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KOMATSU WA270-8E0 WHEEL LOADER SHOP MANUAL SEN06793-05 – PDF DOWNLOAD
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KOMATSU WA270-8E0 WHEEL LOADER SHOP MANUAL SEN06793-05 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA270-8E0 WHEEL LOADER SHOP MANUAL SEN06793-05 – PDF DOWNLOAD
Language : English
Pages : 3506
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS
KOMATSU WA270-8E0 WHEEL LOADER SHOP MANUAL SEN06793-05 – PDF DOWNLOAD
Cover........................................................................................................................................................ 2 00 Index and Foreword................................................................................................................................... 3 Index............................................................................................................................................... 4 Abbreviation List................................................................................................................................... 24 Foreword, Safety, Basic Information................................................................................................................. 30 How to Read the Shop Manual..................................................................................................................... 30 Safety Notice for Operation..................................................................................................................... 32 Precautions to Prevent Fire..................................................................................................................... 40 Procedures If Fire Occurs....................................................................................................................... 42 Precautions for Disposing of Waste Materials.................................................................................................... 43 Procedures for Exhaust Gas Regulations.......................................................................................................... 44 Precautions for DEF............................................................................................................................. 45 General Character and Precautions for Handling.............................................................................................. 45 Precautions for Adding...................................................................................................................... 45 Precautions for Storage..................................................................................................................... 45 Precautions for Fire Hazard and Leakage..................................................................................................... 45 Other Precautions........................................................................................................................... 45 Store DEF....................................................................................................................................... 46 Precautions When You Handle Hydraulic Equipment................................................................................................. 47 Precautions When You Disconnect and Connect Pipings............................................................................................. 50 Precautions When You Handle Electrical Equipment................................................................................................ 57 Precautions When You Handle Fuel System Equipment............................................................................................... 59 Precautions When You Handle Intake System Equipment............................................................................................. 60 Practical Use of KOMTRAX........................................................................................................................ 61 Disconnect and Connect Push-Pull Type Coupler................................................................................................... 62 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................................. 62 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................................. 63 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................................. 64 Precautions for Disconnection and Connection of Connectors...................................................................................... 66 How to Disconnect and Connect Deutsch Connector................................................................................................. 70 How to Disconnect and Connect Slide Lock Type Connector......................................................................................... 71 How to Disconnect and Connect Connector with Lock to Pull....................................................................................... 73 How to Disconnect and Connect Connector with Lock to Push....................................................................................... 74 How to Disconnect and Connect Connector with Housing to Rotate.................................................................................. 76 How to Read the Codes for Electric Cable........................................................................................................ 77 Explanation of Terms for Maintenance Standard................................................................................................... 81 Standard Tightening Torque Table................................................................................................................ 84 Conversion Table................................................................................................................................ 91 01 Specifications....................................................................................................................................... 97 Table of Contents................................................................................................................................... 98 Abbreviation List................................................................................................................................... 99 Specifications...................................................................................................................................... 105 Specification Drawing........................................................................................................................... 105 Specification Drawing: WA270-8E0............................................................................................................ 105 Specifications.................................................................................................................................. 107 Specification: WA270-8E0.................................................................................................................... 107 Weight Table.................................................................................................................................... 112 Weight Table: WA270-8E0..................................................................................................................... 112 Fuel, Coolant, Lubricants (for European Union and Turkey)....................................................................................... 114 How to Use Fuel, Coolant and Lubricants by Ambient Temperature.............................................................................. 115 10 Structure and Function............................................................................................................................... 117 Table of Contents................................................................................................................................... 118 Abbreviation List................................................................................................................................... 122 Urea SCR System..................................................................................................................................... 128 Layout Drawing of Urea SCR System............................................................................................................... 128 Urea SCR System Diagram......................................................................................................................... 130 Function of Urea SCR System..................................................................................................................... 131 Function of DEF System...................................................................................................................... 131 Inducement Strategy......................................................................................................................... 134 Component Parts of Urea SCR System.............................................................................................................. 142 DEF Mixing Tube............................................................................................................................. 142 SCR Assembly................................................................................................................................ 143 DEF Tank.................................................................................................................................... 145 DEF Pump.................................................................................................................................... 147 DEF Injector................................................................................................................................ 148 DEF Hose.................................................................................................................................... 149 DEF Tank Heating Valve...................................................................................................................... 150 Boot-up System...................................................................................................................................... 151 Layout Drawing of Boot-up System................................................................................................................ 151 System Operating Lamp System.................................................................................................................... 153 System Diagram of System Operating Lamp System.............................................................................................. 153 Function of Operation Lamp System........................................................................................................... 153 Battery Disconnect Switch....................................................................................................................... 154 Function of Battery Disconnect Switch....................................................................................................... 154 Preheating System............................................................................................................................... 155 System Diagram of Preheating System......................................................................................................... 155 Function of Automatic Preheating System..................................................................................................... 155 Operation of Automatic Preheating System.................................................................................................... 155 Function of Manual Preheating System........................................................................................................ 156 Operation of Manual Preheating System....................................................................................................... 156 Engine System....................................................................................................................................... 157 Layout Drawing of Engine System................................................................................................................. 157 Function of Engine System................................................................................................................... 159 Engine Control System........................................................................................................................... 160 System Diagram of Engine Control............................................................................................................ 160 Function of Engine Control System........................................................................................................... 162 Operation of Engine Control System.......................................................................................................... 165 Automatic Idle Stop System...................................................................................................................... 167 Function of Automatic Idle Stop System...................................................................................................... 167 Component Parts of Engine System................................................................................................................ 168 Damper...................................................................................................................................... 168 VGT......................................................................................................................................... 170 EGR System.................................................................................................................................. 174 EGR Valve................................................................................................................................... 176 EGR Cooler.................................................................................................................................. 178 KCCV System................................................................................................................................. 180 KCCV Ventilator............................................................................................................................. 182 KDPF........................................................................................................................................ 184 Cooling System...................................................................................................................................... 188 Layout Drawing of Cooling System................................................................................................................ 188 Specifications of Cooling System............................................................................................................ 189 Cooling Fan Control System...................................................................................................................... 190 System Diagram of Cooling Fan Control System................................................................................................ 190 Function of Cooling Fan Control System...................................................................................................... 190 Component Parts of Cooling System............................................................................................................... 195 Cooling Fan Motor........................................................................................................................... 195 Control System...................................................................................................................................... 208 Layout Drawing of Control System................................................................................................................ 208 Machine Monitor System.......................................................................................................................... 210 System Diagram of Machine Monitor System.................................................................................................... 210 Function of Machine Monitor System.......................................................................................................... 210 Rearview Monitor System......................................................................................................................... 212 System Diagram of Rearview Monitor System................................................................................................... 212 Function of Rearview Monitor System......................................................................................................... 212 KOMTRAX System.................................................................................................................................. 213 System Diagram of KOMTRAX System (Machine with Gateway Function Controller)................................................................. 213 Function of KOMTRAX System (Machine with Gateway Function Controller)....................................................................... 213 Component Parts of Control System............................................................................................................... 214 Machine Monitor............................................................................................................................. 214 Switch Panel................................................................................................................................ 232 Rearview Monitor............................................................................................................................ 233 Rearview Camera............................................................................................................................. 235 Gateway Function Controller................................................................................................................. 236 Communication Terminal...................................................................................................................... 239 Monitor Controller.......................................................................................................................... 241 HST Controller.............................................................................................................................. 246 CAN Terminating Resistor.................................................................................................................... 251 Engine Controller........................................................................................................................... 252 Accelerator Pedal........................................................................................................................... 259 Hydraulic System.................................................................................................................................... 261 Layout Drawing of Hydraulic System.............................................................................................................. 261 CLSS............................................................................................................................................ 262 Structure of CLSS........................................................................................................................... 262 Function of CLSS............................................................................................................................ 263 Component Parts of Hydraulic System............................................................................................................. 265 Hydraulic Tank.............................................................................................................................. 265 Hydraulic Oil Filter........................................................................................................................ 268 Steering and Work Equipment Pump............................................................................................................ 269 Brake and Cooling Fan Pump and Transfer Lubrication Pump.................................................................................... 282 Control Valve............................................................................................................................... 283 Power Train System.................................................................................................................................. 313 Layout Drawing of Power Train System............................................................................................................ 313 Operation of Power Train System................................................................................................................. 315 Directional Selector Switch Control Function.................................................................................................... 316 HST Control System.............................................................................................................................. 318 System Diagram of HST Control System........................................................................................................ 318 Engine Overrun Prevention Function.......................................................................................................... 319 Neutralizer Function........................................................................................................................ 319 HST Charge System............................................................................................................................... 320 System Diagram of HST Charge System......................................................................................................... 320 Function of HST Charge System............................................................................................................... 320 HST Pump Control System......................................................................................................................... 321 System Diagram of HST Pump Control System................................................................................................... 321 Directional Selection Function.............................................................................................................. 321 Absorbing Torque Control Function........................................................................................................... 322 Inching Control Function.................................................................................................................... 322 Travel Speed Adjustment Function (at Low Speed)............................................................................................. 322 HST Controller Gear Shift Control Function...................................................................................................... 323 Gear Shift Function......................................................................................................................... 323 Gear Shift Display Function................................................................................................................. 325 Travel Speed Adjustment Function............................................................................................................ 325 Transfer Clutch Control Function................................................................................................................ 326 HST System Protection Function.................................................................................................................. 327 Transfer Protection Function................................................................................................................ 327 Direction Protection Function............................................................................................................... 327 HST Motor 1 Overrun Prevention Function 1................................................................................................... 327 HST Motor 1 Overrun Prevention Function 2................................................................................................... 328 Travel Speed Limitation Function............................................................................................................ 329 Maximum Speed Low Fuel Consumption Control...................................................................................................... 330 Function of Maximum Speed Low Fuel Consumption Control...................................................................................... 