURE CODE [CA1881] 1501
FAILURE CODE [CA1883] 1503
FAILURE CODE [CA1885] 1507
FAILURE CODE [CA1887] 1509
FAILURE CODE [CA1921] 1511
FAILURE CODE [CA1922] 1514
FAILURE CODE [CA1942] 1519
FAILURE CODE [CA1993] 1520
FAILURE CODE [CA2185] 1523
FAILURE CODE [CA2186] 1525
FAILURE CODE [CA2249] 1527
FAILURE CODE [CA2271] 1528
FAILURE CODE [CA2272] 1531
FAILURE CODE [CA2288] 1534
FAILURE CODE [CA2311] 1535
FAILURE CODE [CA2349] 1536
FAILURE CODE [CA2353] 1539
FAILURE CODE [CA2357] 1541
FAILURE CODE [CA2381] 1542
FAILURE CODE [CA2382] 1545
FAILURE CODE [CA2383] 1548
FAILURE CODE [CA2386] 1551
FAILURE CODE [CA2387] 1553
FAILURE CODE [CA2555] 1554
FAILURE CODE [CA2556] 1557
FAILURE CODE [CA2637] 1559
FAILURE CODE [CA2639] 1561
FAILURE CODE [CA2771] 1564
FAILURE CODE [CA2777] 1570
FAILURE CODE [CA2976] 1573
FAILURE CODE [CA3133] 1575
FAILURE CODE [CA3134] 1578
FAILURE CODE [CA3135] 1580
FAILURE CODE [CA3142] 1584
FAILURE CODE [CA3143] 1585
FAILURE CODE [CA3144] 1586
FAILURE CODE [CA3146] 1589
FAILURE CODE [CA3147] 1590
FAILURE CODE [CA3148] 1591
FAILURE CODE [CA3151] 1593
FAILURE CODE [CA3165] 1599
FAILURE CODE [CA3229] 1601
FAILURE CODE [CA3231] 1603
FAILURE CODE [CA3232] 1605
FAILURE CODE [CA3235] 1609
FAILURE CODE [CA3239] 1611
FAILURE CODE [CA3241] 1614
FAILURE CODE [CA3242] 1617
FAILURE CODE [CA3251] 1620
FAILURE CODE [CA3253] 1622
FAILURE CODE [CA3254] 1625
FAILURE CODE [CA3255] 1628
FAILURE CODE [CA3256] 1632
FAILURE CODE [CA3311] 1634
FAILURE CODE [CA3312] 1636
FAILURE CODE [CA3313] 1639
FAILURE CODE [CA3314] 1640
FAILURE CODE [CA3315] 1641
FAILURE CODE [CA3316] 1644
FAILURE CODE [CA3317] 1645
FAILURE CODE [CA3318] 1646
FAILURE CODE [CA3319] 1649
FAILURE CODE [CA3321] 1650
FAILURE CODE [CA3322] 1652
FAILURE CODE [CA3419] 1655
FAILURE CODE [CA3421] 1657
FAILURE CODE [CA3497] 1659
FAILURE CODE [CA3498] 1660
FAILURE CODE [CA3543] 1661
FAILURE CODE [CA3545] 1668
FAILURE CODE [CA3547] 1670
FAILURE CODE [CA3558] 1671
FAILURE CODE [CA3559] 1673
FAILURE CODE [CA3562] 1675
FAILURE CODE [CA3563] 1677
FAILURE CODE [CA3567] 1680
FAILURE CODE [CA3568] 1683
FAILURE CODE [CA3571] 1689
FAILURE CODE [CA3572] 1691
FAILURE CODE [CA3574] 1693
FAILURE CODE [CA3575] 1695
FAILURE CODE [CA3577] 1697
FAILURE CODE [CA3578] 1699
FAILURE CODE [CA3582] 1701
FAILURE CODE [CA3583] 1709
FAILURE CODE [CA3596] 1711
FAILURE CODE [CA3649] 1714
FAILURE CODE [CA3681] 1716
FAILURE CODE [CA3682] 1721
FAILURE CODE [CA3713] 1727
FAILURE CODE [CA3717] 1730
FAILURE CODE [CA3718] 1731
FAILURE CODE [CA3725] 1732
FAILURE CODE [CA3741] 1735
FAILURE CODE [CA3748] 1736
FAILURE CODE [CA3751] 1739
FAILURE CODE [CA3755] 1741
FAILURE CODE [CA3866] 1743
FAILURE CODE [CA3867] 1747
FAILURE CODE [CA3868] 1750
FAILURE CODE [CA3899] 1754
FAILURE CODE [CA3911] 1756
FAILURE CODE [CA3912] 1760
FAILURE CODE [CA3932] 1762
FAILURE CODE [CA3933] 1764
FAILURE CODE [CA3934] 1766
FAILURE CODE [CA3935] 1769
FAILURE CODE [CA3936] 1771
FAILURE CODE [CA4151] 1773
FAILURE CODE [CA4152] 1777
FAILURE CODE [CA4155] 1781
FAILURE CODE [CA4156] 1783
FAILURE CODE [CA4157] 1786
FAILURE CODE [CA4158] 1788
FAILURE CODE [CA4159] 1789
FAILURE CODE [CA4161] 1790
FAILURE CODE [CA4162] 1793
FAILURE CODE [CA4163] 1796
FAILURE CODE [CA4164] 1798
FAILURE CODE [CA4165] 1800
FAILURE CODE [CA4166] 1802
FAILURE CODE [CA4168] 1804
FAILURE CODE [CA4169] 1807
FAILURE CODE [CA4171] 1809
FAILURE CODE [CA4249] 1812
FAILURE CODE [CA4251] 1814
FAILURE CODE [CA4259] 1816
FAILURE CODE [CA4261] 1819
FAILURE CODE [CA4277] 1822
FAILURE CODE [CA4281] 1826
FAILURE CODE [CA4459] 1829
FAILURE CODE [CA4461] 1832
FAILURE CODE [CA4658] 1835
FAILURE CODE [CA4731] 1839
FAILURE CODE [CA4732] 1840
FAILURE CODE [CA4739] 1841
FAILURE CODE [CA4768] 1842
FAILURE CODE [CA4769] 1844
FAILURE CODE [CA4842] 1847
FAILURE CODE [CA4952] 1851
FAILURE CODE [CA5115] 1853
FAILURE CODE [CA5179] 1856
FAILURE CODE [CA5181] 1858
FAILURE CODE [CA5383] 1860
FAILURE CODE [D150KA] 1862
FAILURE CODE [D150KB] 1864
FAILURE CODE [D150KY] 1866
FAILURE CODE [D160KA] 1868
FAILURE CODE [D160KB] 1870
FAILURE CODE [D160KY] 1872
FAILURE CODE [D191KA] 1874
FAILURE CODE [D191KB] 1877
FAILURE CODE [D191KY] 1880
FAILURE CODE [D192KA] 1882
FAILURE CODE [D192KB] 1884
FAILURE CODE [D192KY] 1886
FAILURE CODE [D19JKZ] 1887
FAILURE CODE [D1E6KA] 1889
FAILURE CODE [D1E6KB] 1891
FAILURE CODE [D1E6KY] 1893
FAILURE CODE [D5ZHKA] 1895
FAILURE CODE [D5ZHKB] 1897
FAILURE CODE [D5ZHKZ] 1899
FAILURE CODE [D5ZHL6] 1902
FAILURE CODE [D5ZMLD] 1904
FAILURE CODE [D811MC] 1906
FAILURE CODE [D862KA] 1907
FAILURE CODE [D8ALKA] 1908
FAILURE CODE [D8ALKB] 1910
FAILURE CODE [D8AQK4] 1912
FAILURE CODE [D8AQKR] 1913
FAILURE CODE [DAF0KT] 1915
FAILURE CODE [DAF0MB] 1916
FAILURE CODE [DAF0MC] 1917
FAILURE CODE [DAF3KK] 1918
FAILURE CODE [DAF8KB] 1920
FAILURE CODE [DAFDKB] 1922
FAILURE CODE [DAFGMC] 1924
FAILURE CODE [DAFLKA] 1925
FAILURE CODE [DAFLKB] 1927
FAILURE CODE [DAFQKR] 1929
FAILURE CODE [DAQ0KK] 1930
FAILURE CODE [DAQ0KT] 1933
FAILURE CODE [DAQ0MC] 1934
FAILURE CODE [DAQ1KA] 1935
FAILURE CODE [DAQ2KK] 1937
FAILURE CODE [DAQ4KB] 1940
FAILURE CODE [DAQ9KQ] 1942
FAILURE CODE [DAQLKA] 1943