330 Komatsu Traction Control System (KTCS).......................................................................................................... 333 Komatsu Traction Control System (KTCS) Diagram.............................................................................................. 333 Function of Komatsu Traction Control System (KTCS).......................................................................................... 333 Component Parts of Power Train System........................................................................................................... 339 Drive Shaft................................................................................................................................. 339 HST Pump.................................................................................................................................... 341 HST Charge Pump............................................................................................................................. 354 HST Motor................................................................................................................................... 356 Transfer.................................................................................................................................... 362 Axle........................................................................................................................................ 370 Torque Proportioning Differential........................................................................................................... 372 Limited Slip Differential................................................................................................................... 376 Final Drive................................................................................................................................. 380 Combination Switch.......................................................................................................................... 382 Work Equipment System............................................................................................................................... 386 Layout Drawing of Work Equipment System......................................................................................................... 386 Work Equipment Control System................................................................................................................... 388 Work Equipment Lever Operation Function..................................................................................................... 388 PZ Auto Tilt-in Compensation Control Function............................................................................................... 388 Work Equipment Lock System...................................................................................................................... 389 Work Equipment Lock System Diagram (Applicable Machine: 84424 to 86599)..................................................................... 389 Work Equipment Lock System Diagram (Applicable Machine: 86600 and Up)....................................................................... 389 Function of Work Equipment Lock System...................................................................................................... 390 Bucket Positioner System........................................................................................................................ 391 Bucket Positioner System Diagram............................................................................................................ 391 Function of Bucket Positioner System........................................................................................................ 391 Operation of Bucket Positioner System....................................................................................................... 393 Fork Positioner System.......................................................................................................................... 395 Fork Positioner System Diagram.............................................................................................................. 395 Function of Fork Positioner System.......................................................................................................... 395 Operation of Fork Positioner System......................................................................................................... 396 Remote Positioner System........................................................................................................................ 399 Remote Boom Positioner System Diagram....................................................................................................... 399 Function of Remote Boom Positioner System................................................................................................... 399 ECSS............................................................................................................................................ 402 ECSS Diagram................................................................................................................................ 402 Function of ECSS............................................................................................................................ 402 Operation of ECSS........................................................................................................................... 402 Component Parts of Work Equipment System........................................................................................................ 404 Self-Pressure Reducing Valve................................................................................................................ 404 Work Equipment Lock Solenoid Valve.......................................................................................................... 409 Pilot Circuit Accumulator................................................................................................................... 410 ECSS Circuit Accumulator.................................................................................................................... 411 Multifunction Mono-Lever.................................................................................................................... 412 Multifunction Mono-Lever PPC Valve.......................................................................................................... 414 Steering System..................................................................................................................................... 419 Layout Drawing of Steering System............................................................................................................... 419 Steering Column................................................................................................................................. 420 Structure of Steering Column................................................................................................................ 420 Component Parts of Steering System.............................................................................................................. 421 Priority Valve.............................................................................................................................. 421 Orbitrol Valve.............................................................................................................................. 424 Cushion Valve............................................................................................................................... 429 2-Way Restrictor Valve...................................................................................................................... 431 Secondary Steering Valve.................................................................................................................... 432 Brake System........................................................................................................................................ 435 Layout Drawing of Brake System.................................................................................................................. 435 Parking Brake Control System.................................................................................................................... 437 System Diagram of Parking Brake Control System.............................................................................................. 437 Operation of Parking Brake Control System................................................................................................... 437 Component Parts of Brake System................................................................................................................. 441 Brake Circuit Accumulator Charge Valve...................................................................................................... 441 Parking Brake Solenoid Valve................................................................................................................ 445 Brake Circuit Accumulator................................................................................................................... 447 Brake Valve................................................................................................................................. 449 Slack Adjuster.............................................................................................................................. 452 Brake....................................................................................................................................... 454 Parking Brake............................................................................................................................... 457 Auto-Greasing System................................................................................................................................ 459 Layout Drawing of Auto-Greasing System.......................................................................................................... 459 Specifications of Auto-Greasing System.......................................................................................................... 461 Function of Auto-Greasing System................................................................................................................ 463 Auto-Greasing System............................................................................................................................ 464 Auto-Greasing Pump.......................................................................................................................... 464 Undercarriage and Frame............................................................................................................................. 465 Frame, Axle Mount and Center Hinge Pin.......................................................................................................... 465 Structure of Frame, Axle Mount and Center Hinge Pin......................................................................................... 465 Function of Frame, Axle Mount and Center Hinge Pin.......................................................................................... 468 Tires........................................................................................................................................... 470 Features of Radial Tire When Compared with Bias Tire........................................................................................ 470 Structure of Radial Tire.................................................................................................................... 470 Function of Radial Tire..................................................................................................................... 471 Structure of Bias Tire...................................................................................................................... 471 Function of Bias Tire....................................................................................................................... 471 Work Equipment...................................................................................................................................... 472 Structure of Work Equipment..................................................................................................................... 472 Structure of Bucket............................................................................................................................. 473 CAB Related Parts................................................................................................................................... 474 ROPS CAB........................................................................................................................................ 474 Structure of ROPS CAB....................................................................................................................... 474 Function of ROPS CAB........................................................................................................................ 474 CAB Mount....................................................................................................................................... 475 Structure of CAB Mount...................................................................................................................... 475 Function of CAB Mount....................................................................................................................... 475 20 Standard Value Table................................................................................................................................. 477 Table of Contents................................................................................................................................... 478 Abbreviation List................................................................................................................................... 479 Standard Value Table for Engine..................................................................................................................... 485 Standard Value Table for Engine: WA270-8E0...................................................................................................... 485 Standard Value Table for Machine.................................................................................................................... 490 Standard Value Table for Machine: WA270-8E0..................................................................................................... 490 Machine Posture and Procedures to Measure Performance........................................................................................... 503 30 Testing and Adjusting................................................................................................................................ 507 Table of Contents................................................................................................................................... 508 Precautions Before Work............................................................................................................................. 512 Abbreviation List................................................................................................................................... 513 Related Information on Testing and Adjusting........................................................................................................ 519 Differences In Machine Monitor Symbols.......................................................................................................... 519 Tools for Testing and Adjusting................................................................................................................. 520 Sketch of Tools for Testing and Adjusting....................................................................................................... 529 Engine and Cooling System........................................................................................................................... 530 Examine Engine Speed............................................................................................................................ 530 How to Examine Engine Speed................................................................................................................. 530 Examine Boost Pressure.......................................................................................................................... 533 How to Examine Boost Pressure on Machine Monitor............................................................................................ 533 How to Examine Boost Pressure by Testing Tool............................................................................................... 534 Examine Exhaust Gas Temperature................................................................................................................. 536 How to Examine Exhaust Gas Temperature...................................................................................................... 536 Examine Exhaust Gas Color....................................................................................................................... 538 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................... 538 How to Examine Exhaust Gas Color with Smoke Meter........................................................................................... 540 Examine Mass Air Flow and Temperature Sensor.................................................................................................... 542 How to Examine Mass Air Flow and Temperature Sensor......................................................................................... 542 Examine and Adjust Valve Clearance.............................................................................................................. 544 How to Examine Valve Clearance.............................................................................................................. 544 How to Adjust Valve Clearance............................................................................................................... 545 Examine Compression Pressure.................................................................................................................... 546 How to Examine Compression Pressure......................................................................................................... 546 Examine Blowby Pressure......................................................................................................................... 551 How to Examine Blowby Pressure.............................................................................................................. 551 Examine Engine Oil Pressure..................................................................................................................... 554 How to Examine Engine Oil Pressure.......................................................................................................... 554 Examine EGR Valve and VGT Oil Pressure.......................................................................................................... 556 How to Examine EGR Valve and VGT Oil Pressure............................................................................................... 556 Examine Fuel Pressure........................................................................................................................... 558 How to Examine Fuel Pressure................................................................................................................ 559 Examine Fuel Discharge, Return and Leakage...................................................................................................... 564 How to Examine Fuel Discharge, Return, and Leakage.......................................................................................... 565 Bleed Air from Fuel System...................................................................................................................... 571 How to Bleed Air from Fuel System........................................................................................................... 571 Examine Fuel Circuit for Leakage................................................................................................................ 573 How to Examine Fuel System for Leakage...................................................................................................... 573 Handle Cylinder Cut-out Mode Operation.......................................................................................................... 575 Handle No-Injection Cranking Operation.......................................................................................................... 576 Examine KDPF, SCR and Muffler Stack for Looseness and Damage.................................................................................... 577 How to Examine KDPF, SCR and Muffler Stack for Looseness and Damage......................................................................... 577 Examine Installed Condition of Cylinder Heads and Manifolds..................................................................................... 578 How to Examine Installed Condition of Cylinder Heads and Manifolds.......................................................................... 578 Examine Engine Piping for Damage and Looseness.................................................................................................. 579 How to Examine Engine Piping for Damage and Looseness....................................................................................... 579 Examine and Adjust Air Conditioner Compressor Belt Tension...................................................................................... 580 How to Examine Air Conditioner Compressor Belt.............................................................................................. 580 How to Adjust Air Conditioner Compressor Belt............................................................................................... 580 Examine Alternator Belt......................................................................................................................... 582 How to Examine Alternator Belt.............................................................................................................. 582 Examine Automatic Tensioner..................................................................................................................... 584 How to Examine Automatic Tensioner.......................................................................................................... 584 Write Correction for Ash in Soot Accumulation to Engine Controller.............................................................................. 587 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................... 587 Examine SCR Related Functions................................................................................................................... 588 Examine DEF Pump Raised Pressure............................................................................................................ 592 Examine Injection Volume from DEF Injector.................................................................................................. 595 Examine DEF Line Heater Relay 1............................................................................................................. 600 Examine DEF Line Heater Relay 2............................................................................................................. 604 Examine DEF Pump Heater Relay............................................................................................................... 608 Examine DEF Tank Heater Valve............................................................................................................... 612 Examine SCR Denitration Efficiency.......................................................................................................... 616 Clean DEF Tank.................................................................................................................................. 620 How to Clean DEF Tank....................................................................................................................... 620 Clean DEF Pump.................................................................................................................................. 624 How to Clean DEF Pump....................................................................................................................... 624 Power Train......................................................................................................................................... 630 Examine and Adjust HST Oil Pressure............................................................................................................. 630 How to Examine HST Oil Pressure............................................................................................................. 630 How to Adjust HST Oil Pressure.............................................................................................................. 632 Examine the Control Pressure of Transfer Clutch................................................................................................. 634 How to Examine the Control Pressure of Transfer Clutch...................................................................................... 634 Examine Drive Shaft for Looseness, Backlash, and Damage......................................................................................... 636 How to Examine Drive Shaft for Looseness, Backlash, and Damage.............................................................................. 636 Steering System..................................................................................................................................... 637 Examine Steering Wheel.......................................................................................................................... 637 How to Examine Steering Wheel............................................................................................................... 637 Examine and Adjust Steering Circuit Oil Pressure................................................................................................ 639 How to Examine Steering Circuit Oil Pressure with the Machine Monitor....................................................................... 639 How to Examine Steering Circuit Pressure with Test Tools.................................................................................... 640 How to Adjust Steering Circuit Oil Pressure................................................................................................. 640 Bleed Air from Steering Cylinder Circuit........................................................................................................ 642 How to Bleed Air from Steering Cylinder Circuit............................................................................................. 642 Brake System........................................................................................................................................ 643 Release Remained Pressure in Brake Accumulator Circuit.......................................................................................... 643 How to Release Remained Pressure in Brake Accumulator Circuit............................................................................... 643 Examine Wheel Brake Oil Pressure................................................................................................................ 644 How to Examine Wheel Brake Oil Pressure..................................................................................................... 644 Examine and Adjust Brake Accumulator Charge Pressure............................................................................................ 646 How to Examine Brake Accumulator Charge Pressure............................................................................................ 646 How to Adjust Brake Accumulator Charge Pressure............................................................................................. 647 Bleed Air from Brake Circuit.................................................................................................................... 648 How to Bleed Air from Brake Circuit......................................................................................................... 648 Examine Brake Performance....................................................................................................................... 650 How to Examine Brake Performance............................................................................................................ 650 Examine Brake Pedal............................................................................................................................. 651 How to Examine Brake Pedal.................................................................................................................. 651 Examine Pressure Decrease of Wheel Brake........................................................................................................ 652 How to Examine Pressure Decrease of Wheel Brake............................................................................................. 653 Examine Wear of Wheel Brake Disc................................................................................................................ 655 How to Examine Wear of Wheel Brake Disc..................................................................................................... 655 Examine Parking Brake Oil Pressure.............................................................................................................. 657 How to Examine Parking Brake Oil Pressure................................................................................................... 657 Examine Parking Brake Performance............................................................................................................... 659 How to Examine Parking Brake Performance.................................................................................................... 659 Release Parking Brake Manually.................................................................................................................. 660 How to Release Parking Brake Manually....................................................................................................... 660 Examine Wear Volume of Parking Brake Disc....................................................................................................... 661 How to Examine Wear Quantity of Parking Brake Disc.......................................................................................... 661 Hydraulic System.................................................................................................................................... 662 Release Remained Pressure from Work Equipment Circuit........................................................................................... 662 How to Release Remained Pressure from Work Equipment Circuit................................................................................ 662 Examine and Adjust Work Equipment Oil Pressure.................................................................................................. 664 How to Examine Work Equipment Oil Pressure.................................................................................................. 664 How to Adjust Work Equipment Oil Pressure................................................................................................... 668 Examine and Adjust Work Equipment PPC Oil Pressure.............................................................................................. 670 How to Examine Work Equipment PPC Oil Pressure.............................................................................................. 670 How to Adjust Work Equipment PPC Oil Pressure............................................................................................... 672 Bleed Air from Work Equipment Circuit........................................................................................................... 674 How to Bleed Air from Work Equipment Circuit................................................................................................ 674 Examine Cooling Fan Speed....................................................................................................................... 676 How to Examine Cooling Fan Speed............................................................................................................ 676 Examine Cooling Fan Circuit Oil Pressure........................................................................................................ 677 How to Examine Cooling Fan Circuit Oil Pressure............................................................................................. 677 Bleed Air from Cooling Fan Circuit.............................................................................................................. 680 How to Bleed Air from Cooling Fan Circuit................................................................................................... 680 Examine ECSS Accumulator Nitrogen Gas Pressure and Charge Accumulator with Nitrogen Gas......................................................... 682 How to Examine ECSS Accumulator Nitrogen Gas Pressure....................................................................................... 682 How to Charge ECSS Accumulator with Nitrogen Gas............................................................................................ 684 Work Equipment...................................................................................................................................... 688 Examine and Adjust Bucket Positioner............................................................................................................ 688 How to Examine Bucket Positioner............................................................................................................ 688 How to Adjust Bucket Positioner............................................................................................................. 688 Examine and Adjust Boom Potentiometer Lever..................................................................................................... 690 How to Examine Boom Potentiometer Lever..................................................................................................... 690 How to Adjust Boom Potentiometer Lever...................................................................................................... 690 CAB Related Parts................................................................................................................................... 691 Examine Directional Lever....................................................................................................................... 691 How to Examine Directional Lever............................................................................................................ 691 Examine Multifunction Mono-Lever................................................................................................................ 692 How to Examine Multifunction Mono-Lever..................................................................................................... 692 Examine Accelerator Pedal....................................................................................................................... 694 How to Examine Accelerator Pedal............................................................................................................ 694 Adjust Play of Operator Seat.................................................................................................................... 696 How to Adjust Play of Operator Seat......................................................................................................... 696 Electrical System................................................................................................................................... 697 Set and Adjust Each Equipment................................................................................................................... 697 Set and Operate Machine Monitor................................................................................................................. 701 Operator Mode............................................................................................................................... 705 Function to Show Technician Identification Status Screen.................................................................................... 705 Function to Show Operator Identification Input Screen....................................................................................... 705 Examine Function by LCD (Liquid Crystal Display)............................................................................................ 706 Examine Function of Service Meter and Odometer.............................................................................................. 707 How to Set Usage Limitation and Change Maintenance Password................................................................................. 707 Service Mode................................................................................................................................ 711 How to Operate Service Mode................................................................................................................. 711 How to See Pre-defined Monitoring Information............................................................................................... 714 How to Examine Self-Define Monitor Information.............................................................................................. 721 Abnormality Record Menu..................................................................................................................... 733 How to See Maintenance Record............................................................................................................... 738 Maintenance Mode Setting.................................................................................................................... 740 How to Set Phone Number Entry............................................................................................................... 745 Default Menu................................................................................................................................ 747 Diagnostic Tests Menu....................................................................................................................... 762 Adjustment Menu............................................................................................................................. 773 No-Injection Cranking Operation............................................................................................................. 807 KOMTRAX Settings Menu....................................................................................................................... 809 How to Show Service Message................................................................................................................. 811 How to Start Up KOMTRAX System.................................................................................................................. 813 Adjust Rearview Camera Angle.................................................................................................................... 819 How to Adjust Rearview Camera Angle......................................................................................................... 819 Set Region of Bluetooth(R) Compatible Radio..................................................................................................... 821 How to Set Region of Bluetooth(R) Compatible Radio.......................................................................................... 821 Handle Voltage Circuit of Engine Controller..................................................................................................... 823 Handle Battery Disconnect Switch................................................................................................................ 824 Examine Diodes.................................................................................................................................. 825 How to Examine Diodes by Digital Tester..................................................................................................... 825 How to Examine Diodes by Analog Tester...................................................................................................... 825 Auto-Greasing Device................................................................................................................................ 826 Bleed the Air in Auto-Greasing System........................................................................................................... 826 How to Bleed the Air in Auto-Greasing System................................................................................................ 826 Change Lubrication Time and Lubrication Interval................................................................................................ 829 How to Change Lubrication Time and Lubrication Interval..................................................................................... 830 Pm Clinic........................................................................................................................................... 832 Pm Clinic Service............................................................................................................................... 832 Pm Clinic Check Sheet: WA270-8E0............................................................................................................ 834 40 Troubleshooting...................................................................................................................................... 843 Table of Contents................................................................................................................................... 844 Precautions Before Work............................................................................................................................. 856 Abbreviation List................................................................................................................................... 857 Related Information to Troubleshooting.............................................................................................................. 863 General Troubleshooting Points.................................................................................................................. 863 Troubleshooting Points for Urea SCR System...................................................................................................... 864 Sequence of Events in Troubleshooting........................................................................................................... 876 Checks Before Troubleshooting................................................................................................................... 878 Inspection Procedure Before Troubleshooting..................................................................................................... 880 Walk-Around Check........................................................................................................................... 880 Test in Accordance with Testing Procedure....................................................................................................... 882 Examine Fuel Level and Type................................................................................................................. 882 Examine for Impure Ingredient in Fuel....................................................................................................... 882 Examine DEF Level and Type.................................................................................................................. 883 Examine Fuel Prefilter...................................................................................................................... 883 Examine Fuel Main Filter.................................................................................................................... 885 Examine Engine Oil Level (Oil Quantity in Oil Pan) and Type................................................................................. 886 Examine Coolant Level (Reservoir Tank)...................................................................................................... 887 Examine Air Cleaner Clogging................................................................................................................ 888 Clean Outer Element......................................................................................................................... 888 Replace Element............................................................................................................................. 890 Examine Hydraulic Oil Level................................................................................................................. 892 Examine Hydraulic Oil Strainer.............................................................................................................. 892 Examine Hydraulic Oil Filter................................................................................................................ 895 Examine the Oil Level in the Transfer Case.................................................................................................. 895 Examine Oil Level in Front Axle Case........................................................................................................ 897 Examine Oil Level in Rear Axle Case......................................................................................................... 898 Bleed Air from Fuel System.................................................................................................................. 898 Bleed Air from Hydraulic System............................................................................................................. 898 How to Examine Electric Equipment........................................................................................................... 899 Preparation for Troubleshooting of Electrical System............................................................................................ 904 Procedure for Troubleshooting................................................................................................................... 912 Symptom and Troubleshooting Numbers............................................................................................................. 914 Information Shown in Troubleshooting Table...................................................................................................... 918 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................................. 920 Connector List and Layout (Applicable Machine: 83001 to 86599).................................................................................. 923 Connector List and Layout (Applicable Machine: 86600 and Up).................................................................................... 940 Connector Contact Connection Table.............................................................................................................. 958 T-Branch Box and T-Branch Adapter Table......................................................................................................... 