FAILURE CODE [DAQLKB] 1945
FAILURE CODE [DAQQKR] 1947
FAILURE CODE [DAQRKR] 1948
FAILURE CODE [DAQRMA] 1949
FAILURE CODE [DAZ9KQ] 1950
FAILURE CODE [DAZQKR] 1951
FAILURE CODE [DB2QKR] 1952
FAILURE CODE [DB2RKR] 1957
FAILURE CODE [DB90KK] 1963
FAILURE CODE [DB90KT] 1966
FAILURE CODE [DB90MC] 1967
FAILURE CODE [DB91KA] 1968
FAILURE CODE [DB92KK] 1970
FAILURE CODE [DB95KX] 1973
FAILURE CODE [DB96KX] 1976
FAILURE CODE [DB99KQ] 1978
FAILURE CODE [DB9LKA] 1979
FAILURE CODE [DB9LKB] 1981
FAILURE CODE [DB9QKR] 1983
FAILURE CODE [DB9RKR] 1984
FAILURE CODE [DB9RMA] 1985
FAILURE CODE [DBE5KX] 1986
FAILURE CODE [DBE6KX] 1988
FAILURE CODE [DD1ALD] 1990
FAILURE CODE [DDAAL6] 1992
FAILURE CODE [DDB6L4] 1994
FAILURE CODE [DDD1LD] 1997
FAILURE CODE [DDK3KA] 1999
FAILURE CODE [DDK3KB] 2002
FAILURE CODE [DDK6KA] 2005
FAILURE CODE [DDK6KB] 2008
FAILURE CODE [DDKLKA] 2010
FAILURE CODE [DDKLKB] 2013
FAILURE CODE [DDNRKY] 2015
FAILURE CODE [DDNTKY] 2017
FAILURE CODE [DDT0L4] 2019
FAILURE CODE [DDT4LD] 2021
FAILURE CODE [DDT9LD] 2023
FAILURE CODE [DDTALD] 2025
FAILURE CODE [DDW9LD] 2027
FAILURE CODE [DDWLLD] 2029
FAILURE CODE [DF10KA] 2031
FAILURE CODE [DF10KB] 2034
FAILURE CODE [DGF1KA] 2037
FAILURE CODE [DGF1KB] 2039
FAILURE CODE [DGH2KX] 2041
FAILURE CODE [DGR2KB] 2043
FAILURE CODE [DGR2KZ] 2045
FAILURE CODE [DGT1KA] 2047
FAILURE CODE [DGT1KB] 2049
FAILURE CODE [DH21KA] 2051
FAILURE CODE [DH21KB] 2054
FAILURE CODE [DHA4KA] 2056
FAILURE CODE [DHAAMA] 2058
FAILURE CODE [DHACMA] 2060
FAILURE CODE [DHPCKX] 2062
FAILURE CODE [DHPDKX] 2065
FAILURE CODE [DHT1KX] 2068
FAILURE CODE [DHT5KX] 2071
FAILURE CODE [DHT7KX] 2074
FAILURE CODE [DHT8KA] 2077
FAILURE CODE [DHT8KB] 2080
FAILURE CODE [DHT8ZG] 2082
FAILURE CODE [DHUDKA] 2083
FAILURE CODE [DHUDKB] 2086
FAILURE CODE [DJF1KA] 2088
FAILURE CODE [DK55KA] 2090
FAILURE CODE [DK55KY] 2093
FAILURE CODE [DK55L5] 2095
FAILURE CODE [DK59KA] 2096
FAILURE CODE [DK59KY] 2100
FAILURE CODE [DK59L8] 2104
FAILURE CODE [DK5AKA] 2109
FAILURE CODE [DK5AKY] 2113
FAILURE CODE [DK5BKA] 2117
FAILURE CODE [DK5BKY] 2121
FAILURE CODE [DK5BL8] 2125
FAILURE CODE [DK5CKA] 2130
FAILURE CODE [DK5CKY] 2134
FAILURE CODE [DK5DKA] 2138
FAILURE CODE [DK5DKY] 2141
FAILURE CODE [DK5DL8] 2144
FAILURE CODE [DK5EKA] 2148
FAILURE CODE [DK5EKY] 2151
FAILURE CODE [DK5KKA] 2154
FAILURE CODE [DK5KKY] 2157
FAILURE CODE [DK5KL8] 2160
FAILURE CODE [DK5LKA] 2164
FAILURE CODE [DK5LKY] 2167
FAILURE CODE [DKA0KA] 2170
FAILURE CODE [DKA0KY] 2173
FAILURE CODE [DKA0L0] 2176
FAILURE CODE [DKA1KA] 2179
FAILURE CODE [DKA1KY] 2182
FAILURE CODE [DLF1KA] 2185
FAILURE CODE [DLF1LC] 2187
FAILURE CODE [DLM3KA] 2189
FAILURE CODE [DLM3LC] 2191
FAILURE CODE [DLT3KA] 2193
FAILURE CODE [DLT3LC] 2195
FAILURE CODE [DPQ1KR] 2197
FAILURE CODE [DPQ2KR] 2200
FAILURE CODE [DPQ3KR] 2203
FAILURE CODE [DSJ0KR] 2206
FAILURE CODE [DT20KB] 2209
FAILURE CODE [DT22KB] 2211
FAILURE CODE [DT23KB] 2213
FAILURE CODE [DV00KB] 2215
FAILURE CODE [DW4PKA] 2217
FAILURE CODE [DW4PKB] 2219
FAILURE CODE [DW4PKY] 2221
FAILURE CODE [DW4QKA] 2223
FAILURE CODE [DW4QKB] 2225
FAILURE CODE [DW4QKY] 2227
FAILURE CODE [DW4RKA] 2229
FAILURE CODE [DW4RKB] 2231
FAILURE CODE [DW4RKY] 2233
FAILURE CODE [DW4SKA] 2235
FAILURE CODE [DW4SKB] 2237
FAILURE CODE [DW4SKY] 2239
FAILURE CODE [DW7BKA] 2241
FAILURE CODE [DW7BKB] 2243
FAILURE CODE [DW7BKY] 2245
FAILURE CODE [DWM1KA] 2247
FAILURE CODE [DWM1KB] 2249
FAILURE CODE [DWM1KY] 2251
FAILURE CODE [DWN6KA] 2253
FAILURE CODE [DWN6KB] 2255
FAILURE CODE [DWN6KY] 2257
FAILURE CODE [DWN8KA] 2259
FAILURE CODE [DWN8KB] 2261
FAILURE CODE [DWN8KY] 2263
FAILURE CODE [DX16KA] 2265
FAILURE CODE [DX16KB] 2267
FAILURE CODE [DX16KY] 2269
FAILURE CODE [DXA1KA] 2271
FAILURE CODE [DXA1KB] 2273
FAILURE CODE [DXA1KY] 2275
FAILURE CODE [DXANKA] 2277
FAILURE CODE [DXANKB] 2279
FAILURE CODE [DXANKY] 2281
FAILURE CODE [DXH1KA] 2283
FAILURE CODE [DXH1KB] 2285
FAILURE CODE [DXH1KY] 2287
FAILURE CODE [DXH4KA] 2289
FAILURE CODE [DXH4KB] 2291
FAILURE CODE [DXH4KY] 2293
FAILURE CODE [DXH5KA] 2295
FAILURE CODE [DXH5KB] 2297
FAILURE CODE [DXH5KY] 2299
FAILURE CODE [DXH6KA] 2301
FAILURE CODE [DXH6KB] 2303
FAILURE CODE [DXH6KY] 2305
FAILURE CODE [DXH7KA] 2307
FAILURE CODE [DXH7KB] 2309
FAILURE CODE [DXH7KY] 2311
FAILURE CODE [DXH8KA] 2313
FAILURE CODE [DXH8KB] 2315
FAILURE CODE [DXH8KY] 2317
FAILURE CODE [DXHHKA] 2319
FAILURE CODE [DXHHKB] 2321
FAILURE CODE [DXHHKY] 2323
FAILURE CODE [DXHJKA] 2325
FAILURE CODE [DXHJKB] 2327
FAILURE CODE [DXHJKY] 2329
FAILURE CODE [DXHKKA] 2331
FAILURE CODE [DXHKKB] 2333
FAILURE CODE [DXHKKY] 2335
FAILURE CODE [DXJEKA] 2337
FAILURE CODE [DXJEKB] 2339
FAILURE CODE [DXJEKY] 2341
FAILURE CODE [DXJFKA] 2343
FAILURE CODE [DXJFKB] 2345
FAILURE CODE [DXJFKY] 2347
FAILURE CODE [DY30MA] 2349
FAILURE CODE [DY30MC] 2353
FAILURE CODE [DY30ME] 2358
FAILURE CODE [LA00L3] 2360
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2361
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2361
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2368
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2371
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2374