998 Fuse Location Table.............................................................................................................................1004 Precautions When You Clean and Replace KDPF (KCSF and KDOC).....................................................................................1007 Prepare Troubleshoot Machine Monitor............................................................................................................1011 Procedure to Make Harness Checker on Machine Monitor LCD Unit...................................................................................1013 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])............................................................1019 Failure Code Table..............................................................................................................................1021 Troubleshooting by Failure Code (Display of Code)...................................................................................................1042 Failure Code [2F00MA]...........................................................................................................................1042 Failure Code [2F00MB]...........................................................................................................................1045 Failure Code [2G42ZG]...........................................................................................................................1047 Failure Code [2G43ZG]...........................................................................................................................1049 Failure Code [6091NX]...........................................................................................................................1051 Failure Code [7RHYKA]...........................................................................................................................1053 Failure Code [7RHYKB]...........................................................................................................................1055 Failure Code [7RHYKY]...........................................................................................................................1057 Failure Code [879AKA]...........................................................................................................................1059 Failure Code [879AKB]...........................................................................................................................1061 Failure Code [879BKA]...........................................................................................................................1063 Failure Code [879BKB]...........................................................................................................................1065 Failure Code [879CKA]...........................................................................................................................1067 Failure Code [879CKB]...........................................................................................................................1069 Failure Code [879DKZ]...........................................................................................................................1071 Failure Code [879EMC]...........................................................................................................................1073 Failure Code [879FMC]...........................................................................................................................1074 Failure Code [989FN1]...........................................................................................................................1075 Failure Code [989L00]...........................................................................................................................1076 Failure Code [989M00]...........................................................................................................................1077 Failure Code [989N00]...........................................................................................................................1078 Failure Code [A1U0N3]...........................................................................................................................1079 Failure Code [A1U0N4]...........................................................................................................................1081 Failure Code [AB00KE]...........................................................................................................................1083 Failure Code [AB00KY]...........................................................................................................................1085 Failure Code [AQ10N3]...........................................................................................................................1087 Failure Code [AS00N3]...........................................................................................................................1089 Failure Code [AS00R2]...........................................................................................................................1091 Failure Code [AS00R3]...........................................................................................................................1092 Failure Code [AS00R4]...........................................................................................................................1093 Failure Code [AS00R5]...........................................................................................................................1094 Failure Code [AS00R6]...........................................................................................................................1095 Failure Code [AS00ZK]...........................................................................................................................1096 Failure Code [AS10KM]...........................................................................................................................1097 Failure Code [AS10NR]...........................................................................................................................1098 Failure Code [AS10NT]...........................................................................................................................1099 Failure Code [B@BAZG]...........................................................................................................................1100 Failure Code [B@BCNS]...........................................................................................................................1101 Failure Code [B@BCZK]...........................................................................................................................1102 Failure Code [B@C6NS]...........................................................................................................................1104 Failure Code [B@CRNS]...........................................................................................................................1106 Failure Code [CA115]............................................................................................................................1107 Failure Code [CA122]............................................................................................................................1108 Failure Code [CA123]............................................................................................................................1110 Failure Code [CA131]............................................................................................................................1112 Failure Code [CA132]............................................................................................................................1114 Failure Code [CA144]............................................................................................................................1117 Failure Code [CA145]............................................................................................................................1119 Failure Code [CA153]............................................................................................................................1121 Failure Code [CA154]............................................................................................................................1124 Failure Code [CA187]............................................................................................................................1126 Failure Code [CA221]............................................................................................................................1128 Failure Code [CA222]............................................................................................................................1130 Failure Code [CA227]............................................................................................................................1132 Failure Code [CA234]............................................................................................................................1133 Failure Code [CA238]............................................................................................................................1134 Failure Code [CA239]............................................................................................................................1136 Failure Code [CA249]............................................................................................................................1138 Failure Code [CA256]............................................................................................................................1140 Failure Code [CA271]............................................................................................................................1142 Failure Code [CA272]............................................................................................................................1144 Failure Code [CA322]............................................................................................................................1146 Failure Code [CA323]............................................................................................................................1148 Failure Code [CA324]............................................................................................................................1150 Failure Code [CA325]............................................................................................................................1152 Failure Code [CA331]............................................................................................................................1154 Failure Code [CA332]............................................................................................................................1156 Failure Code [CA343]............................................................................................................................1158 Failure Code [CA351]............................................................................................................................1159 Failure Code [CA352]............................................................................................................................1160 Failure Code [CA356]............................................................................................................................1163 Failure Code [CA357]............................................................................................................................1165 Failure Code [CA386]............................................................................................................................1168 Failure Code [CA428]............................................................................................................................1169 Failure Code [CA429]............................................................................................................................1171 Failure Code [CA431]............................................................................................................................1173 Failure Code [CA432]............................................................................................................................1176 Failure Code [CA435]............................................................................................................................1180 Failure Code [CA441]............................................................................................................................1182 Failure Code [CA442]............................................................................................................................1184 Failure Code [CA449]............................................................................................................................1185 Failure Code [CA451]............................................................................................................................1186 Failure Code [CA452]............................................................................................................................1188 Failure Code [CA488]............................................................................................................................1190 Failure Code [CA515]............................................................................................................................1191 Failure Code [CA516]............................................................................................................................1193 Failure Code [CA553]............................................................................................................................1195 Failure Code [CA555]............................................................................................................................1196 Failure Code [CA556]............................................................................................................................1197 Failure Code [CA559]............................................................................................................................1198 Failure Code [CA595]............................................................................................................................1201 Failure Code [CA687]............................................................................................................................1202 Failure Code [CA689]............................................................................................................................1204 Failure Code [CA691]............................................................................................................................1207 Failure Code [CA692]............................................................................................................................1209 Failure Code [CA697]............................................................................................................................1211 Failure Code [CA698]............................................................................................................................1212 Failure Code [CA731]............................................................................................................................1213 Failure Code [CA778]............................................................................................................................1215 Failure Code [CA1117]...........................................................................................................................1220 Failure Code [CA1664]...........................................................................................................................1221 Failure Code [CA1669]...........................................................................................................................1223 Failure Code [CA1673]...........................................................................................................................1224 Failure Code [CA1677]...........................................................................................................................1225 Failure Code [CA1678]...........................................................................................................................1226 Failure Code [CA1682]...........................................................................................................................1227 Failure Code [CA1683]...........................................................................................................................1232 Failure Code [CA1684]...........................................................................................................................1234 Failure Code [CA1686]...........................................................................................................................1236 Failure Code [CA1691]...........................................................................................................................1237 Failure Code [CA1694]...........................................................................................................................1240 Failure Code [CA1695]...........................................................................................................................1243 Failure Code [CA1696]...........................................................................................................................1244 Failure Code [CA1712]...........................................................................................................................1246 Failure Code [CA1713]...........................................................................................................................1249 Failure Code [CA1714]...........................................................................................................................1251 Failure Code [CA1715]...........................................................................................................................1252 Failure Code [CA1776]...........................................................................................................................1253 Failure Code [CA1777]...........................................................................................................................1256 Failure Code [CA1843]...........................................................................................................................1259 Failure Code [CA1844]...........................................................................................................................1261 Failure Code [CA1879]...........................................................................................................................1264 Failure Code [CA1881]...........................................................................................................................1267 Failure Code [CA1883]...........................................................................................................................1269 Failure Code [CA1885]...........................................................................................................................1273 Failure Code [CA1887]...........................................................................................................................1275 Failure Code [CA1921]...........................................................................................................................1277 Failure Code [CA1922]...........................................................................................................................1280 Failure Code [CA1942]...........................................................................................................................1285 Failure Code [CA1993]...........................................................................................................................1286 Failure Code [CA2185]...........................................................................................................................1289 Failure Code [CA2186]...........................................................................................................................1291 Failure Code [CA2249]...........................................................................................................................1293 Failure Code [CA2271]...........................................................................................................................1294 Failure Code [CA2272]...........................................................................................................................1297 Failure Code [CA2288]...........................................................................................................................1300 Failure Code [CA2311]...........................................................................................................................1301 Failure Code [CA2349]...........................................................................................................................1302 Failure Code [CA2353]...........................................................................................................................1305 Failure Code [CA2357]...........................................................................................................................1307 Failure Code [CA2381]...........................................................................................................................1308 Failure Code [CA2382]...........................................................................................................................1311 Failure Code [CA2383]...........................................................................................................................1314 Failure Code [CA2386]...........................................................................................................................1317 Failure Code [CA2387]...........................................................................................................................1319 Troubleshooting Flowchart...................................................................................................................1323 Failure Code [CA2555]...........................................................................................................................1324 Failure Code [CA2556]...........................................................................................................................1327 Failure Code [CA2637]...........................................................................................................................1329 Failure Code [CA2639]...........................................................................................................................1331 Failure Code [CA2771]...........................................................................................................................1334 Failure Code [CA2777]...........................................................................................................................1340 Failure Code [CA2976]...........................................................................................................................1343 Failure Code [CA3133]...........................................................................................................................1345 Failure Code [CA3134]...........................................................................................................................1348 Failure Code [CA3135]...........................................................................................................................1350 Failure Code [CA3142]...........................................................................................................................1354 Failure Code [CA3143]...........................................................................................................................1355 Failure Code [CA3144]...........................................................................................................................1356 Failure Code [CA3146]...........................................................................................................................1358 Failure Code [CA3147]...........................................................................................................................1359 Failure Code [CA3148]...........................................................................................................................1360 Failure Code [CA3151]...........................................................................................................................1362 Failure Code [CA3165]...........................................................................................................................1368 Failure Code [CA3229]...........................................................................................................................1370 Failure Code [CA3231]...........................................................................................................................1372 Failure Code [CA3232]...........................................................................................................................1374 Failure Code [CA3235]...........................................................................................................................1378 Failure Code [CA3239]...........................................................................................................................1380 Failure Code [CA3241]...........................................................................................................................1383 Failure Code [CA3242]...........................................................................................................................1386 Failure Code [CA3251]...........................................................................................................................1389 Failure Code [CA3253]...........................................................................................................................1391 Failure Code [CA3254]...........................................................................................................................1394 Failure Code [CA3255]...........................................................................................................................1397 Failure Code [CA3256]...........................................................................................................................1401 Failure Code [CA3311]...........................................................................................................................1403 Failure Code [CA3312]...........................................................................................................................1405 Failure Code [CA3313]...........................................................................................................................1408 Failure Code [CA3314]...........................................................................................................................1409 Failure Code [CA3315]...........................................................................................................................1410 Failure Code [CA3316]...........................................................................................................................1413 Failure Code [CA3317]...........................................................................................................................1414 Failure Code [CA3318]...........................................................................................................................1415 Failure Code [CA3319]...........................................................................................................................1418 Failure Code [CA3321]...........................................................................................................................1419 Failure Code [CA3322]...........................................................................................................................1421 Failure Code [CA3419]...........................................................................................................................1424 Failure Code [CA3421]...........................................................................................................................1426 Failure Code [CA3497]...........................................................................................................................1428 Failure Code [CA3498]...........................................................................................................................1429 Failure Code [CA3543]...........................................................................................................................1430 Failure Code [CA3545]...........................................................................................................................1437 Failure Code [CA3547]...........................................................................................................................1439 Failure Code [CA3558]...........................................................................................................................1440 Failure Code [CA3559]...........................................................................................................................1442 Failure Code [CA3562]...........................................................................................................................1444 Failure Code [CA3563]...........................................................................................................................1446 Failure Code [CA3567]...........................................................................................................................1449 Failure Code [CA3568]...........................................................................................................................1452 Failure Code [CA3571]...........................................................................................................................1458 Failure Code [CA3572]...........................................................................................................................1460 Failure Code [CA3574]...........................................................................................................................1462 Failure Code [CA3575]...........................................................................................................................1465 Failure Code [CA3577]...........................................................................................................................1467 Failure Code [CA3578]...........................................................................................................................1469 Failure Code [CA3582]...........................................................................................................................1471 Failure Code [CA3583]...........................................................................................................................1479 Failure Code [CA3596]...........................................................................................................................1481 Failure Code [CA3649]...........................................................................................................................1484 Failure Code [CA3681]...........................................................................................................................1486 Failure Code [CA3682]...........................................................................................................................1491 Failure Code [CA3713]...........................................................................................................................1497 Failure Code [CA3717]...........................................................................................................................1500 Failure Code [CA3718]...........................................................................................................................1501 Failure Code [CA3725]...........................................................................................................................1502 Failure Code [CA3741]...........................................................................................................................1505 Failure Code [CA3748]...........................................................................................................................1506 Failure Code [CA3751]...........................................................................................................................1509 Failure Code [CA3755]...........................................................................................................................1511 Failure Code [CA3866]...........................................................................................................................1513 Failure Code [CA3867]...........................................................................................................................1517 Failure Code [CA3868]...........................................................................................................................1520 Failure Code [CA3899]...........................................................................................................................1524 Failure Code [CA3911]...........................................................................................................................1526 Failure Code [CA3912]...........................................................................................................................1530 Failure Code [CA3932]...........................................................................................................................1532 Failure Code [CA3933]...........................................................................................................................1534 Failure Code [CA3934]...........................................................................................................................1536 Failure Code [CA3935]...........................................................................................................................1539 Failure Code [CA3936]...........................................................................................................................1541 Failure Code [CA4151]...........................................................................................................................1543 Failure Code [CA4152]...........................................................................................................................1547 Failure Code [CA4155]...........................................................................................................................1551 Failure Code [CA4156]...........................................................................................................................1553 Failure Code [CA4157]...........................................................................................................................1556 Failure Code [CA4158]...........................................................................................................................1558 Failure Code [CA4159]...........................................................................................................................1559 Failure Code [CA4161]...........................................................................................................................1560 Failure Code [CA4162]...........................................................................................................................1563 Failure Code [CA4163]...........................................................................................................................1566 Failure Code [CA4164]...........................................................................................................................1568 Failure Code [CA4165]...........................................................................................................................1570 Failure Code [CA4166]...........................................................................................................................1572 Failure Code [CA4168]...........................................................................................................................1574 Failure Code [CA4169]...........................................................................................................................1577 Failure Code [CA4171]...........................................................................................................................1579 Failure Code [CA4249]...........................................................................................................................1582 Failure Code [CA4251]...........................................................................................................................1584 Failure Code [CA4259]...........................................................................................................................1586 Failure Code [CA4261]...........................................................................................................................1589 Failure Code [CA4277]...........................................................................................................................1592 Failure Code [CA4281]...........................................................................................................................1596 Failure Code [CA4459]...........................................................................................................................1599 Failure Code [CA4461]...........................................................................................................................1601 Failure Code [CA4658]...........................................................................................................................1604 Failure Code [CA4731]...........................................................................................................................1608 Failure Code [CA4732]...........................................................................................................................1609 Failure Code [CA4739]...........................................................................................................................1610 Failure Code [CA4768]...........................................................................................................................1611 Failure Code [CA4769]...........................................................................................................................1613 Failure Code [CA4842]...........................................................................................................................1615 Failure Code [CA4952]...........................................................................................................................1619 Failure Code [CA5115]...........................................................................................................................1621 Failure Code [CA5179]...........................................................................................................................1624 Failure Code [CA5181]...........................................................................................................................1626 Failure Code [CA5383]...........................................................................................................................1628 Failure Code [D103KA]...........................................................................................................................1630 Failure Code [D103KB]...........................................................................................................................1632 Failure Code [D103KY]...........................................................................................................................1634 Failure Code [D103MC]...........................................................................................................................1636 Failure Code [D104KA]...........................................................................................................................1638 Failure Code [D104KB]...........................................................................................................................1640 Failure Code [D104KY]...........................................................................................................................1642 Failure Code [D104MC]...........................................................................................................................1644 Failure Code [D110L4]...........................................................................................................................1646 Failure Code [D160KA]...........................................................................................................................1648 Failure Code [D160KY]...........................................................................................................................1650 Failure Code [D191KA]...........................................................................................................................1651 Failure Code [D191KB]...........................................................................................................................1653 Failure Code [D191KY]...........................................................................................................................1655 Failure Code [D192KA]...........................................................................................................................1656 Failure Code [D192KB]...........................................................................................................................1657 Failure Code [D192KY]...........................................................................................................................1658 Failure Code [D19JKZ]...........................................................................................................................1659 Failure Code [D1B0KA]...........................................................................................................................1661 Failure Code [D1B0KB]...........................................................................................................................1663 Failure Code [D1B0KY]...........................................................................................................................1665 Failure Code [D1B0MC]...........................................................................................................................1667 Failure Code [D1E6KA]...........................................................................................................................1669 Failure Code [D1E6KB]...........................................................................................................................1671 Failure Code [D1E6KY]...........................................................................................................................1673 Failure Code [D5ZHKA]...........................................................................................................................1675 Failure Code [D5ZHKB]...........................................................................................................................1677 Failure Code [D5ZHL6]...........................................................................................................................1679 Failure Code [D811MC]...........................................................................................................................1680 Failure Code [D862KA]...........................................................................................................................1681 Failure Code [D8ALKA]...........................................................................................................................1682 Failure Code [D8ALKB]...........................................................................................................................1684 Failure Code [D8AQK4]...........................................................................................................................1686 Failure Code [D8AQKR]...........................................................................................................................1690 Failure Code [D8G1KT]...........................................................................................................................1694 Failure Code [D8G6KT]...........................................................................................................................1695 Failure Code [DAF0KT]...........................................................................................................................1696 Failure Code [DAF0MB]...........................................................................................................................1697 Failure Code [DAF0MC]...........................................................................................................................1698 Failure Code [DAF3KK]...........................................................................................................................1699 Failure Code [DAF8KB]...........................................................................................................................1701 Failure Code [DAFDKB]...........................................................................................................................1702 Failure Code [DAFGMC]...........................................................................................................................1704 Failure Code [DAFLKA]...........................................................................................................................1705 Failure Code [DAFLKB]...........................................................................................................................1707 Failure Code [DAFQKR]...........................................................................................................................1709 Failure Code [DAJ0KK]...........................................................................................................................1714 Failure Code [DAJ0KT]...........................................................................................................................1717 Failure Code [DAJ0MC]...........................................................................................................................1718 Failure Code [DAJ1KA]...........................................................................................................................1719 Failure Code [DAJ2KK]...........................................................................................................................1721 Failure Code [DAJ2KT]...........................................................................................................................1724 Failure Code [DAJ4KB]...........................................................................................................................1727 Failure Code [DAJ4KZ]...........................................................................................................................1729 Failure Code [DAJ5KX] (Applicable Machine: 83001 to 86599)......................................................................................1731 Failure Code [DAJ5KX] (Applicable Machine: 86600 and Up)........................................................................................1733 Failure Code [DAJ6KX] (Applicable Machine: 83001 to 86599)......................................................................................1735 Failure Code [DAJ6KX] (Applicable Machine: 86600 and Up)........................................................................................1737 Failure Code [DAJ9KQ]...........................................................................................................................1739 Failure Code [DAJLKA]...........................................................................................................................1740 Failure Code [DAJLKB]...........................................................................................................................1742 Failure Code [DAJQKR]...........................................................................................................................1744 Failure Code [DAJRKR]...........................................................................................................................1749 Failure Code [DAJRMA]...........................................................................................................................1754 Failure Code [DAZ9KQ]...........................................................................................................................1755 Failure Code [DAZQKR]...........................................................................................................................1756 Failure Code [DB2QKR]...........................................................................................................................1760 Failure Code [DB2RKR]...........................................................................................................................1766 Failure Code [DD1ALD]...........................................................................................................................1771 Failure Code [DDAAL6]...........................................................................................................................1773 Failure Code [DDB2L4]...........................................................................................................................1775 Failure Code [DDB6L4]...........................................................................................................................1777 Failure Code [DDD7KA]...........................................................................................................................1779 Failure Code [DDD7KY]...........................................................................................................................1781 Failure Code [DDK3KA]...........................................................................................................................1783 Failure Code [DDK3KB]...........................................................................................................................1786 Failure Code [DDK6KA]...........................................................................................................................1789 Failure Code [DDK6KB]...........................................................................................................................1792 Failure Code [DDNRLD] (Applicable Machine: 83001 to 86599)......................................................................................1795 Failure Code [DDNRLD] (Applicable Machine: 86600 and Up)........................................................................................1797 Failure Code [DF10KA]...........................................................................................................................1799 Failure Code [DF10KB]...........................................................................................................................1802 Failure Code [DGH1KX]...........................................................................................................................1805 Failure Code [DGR2KB]...........................................................................................................................1807 Failure Code [DGR2KZ]...........................................................................................................................1809 Failure Code [DHHBKA]...........................................................................................................................1811 Failure Code [DHHBKY]...........................................................................................................................1813 Failure Code [DHHCKA]...........................................................................................................................1815 Failure Code [DHHCKY]...........................................................................................................................1817 Failure Code [DHPCKA]...........................................................................................................................1819 Failure Code [DHPCKY]...........................................................................................................................1821 Failure Code [DHPEKA]...........................................................................................................................1823 Failure Code [DHPEKY]...........................................................................................................................1825 Failure Code [DHS8KA]...........................................................................................................................1827 Failure Code [DHS8KY]...........................................................................................................................1829 Failure Code [DHS9KA]...........................................................................................................................1831 Failure Code [DHS9KY]...........................................................................................................................1833 Failure Code [DHSDKA]...........................................................................................................................1835 Failure Code [DHSDKY]...........................................................................................................................1837 Failure Code [DHSNKA]...........................................................................................................................1839 Failure Code [DHSNKY]...........................................................................................................................1841 Failure Code [DHT8ZG]...........................................................................................................................1843 Failure Code [DHTCL6]...........................................................................................................................1844 Failure Code [DJF1KA]...........................................................................................................................1846 Failure Code [DK55KA]...........................................................................................................................1847 Failure Code [DK55KY]...........................................................................................................................1849 Failure Code [DK55L5]...........................................................................................................................1851 Failure Code [DK5DKA] (Applicable Machine: 83001 to 86599)......................................................................................1852 Failure Code [DK5DKA] (Applicable Machine: 86600 and Up)........................................................................................1855 Failure Code [DK5DKY] (Applicable Machine: 83001 to 86599)......................................................................................1858 Failure Code [DK5DKY] (Applicable Machine: 86600 and Up)........................................................................................1861 Failure Code [DK5DL8] (Applicable Machine: 83001 to 86599)......................................................................................1864 Failure Code [DK5DL8] (Applicable Machine: 86600 and Up)........................................................................................1868 Failure Code [DK5EKA] (Applicable Machine: 83001 to 86599)......................................................................................1872 Failure Code [DK5EKA] (Applicable Machine: 86600 and Up)........................................................................................1875 Failure Code [DK5EKY] (Applicable Machine: 83001 to 86599)......................................................................................1878 Failure Code [DK5EKY] (Applicable Machine: 86600 and Up)........................................................................................1881 Failure Code [DK70KA]...........................................................................................................................1884 Failure Code [DK70KY]...........................................................................................................................1886 Failure Code [DKA0KA]...........................................................................................................................1888 Failure Code [DKA0KY]...........................................................................................................................1891 Failure Code [DKA0L0]...........................................................................................................................1893 Failure Code [DLM3KA]...........................................................................................................................1895 Failure Code [DLM3LC]...........................................................................................................................1897 Failure Code [DLT3KX] (Applicable Machine: 83001 to 86599)......................................................................................1899 Failure Code [DLT3KX] (Applicable Machine: 86600 and Up)........................................................................................1901 Failure Code [DLT4KX] (Applicable Machine: 83001 to 86599)......................................................................................1903 Failure Code [DLT4KX] (Applicable Machine: 86600 and Up)........................................................................................1905 Failure Code [DLT4L0]...........................................................................................................................1907 Failure Code [DLT4LC] (Applicable Machine: 83001 to 86599)......................................................................................1908 Failure Code [DLT4LC] (Applicable Machine: 86600 and Up)........................................................................................1910 Failure Code [DPQ1KR]...........................................................................................................................1912 Failure Code [DPQ2KR]...........................................................................................................................1915 Failure Code [DPQ3KR]...........................................................................................................................1918 Failure Code [DSJ0KR]...........................................................................................................................1922 Failure Code [DT22KB] (Applicable Machine: 83001 to 86599)......................................................................................1927 Failure Code [DT22KB] (Applicable Machine: 86600 and Up)........................................................................................1929 Failure Code [DV00KB]...........................................................................................................................1931 Failure Code [DW26KA]...........................................................................................................................1932 Failure Code [DW26KB]...........................................................................................................................1934 Failure Code [DW26KY]...........................................................................................................................1936 Failure Code [DW4BKA] (Applicable Machine: 83001 to 86599)......................................................................................1938 Failure Code [DW4BKA] (Applicable Machine: 86600 and Up)........................................................................................1940 Failure Code [DW4BKB] (Applicable Machine: 83001 to 86599)......................................................................................1942 Failure Code [DW4BKB] (Applicable Machine: 86600 and Up)........................................................................................1944 Failure Code [DW4BKY] (Applicable Machine: 83001 to 86599)......................................................................................1946 Failure Code [DW4BKY] (Applicable Machine: 86600 and Up)........................................................................................1947 Failure Code [DW4RKA]...........................................................................................................................1949 Failure Code [DW4RKB]...........................................................................................................................1951 Failure Code [DW4RKY]...........................................................................................................................1953 Failure Code [DWM1KA] (Applicable Machine: 83001 to 86599)......................................................................................1955 Failure Code [DWM1KA] (Applicable Machine: 86600 and Up)........................................................................................1956 Failure Code [DWM1KB] (Applicable Machine: 83001 to 86599)......................................................................................1958 Failure Code [DWM1KB] (Applicable Machine: 86600 and Up)........................................................................................1960 Failure Code [DWM1KY] (Applicable Machine: 83001 to 86599)......................................................................................1962 Failure Code [DWM1KY] (Applicable Machine: 86600 and Up)........................................................................................1963 Failure Code [DWN6KA]...........................................................................................................................1965 Failure Code [DWN6KB]...........................................................................................................................1967 Failure Code [DWN6KY]...........................................................................................................................1969 Failure Code [DWN8KA]...........................................................................................................................1970 Failure Code [DWN8KB]...........................................................................................................................1971 Failure Code [DWN8KY]...........................................................................................................................1972 Failure Code [DX19KA]...........................................................................................................................1973 Failure Code [DX19KB]...........................................................................................................................1975 Failure Code [DX19KY]...........................................................................................................................1977 Failure Code [DX20KA]...........................................................................................................................1979 Failure Code [DX20KB]...........................................................................................................................1981 Failure Code [DX20KY]...........................................................................................................................1983 Failure Code [DXAWKA]...........................................................................................................................1984 Failure Code [DXAWKB]...........................................................................................................................1987 Failure Code [DXAWKY]...........................................................................................................................1990 Failure Code [DXH7KA]...........................................................................................................................1993 Failure Code [DXH7KB]...........................................................................................................................1995 Failure Code [DXH7KY]...........................................................................................................................1997 Failure Code [DXH8KA]...........................................................................................................................1999 Failure Code [DXH8KB]...........................................................................................................................2001 Failure Code [DXH8KY]...........................................................................................................................2003 Failure Code [DXHJKA]...........................................................................................................................2005 Failure Code [DXHJKB]...........................................................................................................................2007 Failure Code [DXHJKY]...........................................................................................................................2009 Failure Code [DXHKKA]...........................................................................................................................2010 Failure Code [DXHKKB]...........................................................................................................................2012 Failure Code [DXHKKY]...........................................................................................................................2014 Failure Code [F313KA]...........................................................................................................................2015 Failure Code [F313KB]...........................................................................................................................2017 Failure Code [F314KA]...........................................................................................................................2018 Failure Code [F314KB]...........................................................................................................................2020 Failure Code [F315KB]...........................................................................................................................2022 Failure Code [F315KY]...........................................................................................................................2024 Failure Code [F316KB]...........................................................................................................................2026 Failure Code [F316KY]...........................................................................................................................2028 Failure Code [F318KB]...........................................................................................................................2030 Failure Code [F318KY]...........................................................................................................................2032 Failure Code [F31AKB]...........................................................................................................................2033 Failure Code [F31AKY]...........................................................................................................................2035 Failure Code [F31BKB]...........................................................................................................................2037 Failure Code [F31BKY]...........................................................................................................................2039 Failure Code [F31CKB]...........................................................................................................................2041 Failure Code [F31CKY]...........................................................................................................................2043 Failure Code [F31DKB]...........................................................................................................................2045 Failure Code [F31DKY]...........................................................................................................................2047 Failure Code [F31EKB]...........................................................................................................................2049 Failure Code [F31EKY]...........................................................................................................................2051 Failure Code [FS10ZE]...........................................................................................................................2053 Failure Code [H2K0KA]...........................................................................................................................2054 Failure Code [H2K0KY]...........................................................................................................................2056 Failure Code [J141N1]...........................................................................................................................2058 Failure Code [LA00L3]...........................................................................................................................2059 Failure Code [M100N1]...........................................................................................................................2060 Failure Code [M400N1]...........................................................................................................................2061 Troubleshooting of Electrical System (E-Mode).......................................................................................................2062 Engine Does Not Start (Engine Does Not Crank)...................................................................................................2062 Manual Preheating System Does Not Operate.......................................................................................................2070 Automatic Preheating System Does Not Operate....................................................................................................2073 While Preheating is in Operation, Preheating Monitor Does Not Come On...........................................................................2076 The LCD Unit, LED Unit, and Meter Unit of the Machine Monitor Show Nothing......................................................................2078 LCD Unit on Machine Monitor Shows Nothing.......................................................................................................2081 Backlight of LCD Unit on Machine Monitor is Abnormal (Backlight Goes Off or Flickers)...........................................................2083 LCD Screen on Machine Monitor Does Not Show Correctly...........................................................................................2085 Meter Unit Display on Machine Monitor is Abnormal...............................................................................................2087 Night Mode Lamp of Meter Unit on Machine Monitor is Abnormal....................................................................................2090 LED Unit Lamp on Machine Monitor is Abnormal....................................................................................................2093 Night Mode Lamp of Switch Panel on Machine Monitor is Abnormal or Switches Do Not Operate Correctly.............................................2095 Two Switches Operation of Switch Panel on Machine Monitor Does Not Operate......................................................................2098 Switch Panel Buzzer of Machine Monitor is Abnormal..............................................................................................2101 Some Items of Gauges and Caution Lamps on Machine Monitor are Not Shown Normally................................................................2104 DEF Level is Not Shown Correctly................................................................................................................2105 Rearview Monitor Does Not Come On or Backlight Flickers.........................................................................................2108 Rearview Monitor Images are Not Shown Clearly...................................................................................................2111 Rearview Monitor Brightness Cannot be Adjusted..................................................................................................2115 Night Mode Lamp of Rearview Monitor is Abnormal.................................................................................................2119 Radiator Coolant Level Caution Lamp Does Not Come On............................................................................................2121 Parking Brake Indicator Lamp Does Not Light When Parking Brake is Set to ON (Parking) Position..................................................2123 Brake Oil Pressure Caution Lamp Does Not Come On When Front Brake Accumulator Oil Pressure is Low...............................................2127 Brake Oil Pressure Caution Lamp Does Not Come On When Rear Brake Accumulator Oil Pressure is Low................................................2128 Indication of HST Oil Temperature Gauge Does Not Increase, or HST Oil Temperature Caution Lamp Does Not Come On.................................2129 When the Inching Pedal is Pushed, Inching Function Does Not Work or While the Pedal is Not Pushed, Inching Function Operates....................2130 Fuel Gauge Does Not Show Normally...............................................................................................................2132 Seatbelt Caution Lamp Does Not Show Normally....................................................................................................2134 Alarm Buzzer Does Not Operate...................................................................................................................2135 Alarm Buzzer Does Not Stop......................................................................................................................2137 When the Emergency HST Pump Drive Switch is Operated, It Does Not Work or When the Emergency HST Pump Drive Switch is Not Operated, It Works....2138 Setting Does Not Change While You Operate the Traction Control Switch...........................................................................2141 The Remote Positioner Does Not Work or Cannot be Released.......................................................................................2143 The Bucket Positioner Does Not Work or Cannot be Released.......................................................................................2145 Parking Brake Does Not Operate Even If It is Applied, or the Brake Drags in Forward or Reverse Travel When Parking Brake is Released............2148 Directional Selector (FNR) Switch Mode is Not Selected or Not Released..........................................................................2152 PZ Auto Tilt-in Does Not Work...................................................................................................................2154 PZ Auto Tilt-in Does Not Work (Applicable Machine: 83001 to 86599)..........................................................................2155 PZ Auto Tilt-in Does Not Work (Applicable Machine: 86600 and Up)............................................................................2158 Traction Level Does Not Show MAX When Max. Traction Switch is Turned on.........................................................................2161 ECSS Function Cannot be Selected or Cannot be Released..........................................................................................2163 