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 2376
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 2379
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) 2382
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 2385
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 2388
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 2391
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 2395
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 2397
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 2400
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 2403
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 2406
E-16 AdBlue/DEF LEVEL IS NOT DISPLAYED PROPERLY 2407
E-17 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 2410
E-18 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 2413
E-19 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 2416
E-20 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 2420
E-21 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP 2422
E-22 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP 2424
E-23 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 2426
E-24 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2430
E-25 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 2431
E-26 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 2432
E-27 TORQUE CONVERTER OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 2434
E-28 INDICATION OF HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT 2435
E-29 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 2437
E-30 ALARM BUZZER DOES NOT SOUND 2438
E-31 ALARM BUZZER DOES NOT STOP SOUNDING 2440
E-32 KICKDOWN DOES NOT WORK WHEN KICKDOWN SWITCH IS TURNED ON 2441
E-33 HOLD SWITCH DOES NOT WORK WHEN IT IS PRESSED 2443
E-34 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED 2445
E-35 TRANSMISSION CUT-OFF MODE IS NOT SELECTED OR NOT RELEASED 2449
E-36 TRANSMISSION CUT-OFF SETTING CANNOT BE RELEASED 2451
E-37 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2453
E-38 ENGINE MODE SELECTOR FUNCTION DOES NOT OPERATE NORMALLY WHEN ENGINE POWER MODE SELECTOR SWITCH IS OPERATED 2455
E-39 FLOW OF LOADER PUMP DOES NOT INCREASE FROM THE MINIMUM RATE 2457
E-40 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2458
E-41 HORN DOES NOT SOUND 2460
E-42 HORN DOES NOT STOP SOUNDING 2463
E-43 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2465
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2467
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT 2471
E-46 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2475
E-47 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2477
E-48 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2479
E-49 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2484
E-50 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2489
E-51 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2493
E-52 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT 2498
E-53 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT 2501
E-54 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT 2504
E-55 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2508
E-56 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2512
E-57 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2515
E-58 FRONT WIPER DOES NOT OPERATE 2517
E-59 REAR WIPER DOES NOT OPERATE 2521
E-60 FAN DOES NOT ROTATE IN REVERSE 2524
E-61 FAN REMAINS ROTATED IN REVERSE 2525
E-62 WINDOW WASHER DOES NOT OPERATE 2526
E-63 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2529
E-64 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2530
E-65 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2532
E-66 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP 2533
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2535
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2535
FAILURE MODE AND CAUSE TABLE 2536
H-1 MACHINE DOES NOT START 2549
H-2 LOCKUP IS NOT RELEASED 2553
H-3 TORQUE CONVERTER LOCKUP CLUTCH DOES NOT ENGAGE 2554
H-4 TRAVEL SPEED IS SLOW, BUCKET THRUST FORCE IS WEAK, GRADABILITY IS LOW, OR GEAR SPEED DOES NOT SHIFT 2555
H-5 LARGE SHOCK IS MADE WHEN MACHINE MOVES OFF OR GEAR IS SHIFTED 2558
H-6 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 2561
H-7 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 2564
H-8 MACHINE DOES NOT TURN (FOR STEERING WHEEL SPEC) 2567
H-9 TURNING RESPONSE IS POOR (FOR STEERING WHEEL SPEC) 2570
H-10 STEERING WHEEL IS HEAVY TO OPERATE 2573
H-11 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS (FOR STEERING WHEEL SPEC) 2574
H-12 TURNING RADIUS DIFFERS BETWEEN RIGHT AND LEFT TURNS 2576
H-13 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2577
H-14 WHEEL BRAKES ARE NOT RELEASED OR DRAG 2579
H-15 PARKING BRAKE DOES NOT WORK OR IT IS WEAK 2580
H-16 PARKING BRAKE IS NOT RELEASED OR DRAGS 2581
H-17 BOOM DOES NOT RISE 2582
H-18 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE 2585
H-19 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2588
H-20 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2589
H-21 HYDRAULIC DRIFT OF BOOM IS LARGE 2591
H-22 BOOM MOVES UP AND DOWN DURING OPERATION 2592
H-23 BUCKET DOES NOT TILT BACK 2593
H-24 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2596
H-25 BUCKET DECELERATES DURING TILT-BACK OPERATION 2599
H-26 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2600
H-27 HYDRAULIC DRIFT OF BUCKET IS LARGE 2602
H-28 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) 2603
H-29 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (2-LEVER TYPE OR 3-LEVER TYPE) 2604
H-30 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE (MULTI-FUNCTION MONO-LEVER TYPE) 2605
H-31 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2606
H-32 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2607
H-33 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2609
H-34 E C S S (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2610
H-35 BUCKET DOES NOT STOP AT THE POSITION WHICH IS SET WITH REMOTE BUCKET POSITIONER 2611
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2612
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2614
TROUBLESHOOTING OF ENGINE (S-MODE) 2615
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2615
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2616
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2617
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2618
S-4 ENGINE STARTABILITY IS POOR 2620
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2622
S-6 ENGINE STOPS DURING OPERATION 2624
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2626
S-8 ENGINE LACKS POWER 2627
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2629
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2631
S-11 OIL BECOMES CONTAMINATED QUICKLY 2632
S-12 FUEL CONSUMPTION IS EXCESSIVE 2633
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2634
S-14 OIL PRESSURE DROPS 2635
S-15 FUEL MIXES INTO ENGINE OIL 2637
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2638
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2639
S-18 UNUSUAL NOISE IS HEARD 2640
S-19 VIBRATION IS EXCESSIVE 2641
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2642
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2643
S-22 ACTIVE REGENERATION TAKES TIME 2645
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2646
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2647
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2649
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM 2650
OUTLINE OF FAILURE DISPLAY 2650
TROUBLESHOOTING FOR FCS 2651
TROUBLESHOOTING FOR AUTO-GREASING PUMP 2652
REPLACEMENT OF PUMP ELEMENT 2655
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM 2656
REPLACEMENT OF AUTO-GREASING CONTROLLER 2658
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2659
TROUBLESHOOTING FOR RDS LOAD METER SYSTEM 2660
OUTLINE OF FAILURE DISPLAY 2660
METHOD FOR DISPLAYING DIAGNOSTICS SCREEN 2661
TROUBLESHOOTING FOR RDS LOAD METER 2662
50 DISASSEMBLY AND ASSEMBLY 2665
CONTENTS 2666
ABBREVIATION LIST 2671
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2677
HOW TO READ THIS MANUAL 2677
COATING MATERIALS LIST 2679
SPECIAL TOOLS LIST 2683
SKETCHES OF SPECIAL TOOLS 2702
ENGINE AND COOLING SYSTEM 2710
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2710
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2711
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2713
REMOVE AND INSTALL INJECTOR ASSEMBLY 2717
METHOD FOR REMOVING INJECTOR ASSEMBLY 2718
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2725
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2735
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2737
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2750
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2770
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2770
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2772
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2774
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2775
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2778
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2783
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2783
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2784
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT 2786
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2786
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2787
REMOVE AND INSTALL ALTERNATOR BELT 2788
METHOD FOR REMOVING ALTERNATOR BELT 2788
METHOD FOR INSTALLING ALTERNATOR BELT 2790
REMOVE AND INSTALL AUTOMATIC TENSIONER 2791
METHOD FOR REMOVING AUTOMATIC TENSIONER 2791
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2791
REMOVE AND INSTALL RADIATOR CORE 2793
METHOD FOR REMOVING RADIATOR CORE 2794
METHOD FOR INSTALLING RADIATOR CORE 2801
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2809
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2809
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2813
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2817
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2817
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2819