ECSS Function Cannot be Selected or Cannot be Released (Applicable Machine: 83001 to 86599).................................................2164 ECSS Function Cannot be Selected or Cannot be Released (Applicable Machine: 86600 and Up)...................................................2166 Horn Does Not Sound.............................................................................................................................2168 Horn Does Not Stop..............................................................................................................................2171 Headlamp, Clearance Lamp, and Tail Lamp Do Not Come On..........................................................................................2173 Clearance Lamp and Tail Lamp Do Not Come On or Go Out...........................................................................................2175 Clearance Lamp and Tail Lamp Do Not Come On or Go Out (for European Union and Turkey)...........................................................2179 High and Low Beams of Headlamp Do Not Come On or Go Out.........................................................................................2183 Both High and Low Beams of Headlamp Do Not Come On or Go Out (for European Union and Turkey)....................................................2187 Low Beam of Headlamp Does Not Come On or Go Out.................................................................................................2191 Low Beam of Headlamp Does Not Come on or Go off (for European Union and Turkey).................................................................2193 High Beam of Headlamp Does Not Come On or Go Out................................................................................................2195 High Beam of Headlamp Does Not Come On or Go Out (for European Union and Turkey)................................................................2197 Front Working Lamp Does Not Come On or Go Out...................................................................................................2199 Rear Working Lamp Does Not Come On or Go Out....................................................................................................2204 Turn Signal Lamp and Hazard Lamp Do Not Come On or Go Out.......................................................................................2208 Turn Signal Lamp Does Not Come On or Go Out.....................................................................................................2211 Turn Signal Lamps Do Not Come on or Go off (for European Union and Turkey)......................................................................2214 Hazard Lamp Does Not Come On or Go Out..........................................................................................................2217 Hazard Lamp Does Not Come On or Go Out (for European Union and Turkey)..........................................................................2221 Brake Lamp Does Not Come On or Stays Lit........................................................................................................2225 Brake Lamp Does Not Light or Stays Lighted (for European Union and Turkey)......................................................................2229 Backup Lamp Does Not Come On or Stays Lit.......................................................................................................2233 Backup Lamp Does Not Come On or Does Not Go Out (for European Union and Turkey).................................................................2237 Backup Buzzer Does Not Sound or Continues to Sound..............................................................................................2241 Front Wiper Does Not Operate....................................................................................................................2243 Rear Wiper Does Not Operate.....................................................................................................................2247 Window Washer Does Not Operate..................................................................................................................2250 KOMTRAX System Does Not Operate Correctly.......................................................................................................2253 Auto-Greasing Pump Display Shows [FCS]..........................................................................................................2254 Auto-Greasing Pump Display Shows [FLL]..........................................................................................................2255 Auto-Greasing System Does Not Operate or Stop...................................................................................................2256 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).......................................................................................2257 Information Shown in Troubleshooting Table (H-Mode).............................................................................................2257 Failure Mode and Cause Table....................................................................................................................2258 Machine Can Not Move Forward or Reverse.........................................................................................................2272 Machine Can Not Travel FORWARD (Machine Travels REVERSE Normally)...............................................................................2275 Machine Can Not Travel REVERSE (Machine Travels FORWARD Normally)...............................................................................2276 Travel Speed of FORWARD Travel and REVERSE Travel is Slow, or Power is Low......................................................................2277 Forward Travel Speed is Slow or Power is Low (Machine Travels REVERSE Normally).................................................................2281 REVERSE Travel Speed is Slow or Power is Low (Machine Travels FORWARD Normally).................................................................2282 Engine Speed Drops Largely or Engine Stops......................................................................................................2283 Machine Does Not Turn...........................................................................................................................2285 Steering Wheel is Heavy to Operate..............................................................................................................2287 Machine Sways or Large Shocks are Made While Machine Turns......................................................................................2289 Machine Unintentionally Turns to One Side When Machine Travels..................................................................................2290 Wheel Brakes Do Not Operate or are Weak.........................................................................................................2291 Wheel Brakes are Not Released or Drag...........................................................................................................2293 Parking Brake Does Not Operate or is Weak.......................................................................................................2294 Parking Brake is Not Released or Drags..........................................................................................................2295 Boom Does Not Rise..............................................................................................................................2297 Boom Moves Slow or Lacks Lifting Force..........................................................................................................2300 Rising Boom Slows Down at Specified Height......................................................................................................2303 Lift Cylinders Can Not Hold Bucket on Ground....................................................................................................2304 Hydraulic Drift of Boom is Large................................................................................................................2306 Boom Moves Up and Down During Operation.........................................................................................................2307 Bucket Does Not Tilt Back.......................................................................................................................2308 Bucket Moves Slow or Lacks Tilt-Back Force......................................................................................................2311 Bucket Slows Down During Tilt Back Operation....................................................................................................2314 Bucket Cylinder Does Not Hold Bucket on Ground..................................................................................................2315 Hydraulic Drift of Bucket is Large..............................................................................................................2317 Bucket Tilts Back and Forth When You Carry Load (Work Equipment Valve is in Hold)...............................................................2318 Boom and Bucket Control Levers Do Not Move Smoothly and are Heavy to Move.......................................................................2319 Engine Speed Drops Largely or Engine Stops When You Operate Work Equipment......................................................................2320 Large Shocks are Made When Work Equipment Starts to Move and Stops..............................................................................2321 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves................................................................2323 ECSS Does Not Operate and Machine Pitches and Bounces...........................................................................................2324 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate).....................................................................................2325 Unusual Noise is Heard from Around Fan..........................................................................................................2328 Troubleshooting of Engine (S-Mode)..................................................................................................................2329 Information Shown in Troubleshooting Table (S-Mode).............................................................................................2329 Engine Does Not Crank When Starting Switch is Turned to Start Position..........................................................................2330 Engine Cranks but No Exhaust Smoke Comes Out....................................................................................................2331 Fuel is Sprayed but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start).........................................................2332 Engine Startability is Unsatisfactory...........................................................................................................2334 Engine Does Not Pick Up Smoothly................................................................................................................2336 Engine Stops During Operation...................................................................................................................2338 Engine Does Not Rotate Smoothly.................................................................................................................2340 Engine Lacks Output (or Lacks Power)............................................................................................................2341 KDPF Becomes Clogged in a Short Time............................................................................................................2343 Engine Oil Consumption is Excessive.............................................................................................................2345 Engine Oil Becomes Dirty Quickly................................................................................................................2346 Fuel Consumption is Excessive...................................................................................................................2347 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down)...........................................................................2348 Engine Oil Pressure Drops.......................................................................................................................2349 Fuel Mixes Into Engine Oil......................................................................................................................2351 Water Mixes Into Engine Oil (Milky).............................................................................................................2352 Coolant Temperature Increases Too High (Overheat)...............................................................................................2353 Unusual Noise is Heard..........................................................................................................................2354 Vibration is Excessive..........................................................................................................................2355 Air Cannot be Bled from Fuel Circuit............................................................................................................2356 Active Regeneration is Done Frequently..........................................................................................................2357 Active Regeneration Continues Long..............................................................................................................2359 White Smoke is Exhausted During Active Regeneration.............................................................................................2360 DEF Consumption is Excessive....................................................................................................................2361 Foreign Materials Enter DEF (DEF Increases).....................................................................................................2363 Troubleshooting for Auto-Greasing System............................................................................................................2364 Outline of Failure Display......................................................................................................................2364 Troubleshooting for FCS.........................................................................................................................2365 Replacement of Pump Element.....................................................................................................................2366 Troubleshooting for Grease Supply System........................................................................................................2367 Replace Auto-Greasing Controller................................................................................................................2369 Assembly procedure when disassembled in troubleshooting.........................................................................................2370 50 Disassembly and Assembly.............................................................................................................................2371 Table of Contents...................................................................................................................................2372 Precautions Before Work.............................................................................................................................2376 Abbreviation List...................................................................................................................................2377 Related Information on Disassembly and Assembly.....................................................................................................2383 How to Read This Manual.........................................................................................................................2383 Coating Materials List..........................................................................................................................2384 Special Tool List...............................................................................................................................2389 Sketches of Special Tools.......................................................................................................................2412 Engine and Cooling System...........................................................................................................................2433 Remove and Install Supply Pump Assembly.........................................................................................................2433 How to Remove Supply Pump Assembly..........................................................................................................2434 How to Install Supply Pump Assembly.........................................................................................................2439 Remove and Install Injector Assembly............................................................................................................2446 How to Remove Injector Assembly.............................................................................................................2446 How to Install Injector Assembly............................................................................................................2454 Remove and Install Cylinder Head Assembly.......................................................................................................2464 How to Remove Cylinder Head Assembly........................................................................................................2465 How to Install Cylinder Head Assembly.......................................................................................................2476 Remove and Install EGR Valve Assembly...........................................................................................................2491 How to Remove EGR Valve Assembly............................................................................................................2491 How to Install EGR Valve Assembly...........................................................................................................2495 Remove and Install EGR Cooler Assembly..........................................................................................................2499 How to Remove EGR Cooler Assembly...........................................................................................................2499 How to Install EGR Cooler Assembly..........................................................................................................2503 Remove and Install Starter Assembly.............................................................................................................2507 How to Remove Starting Motor Assembly.......................................................................................................2507 How to Install Starting Motor Assembly......................................................................................................2509 Remove and Install Air Conditioner Compressor Belt..............................................................................................2512 How to Remove Air Conditioner Compressor Belt...............................................................................................2512 How to Install Air Conditioner Compressor Belt..............................................................................................2513 Remove and Install Alternator Belt..............................................................................................................2515 How to Remove Alternator Belt...............................................................................................................2515 How to Install Alternator Belt..............................................................................................................2518 Remove and Install Alternator Assembly..........................................................................................................2520 How to Remove Alternator Assembly...........................................................................................................2520 How to Install Alternator Assembly..........................................................................................................2523 Remove and Install Automatic Tensioner..........................................................................................................2527 How to Remove Automatic Tensioner...........................................................................................................2527 How to Install Automatic Tensioner..........................................................................................................2527 Remove and Install Radiator Assembly............................................................................................................2528 How to Remove Radiator Assembly.............................................................................................................2528 How to Install Radiator Assembly............................................................................................................2532 Remove and Install Cooling Fan and Fan Motor Assembly...........................................................................................2535 How to Remove Cooling Fan and Fan Motor Assembly............................................................................................2535 How to Install Cooling Fan and Fan Motor Assembly...........................................................................................2538 Remove and Install Hydraulic Oil Cooler Assembly................................................................................................2542 How to Remove Hydraulic Oil Cooler Assembly.................................................................................................2542 How to Install Hydraulic Oil Cooler Assembly................................................................................................2544 Remove and Install Aftercooler Assembly.........................................................................................................2546 How to Remove Aftercooler Assembly..........................................................................................................2546 How to Install Aftercooler Assembly.........................................................................................................2547 Remove and Install Engine Assembly..............................................................................................................2549 How to Remove Engine Assembly...............................................................................................................2550 How to Install Engine Assembly..............................................................................................................2568 Remove and Install Engine Front Oil Seal........................................................................................................2588 How to Remove Engine Front Oil Seal.........................................................................................................2588 How to Install Engine Front Oil Seal........................................................................................................2590 Remove and Install Engine Rear Oil Seal.........................................................................................................2593 How to Remove Engine Rear Oil Seal..........................................................................................................2593 How to Install Engine Rear Oil Seal.........................................................................................................2595 Remove and Install Engine Hood Assembly.........................................................................................................2599 How to Remove Engine Hood Assembly..........................................................................................................2599 How to Install Engine Hood Assembly.........................................................................................................2605 Remove and Install Fuel Tank Assembly...........................................................................................................2612 How to Remove Fuel Tank Assembly............................................................................................................2612 How to Install Fuel Tank Assembly...........................................................................................................2616 Remove and Install DEF Tank Assembly............................................................................................................2621 How to Remove DEF Tank