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2822
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2822
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2827
REMOVE AND INSTALL POWER TRAIN OIL COOLER ASSEMBLY 2833
METHOD FOR REMOVING POWER TRAIN OIL COOLER ASSEMBLY 2834
METHOD FOR INSTALLING POWER TRAIN OIL COOLER ASSEMBLY 2837
REMOVE AND INSTALL ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2841
METHOD FOR REMOVING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2843
METHOD FOR INSTALLING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2859
DISCONNECT AND CONNECT ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2877
METHOD FOR DISCONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2877
METHOD FOR CONNECTING ENGINE, TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 2878
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2881
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2881
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2882
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2884
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2884
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2885
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2889
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2889
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2893
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2898
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2898
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2901
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2905
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2906
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2911
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2917
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2917
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2917
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2920
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2920
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2921
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2928
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2928
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2928
REMOVE AND INSTALL KDPF ASSEMBLY 2930
METHOD FOR REMOVING KDPF ASSEMBLY 2931
METHOD FOR INSTALLING KDPF ASSEMBLY 2940
DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY 2955
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2956
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2959
REMOVE AND INSTALL SCR ASSEMBLY 2964
METHOD FOR REMOVING SCR ASSEMBLY 2965
METHOD FOR INSTALLING SCR ASSEMBLY 2974
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2987
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2988
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2997
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 3007
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 3007
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 3013
REMOVE AND INSTALL KCCV ASSEMBLY 3021
METHOD FOR REMOVING KCCV ASSEMBLY 3021
METHOD FOR INSTALLING KCCV ASSEMBLY 3022
REMOVE AND INSTALL VGT ASSEMBLY 3026
METHOD FOR REMOVING VGT ASSEMBLY 3027
METHOD FOR INSTALLING VGT ASSEMBLY 3031
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 3037
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 3038
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 3045
REMOVE AND INSTALL AdBlue/DEF INJECTOR 3054
METHOD FOR REMOVING AdBlue/DEF INJECTOR 3055
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 3058
REMOVE AND INSTALL AdBlue/DEF PUMP 3061
METHOD FOR REMOVING AdBlue/DEF PUMP 3062
METHOD FOR INSTALLING AdBlue/DEF PUMP 3065
REMOVE AND INSTALL AdBlue/DEF HOSE 3068
METHOD FOR REMOVING AdBlue/DEF HOSE 3069
METHOD FOR INSTALLING AdBlue/DEF HOSE 3075
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 3083
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 3083
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 3085
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 3088
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 3089
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 3092
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 3095
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 3095
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 3096
POWER TRAIN 3098
DISASSEMBLE AND ASSEMBLE TORQUE CONVERTER ASSEMBLY 3098
METHOD FOR DISASSEMBLING TORQUE CONVERTER ASSEMBLY 3098
METHOD FOR ASSEMBLING TORQUE CONVERTER ASSEMBLY 3101
DISASSEMBLE AND ASSEMBLE TRANSMISSION ASSEMBLY 3107
METHOD FOR DISASSEMBLING TRANSMISSION ASSEMBLY 3108
METHOD FOR ASSEMBLING TRANSMISSION ASSEMBLY 3116
DISASSEMBLE AND ASSEMBLE TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3128
METHOD FOR DISASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3129
METHOD FOR ASSEMBLING TRANSMISSION GEAR KIT WITH CLUTCH ASSEMBLY 3138
DISASSEMBLE AND ASSEMBLE PARKING BRAKE ASSEMBLY 3150
METHOD FOR DISASSEMBLING PARKING BRAKE ASSEMBLY 3151
METHOD FOR ASSEMBLING PARKING BRAKE ASSEMBLY 3153
REMOVE AND INSTALL FRONT AXLE ASSEMBLY 3161
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 3162
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 3163
REMOVE AND INSTALL REAR AXLE ASSEMBLY 3166
METHOD FOR REMOVING REAR AXLE ASSEMBLY 3167
METHOD FOR INSTALLING REAR AXLE ASSEMBLY 3171
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY 3176
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY 3177
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 3182
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY 3190
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY 3191
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 3201
STEERING SYSTEM 3219
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 3219
METHOD FOR REMOVING STEERING VALVE ASSEMBLY 3220
METHOD FOR INSTALLING STEERING VALVE ASSEMBLY 3222
BRAKE SYSTEM 3226
REMOVE AND INSTALL PARKING BRAKE DISC AND PLATE 3226
METHOD FOR REMOVING PARKING BRAKE DISC AND PLATE 3226
METHOD FOR INSTALLING PARKING BRAKE DISC AND PLATE 3229
UNDERCARRIAGE AND FRAME 3232
REMOVE AND INSTALL CENTER HINGE PIN 3232
METHOD FOR REMOVING CENTER HINGE PIN 3233
METHOD FOR INSTALLING CENTER HINGE PIN 3239
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 3248
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 3248
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 3254
REMOVE AND INSTALL FULL-LENGTH FENDER ASSEMBLY 3260
METHOD FOR REMOVING FULL-LENGTH FENDER ASSEMBLY 3260
METHOD FOR INSTALLING FULL-LENGTH FENDER ASSEMBLY 3261
HYDRAULIC SYSTEM 3262
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 3262
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 3263
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 3267
REMOVE AND INSTALL WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3271
METHOD FOR REMOVING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3272
METHOD FOR INSTALLING WORK EQUIPMENT PUMP AND POWER TRAIN PUMP ASSEMBLY 3273
REMOVE AND INSTALL STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3276
METHOD FOR REMOVING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3277
METHOD FOR INSTALLING STEERING PUMP AND COOLING FAN PUMP ASSEMBLY 3279
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 3283
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 3284
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 3288
WORK EQUIPMENT 3294
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 3294
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 3295
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 3299
DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLY 3306
METHOD FOR DISASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3307
METHOD FOR ASSEMBLING HYDRAULIC CYLINDER ASSEMBLY 3310
CAB AND ITS ATTACHMENTS 3316
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 3316
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 3317
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 3322
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 3328
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) 3329
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) 3329
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 3340
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 3341
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 3347
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 3353
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY 3353
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY 3356
REMOVE AND INSTALL SEAT BELT 3359
METHOD FOR REMOVING SEAT BELT 3359
METHOD FOR INSTALLING SEAT BELT 3360
ELECTRICAL SYSTEM 3361
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 3361
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 3361
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 3363
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY 3367
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY 3367
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY 3369
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 3372
METHOD FOR REMOVING TRANSMISSION CONTROLLER ASSEMBLY 3372
METHOD FOR INSTALLING TRANSMISSION CONTROLLER ASSEMBLY 3373
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 3374
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 3374
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 3376
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 3379
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 3379
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 3381
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 3383
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 3383
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 3384
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 3385
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 3385
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 3386
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR 3388
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 3388
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 3391
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR 3395
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 3395
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 3398
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 3402
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 3402
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 3406
REMOVE AND INSTALL AMMONIA SENSOR 3409
METHOD FOR REMOVING AMMONIA SENSOR 3409
METHOD FOR INSTALLING AMMONIA SENSOR 3411
REMOVE AND INSTALL SCR OUTLET NOx SENSOR 3413
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3413
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3415
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 3417
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3417
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3418
60 MAINTENANCE STANDARD 3421
CONTENTS 3422
ABBREVIATION LIST 3424
ENGINE AND COOLING SYSTEM 3430
MAINTENANCE STANDARD OF ENGINE MOUNT 3430
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP 3431
MAINTENANCE STANDARD OF SERVO VALVE OF BRAKE AND COOLING FAN PUMP 3433
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3434
POWER TRAIN 3436
MAINTENANCE STANDARD OF DRIVE SHAFT 3436
MAINTENANCE STANDARD OF TORQUE CONVERTER 3437
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 3439
MAINTENANCE STANDARD OF TRANSMISSION 3440
MAINTENANCE STANDARD OF F, R CLUTCH 3445
MAINTENANCE STANDARD OF 1ST, 4TH CLUTCH 3446
MAINTENANCE STANDARD OF 2ND, 3RD CLUTCH 3447
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 3448
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV 3449
MAINTENANCE STANDARD OF MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE 3450
MAINTENANCE STANDARD OF FRONT AXLE 3451
MAINTENANCE STANDARD OF REAR AXLE 3452
MAINTENANCE STANDARD OF FRONT CONVENTIONAL DIFFERENTIAL 3453
MAINTENANCE STANDARD OF REAR CONVENTIONAL DIFFERENTIAL 3454
MAINTENANCE STANDARD OF FRONT LIMITED SLIP DIFFERENTIAL 3455
MAINTENANCE STANDARD OF REAR LIMITED SLIP DIFFERENTIAL 3457
MAINTENANCE STANDARD OF FINAL DRIVE 3459
STEERING SYSTEM 3461
MAINTENANCE STANDARD OF STEERING COLUMN 3461
MAINTENANCE STANDARD OF STEERING PUMP 3462
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING PUMP 3465
MAINTENANCE STANDARD OF STEERING VALVE 3466
MAINTENANCE STANDARD OF STEERING CYLINDER 3468
MAINTENANCE STANDARD OF SECONDARY STEERING PUMP 3470
BRAKE SYSTEM 3471
MAINTENANCE STANDARD OF CHARGE VALVE 3471
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR 3473
MAINTENANCE STANDARD OF FRONT BRAKE 3474
MAINTENANCE STANDARD OF REAR BRAKE 3475
MAINTENANCE STANDARD OF PARKING BRAKE 3476
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE 3477
MAINTENANCE STANDARD OF FLOW PRIORITY VALVE 3478
MAINTENANCE STANDARD OF BRAKE COOLING PUMP 3479
MAINTENANCE STANDARD OF BRAKE COOLING STRAINER 3480
UNDERCARRIAGE AND FRAME 3481
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 3481
HYDRAULIC SYSTEM 3486
MAINTENANCE STANDARD OF HYDRAULIC TANK 3486
MAINTENANCE STANDARD OF WORK EQUIPMENT PUMP 3487
MAINTENANCE STANDARD OF SERVO VALVEWORK OF EQUIPMENT PUMP 3490
MAINTENANCE STANDARD OF POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP 3492
MAINTENANCE STANDARD OF CONTROL VALVE 3493
MAINTENANCE STANDARD OF STABILIZER VALVE 3505
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE 3506
WORK EQUIPMENT 3507
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3507
MAINTENANCE STANDARD OF BUCKET 3510
MAINTENANCE STANDARD OF LIFT CYLINDER 3511
MAINTENANCE STANDARD OF BUCKET CYLINDER 3512
80 APPENDIX 3513
CONTENTS 3514
ABBREVIATION LIST 3516
AIR CONDITIONER SYSTEM 3522
PRECAUTIONS FOR REFRIGERANT 3522
AIR CONDITIONER COMPONENT 3523
SPECIFICATIONS OF AIR CONDITIONER 3525
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3526
OUTLINE OF REFRIGERATION CYCLE 3527
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3529
AIR CONDITIONER UNIT 3529
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3529
FUNCTION OF AIR CONDITIONER UNIT 3530
COMPONENT PARTS OF AIR CONDITIONER UNIT 3531
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3531
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3531
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT 3532
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT 3532
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3532
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3532
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3532
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3533
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3533
FUNCTION OF DUAL PRESSURE SWITCH 3533
AIR CONDITIONER CONTROLLER 3534
STRUCTURE OF AIR CONDITIONER CONTROLLER 3534
COMPRESSOR 3535
STRUCTURE OF COMPRESSOR 3535
SPECIFICATIONS OF COMPRESSOR 3535
FUNCTION OF COMPRESSOR 3535
CONDENSER 3536
STRUCTURE OF CONDENSER 3536
SPECIFICATIONS OF CONDENSER 3536
FUNCTION OF CONDENSER 3536
RECEIVER DRIER 3537
STRUCTURE OF RECEIVER DRIER 3537
SPECIFICATIONS OF RECEIVER DRIER 3537
FUNCTION OF RECEIVER DRIER 3537
SENSORS FOR AIR CONDITIONER SYSTEM 3538
FUNCTION OF SUNLIGHT SENSOR 3538
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3538
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3539
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3541
AIR CONDITIONER SYSTEM DIAGRAM 3544
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3545
FUNCTION OF AIR CONDITIONER CONTROLLER 3546
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3547
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3553
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3554
CHECK TEMPERATURE CONTROL FUNCTION 3555
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION 3555
TEST VENT (MODE) CHANGEOVER 3557
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3557
TESTING FRESH/RECIRC AIR CHANGEOVER 3559
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3559
TEST EVAPORATOR TEMPERATURE SENSOR 3561
TEST RELAYS 3563
METHOD FOR TESTING RELAYS 3563
AIR CONDITIONER TROUBLESHOOTING CHART 1 3565
AIR CONDITIONER TROUBLESHOOTING CHART 2 3566
FAILURE CODE [879AKA] 3569
FAILURE CODE [879AKB] 3571
FAILURE CODE [879BKA] 3573
FAILURE CODE [879BKB] 3575
FAILURE CODE [879CKA] 3577
FAILURE CODE [879CKB] 3579
FAILURE CODE [879DKZ] 3581
FAILURE CODE [879EMC] 3583
FAILURE CODE [879FMC] 3586
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3589
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3592
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3595
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3599
TROUBLESHOOTING USING GAUGE PRESSURE 3601
CONNECTION OF SERVICE TOOL 3604
METHOD FOR CONNECTING SERVICE TOOL 3605
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3606
HANDLE COMPRESSOR OIL 3608
90 CIRCUIT DIAGRAMS 3611
CONTENTS 3612
ABBREVIATION LIST 3614
HYDRAULIC CIRCUIT DIAGRAM 3620
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3620
HYDRAULIC CIRCUIT DIAGRAM 3625
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 3627
HYDRAULIC OIL PRESSURE OF BRAKE COOLING SYSTEM 3629
HYDRAULIC AUTO-GREASING DIAGRAM 3631
HYDRAULIC CIRCUIT DIAGRAM (BOOM RAISE, TILT) 3633
HYDRAULIC CIRCUIT DIAGRAM (BOOM LOWER, LEFT TURN, LEFT BRAKE) 3635
ELECTRICAL CIRCUIT DIAGRAM 3637
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3637
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/10) 3641
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/10) 3643
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/10) 3645
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/10) 3647
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/10) 3649
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/10) 3651
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/10) 3653
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/10) 3655
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (9/10) 3657
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (10/10) 3659
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (1/8) 3661
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (2/8) 3663
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (3/8) 3665
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (4/8) 3667
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (5/8) 3669
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (6/8) 3671
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (7/8) 3673
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR NORTH AMERICA) (8/8) 3675
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (1/9) 3677
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (2/9) 3679
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (3/9) 3681
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (4/9) 3683
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (5/9) 3685
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (6/9) 3687
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (7/9) 3689
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (8/9) 3691
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (FOR EUROPEAN UNION AND JAPAN) (9/9) 3693
WIRING HARNESS DIAGRAM 3695
WIRING HARNESS DIAGRAM (1/34) 3697
WIRING HARNESS DIAGRAM (2/34) 3699
WIRING HARNESS DIAGRAM (3/34) 3701
WIRING HARNESS DIAGRAM (4/34) 3703
WIRING HARNESS DIAGRAM (5/34) 3705
WIRING HARNESS DIAGRAM (6/34) 3707
WIRING HARNESS DIAGRAM (7/34) 3709
WIRING HARNESS DIAGRAM (8/34) 3711
WIRING HARNESS DIAGRAM (9/34) 3713
WIRING HARNESS DIAGRAM (10/34) 3715
WIRING HARNESS DIAGRAM (11/34) 3717
WIRING HARNESS DIAGRAM (12/34) 3719
WIRING HARNESS DIAGRAM (13/34) 3721
WIRING HARNESS DIAGRAM (14/34) 3723
WIRING HARNESS DIAGRAM (15/34) 3725
WIRING HARNESS DIAGRAM (16/34) 3727
WIRING HARNESS DIAGRAM (17/34) 3729
WIRING HARNESS DIAGRAM (18/34) 3731
WIRING HARNESS DIAGRAM (19/34) 3733
WIRING HARNESS DIAGRAM (20/34) 3735
WIRING HARNESS DIAGRAM (21/34) 3737
WIRING HARNESS DIAGRAM (22/34) 3739
WIRING HARNESS DIAGRAM (23/34) 3741
WIRING HARNESS DIAGRAM (24/34) 3743
WIRING HARNESS DIAGRAM (25/34) 3745
WIRING HARNESS DIAGRAM (26/34) 3747
WIRING HARNESS DIAGRAM (27/34) 3749
WIRING HARNESS DIAGRAM (28/34) 3751
WIRING HARNESS DIAGRAM (29/34) 3753
WIRING HARNESS DIAGRAM (30/34) 3755
WIRING HARNESS DIAGRAM (31/34) 3757
WIRING HARNESS DIAGRAM (32/34) 3759
WIRING HARNESS DIAGRAM (33/34) 3761
WIRING HARNESS DIAGRAM (34/34) 3763
INDEX 3765

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