Assembly.............................................................................................................2622 How to Install DEF Tank Assembly............................................................................................................2629 Remove and Install DEF Tank Sensor Flange Assembly..............................................................................................2635 How to Remove DEF Tank Sensor Flange Assembly...............................................................................................2635 How to Install DEF Tank Sensor Flange Assembly..............................................................................................2637 Remove and Install DEF Tank Sensor..............................................................................................................2640 How to Remove DEF Tank Sensor...............................................................................................................2640 How to Install DEF Tank Sensor..............................................................................................................2641 Remove and Install DEF Tank Strainer............................................................................................................2648 How to Remove DEF Tank Strainer.............................................................................................................2648 How to Install DEF Tank Strainer............................................................................................................2649 Remove and Install KDPF Assembly................................................................................................................2650 How to Remove KDPF Assembly.................................................................................................................2651 How to Install KDPF Assembly................................................................................................................2661 Disassemble and Assemble KDPF Assembly..........................................................................................................2673 How to Disassemble KDPF Assembly............................................................................................................2673 How to Assemble KDPF Assembly...............................................................................................................2678 Remove and Install SCR Assembly.................................................................................................................2683 How to Remove SCR Assembly..................................................................................................................2684 How to Install SCR Assembly.................................................................................................................2694 Remove and Install KDPF and SCR Assembly........................................................................................................2707 How to Remove KDPF and SCR Assembly.........................................................................................................2708 How to Install KDPF and SCR Assembly........................................................................................................2718 Remove and Install Bellows Pipe Assembly........................................................................................................2733 How to Remove Bellows Pipe Assembly.........................................................................................................2733 How to Install Bellows Pipe Assembly........................................................................................................2736 Remove and Install KCCV Assembly................................................................................................................2741 How to Remove KCCV Assembly.................................................................................................................2741 How to Install KCCV Assembly................................................................................................................2743 Remove and Install VGT Assembly.................................................................................................................2746 How to Remove VGT Assembly..................................................................................................................2746 How to Install VGT Assembly.................................................................................................................2753 Remove and Install DEF Mixing Tube..............................................................................................................2762 How to Remove DEF Mixing Tube...............................................................................................................2763 How to Install DEF Mixing Tube..............................................................................................................2768 Remove and Install DEF Injector.................................................................................................................2775 How to Remove DEF Injector..................................................................................................................2775 How to Install DEF Injector.................................................................................................................2777 Remove and Install DEF Pump.....................................................................................................................2781 How to Remove DEF Pump......................................................................................................................2781 How to Install DEF Pump.....................................................................................................................2784 Remove and Install DEF Hose.....................................................................................................................2788 How to Remove DEF Hose......................................................................................................................2788 How to Install DEF Hose.....................................................................................................................2798 Remove and Install Air Cleaner Assembly.........................................................................................................2808 How to Remove Air Cleaner Assembly..........................................................................................................2808 How to Install Air Cleaner Assembly.........................................................................................................2811 Remove and Install Air Conditioner Compressor Assembly..........................................................................................2814 How to Remove Air Conditioner Compressor Assembly...........................................................................................2815 How to Install Air Conditioner Compressor Assembly..........................................................................................2817 Remove and Install Air Conditioner Condenser Assembly...........................................................................................2820 How to Remove Air Conditioner Condenser Assembly............................................................................................2820 How to Install Air Conditioner Condenser Assembly...........................................................................................2822 Power Train.........................................................................................................................................2825 Remove and Install HST Pump Assembly............................................................................................................2825 How to Remove HST Pump Assembly.............................................................................................................2826 How to Install HST Pump Assembly............................................................................................................2832 Remove and Install HST Motor 1 Assembly.........................................................................................................2841 How to Remove HST Motor 1 Assembly..........................................................................................................2841 How to Install HST Motor 1 Assembly.........................................................................................................2844 Remove and Install HST Motor 2 Assembly.........................................................................................................2847 How to Remove HST Motor 2 Assembly..........................................................................................................2848 How to Install HST Motor 2 Assembly.........................................................................................................2856 Remove and Install Transfer Assembly............................................................................................................2865 How to Remove Transfer Assembly.............................................................................................................2866 How to Install Transfer Assembly............................................................................................................2870 Disassemble and Assemble Transfer Assembly......................................................................................................2875 How to Disassemble Transfer Assembly........................................................................................................2878 How to Assemble Transfer Assembly...........................................................................................................2897 Remove and Install Front Axle Assembly..........................................................................................................2922 How to Remove Front Axle Assembly...........................................................................................................2922 How to Install Front Axle Assembly..........................................................................................................2924 Remove and Install Rear Axle Assembly...........................................................................................................2927 How to Remove Rear Axle Assembly............................................................................................................2927 How to Install Rear Axle Assembly...........................................................................................................2931 Disassemble and Assemble Axle Housing Assembly..................................................................................................2935 How to Disassemble Axle Housing Assembly....................................................................................................2936 How to Assemble Axle Housing Assembly.......................................................................................................2944 Disassemble and Assemble Differential Assembly..................................................................................................2954 How to Disassemble Differential Assembly....................................................................................................2955 How to Assemble Differential Assembly.......................................................................................................2968 Undercarriage and Frame.............................................................................................................................2988 Remove and Install Center Hinge Pin.............................................................................................................2988 How to Remove Center Hinge Pin..............................................................................................................2989 How to Install Center Hinge Pin.............................................................................................................2996 Remove and Install Counterweight Assembly.......................................................................................................3011 How to Remove Counterweight Assembly........................................................................................................3011 How to Install Counterweight Assembly.......................................................................................................3017 Hydraulic System....................................................................................................................................3022 Remove and Install Hydraulic Tank Assembly......................................................................................................3022 How to Remove Hydraulic Tank Assembly.......................................................................................................3022 How to Install Hydraulic Tank Assembly......................................................................................................3032 Remove and Install Control Valve Assembly.......................................................................................................3041 How to Remove Control Valve Assembly........................................................................................................3041 How to Install Control Valve Assembly.......................................................................................................3047 Remove and Install Quick Coupler LS Pressure Rise Valve Assembly................................................................................3052 How to Remove Quick Coupler LS Pressure Rise Valve Assembly.................................................................................3052 How to Install Quick Coupler LS Pressure Rise Valve Assembly................................................................................3055 Work Equipment......................................................................................................................................3058 Remove and Install Work Equipment Assembly......................................................................................................3058 How to Remove Work Equipment Assembly.......................................................................................................3059 How to Install Work Equipment Assembly......................................................................................................3063 Disassemble and Assemble Work Equipment Cylinder Assembly.......................................................................................3074 How to Disassemble Work Equipment Cylinder Assembly.........................................................................................3075 How to Assemble Work Equipment Cylinder Assembly............................................................................................3079 CAB Related Parts...................................................................................................................................3086 Remove and Install Operator Cab and Floor Frame Assembly........................................................................................3086 How to Remove Operator Cab and Floor Frame Assembly.........................................................................................3087 How to Install Operator Cab and Floor Frame Assembly........................................................................................3094 Remove and Install Operator Cab Glass (Adhered Glass)...........................................................................................3103 How to Remove Operator Cab Glass (Adhered Glass)............................................................................................3103 How to Install Operator Cab Glass (Adhered Glass)...........................................................................................3104 Remove and Install Air Conditioner Unit Assembly................................................................................................3113 How to Remove Air Conditioner Unit Assembly.................................................................................................3113 How to Install Air Conditioner Unit Assembly................................................................................................3119 Remove and Install Operator Seat Assembly.......................................................................................................3126 How to Remove Operator Seat Assembly........................................................................................................3126 How to Install Operator Seat Assembly.......................................................................................................3126 How to Remove and Install Seat Belt.............................................................................................................3128 How to Remove Seat Belt.....................................................................................................................3128 How to Install Seatbelt.....................................................................................................................3128 Electrical System...................................................................................................................................3130 Remove and Install Engine Controller Assembly...................................................................................................3130 How to Remove Engine Controller Assembly....................................................................................................3130 How to Install Engine Controller Assembly...................................................................................................3134 Remove and Install HST Controller Assembly......................................................................................................3139 How to Remove HST Controller Assembly.......................................................................................................3139 How to Install HST Controller Assembly......................................................................................................3141 Remove and Install Air Conditioner Controller Assembly..........................................................................................3143 How to Remove Air Conditioner Controller Assembly...........................................................................................3143 How to Install Air Conditioner Controller Assembly..........................................................................................3144 Remove and Install Monitor Controller Assembly..................................................................................................3146 How to Remove Monitor Controller Assembly...................................................................................................3146 How to Install Monitor Controller Assembly..................................................................................................3149 Remove and Install Machine Monitor Assembly.....................................................................................................3151 How to Remove Machine Monitor Assembly......................................................................................................3151 How to Install Machine Monitor Assembly.....................................................................................................3154 Remove and Install Mass Air Flow and Temperature Sensor.........................................................................................3157 How to Remove Mass Air Flow and Temperature Sensor..........................................................................................3157 How to Install Mass Air Flow and Temperature Sensor.........................................................................................3158 Remove and Install KCCV Crankcase Pressure Sensor...............................................................................................3159 How to Remove KCCV Crankcase Pressure Sensor................................................................................................3159 How to Install KCCV Crankcase Pressure Sensor...............................................................................................3160 Remove and Install KDPF Temperature Sensor......................................................................................................3162 How to Remove KDPF Temperature Sensor.......................................................................................................3162 How to Install KDPF Temperature Sensor......................................................................................................3164 Remove and Install KDPF Differential Pressure Sensor............................................................................................3167 How to Remove KDPF Differential Pressure Sensor.............................................................................................3167 How to Install KDPF Differential Pressure Sensor............................................................................................3170 Remove and Install SCR Temperature Sensor.......................................................................................................3173 How to Remove SCR Temperature Sensor........................................................................................................3173 How to Install SCR Temperature Sensor.......................................................................................................3174 Remove and Install Ammonia Sensor...............................................................................................................3176 How to Remove Ammonia Sensor................................................................................................................3176 How to Install Ammonia Sensor...............................................................................................................3178 Remove and Install SCR Outlet NOx Sensor........................................................................................................3181 How to Remove SCR Outlet NOx Sensor.........................................................................................................3181 How to Install SCR Outlet NOx Sensor........................................................................................................3184 Remove and Install Gateway Function Controller Assembly.........................................................................................3187 How to Remove Gateway Function Controller Assembly..........................................................................................3187 How to Install Gateway Function Controller Assembly.........................................................................................3188 Remove and Install Communication Terminal.......................................................................................................3189 How to Remove Communication Terminal........................................................................................................3189 How to Install Communication Terminal.......................................................................................................3191 60 Maintenance Standard.................................................................................................................................3195 Table of Contents...................................................................................................................................3196 Abbreviation List...................................................................................................................................3197 Engine and Cooling System...........................................................................................................................3203 Maintenance Standard for Engine Mount...........................................................................................................3203 Maintenance Standard for Damper.................................................................................................................3204 Maintenance Standard for Cooling Fan Motor......................................................................................................3206 Power Train.........................................................................................................................................3208 Maintenance Standard for Drive Shaft............................................................................................................3208 Maintenance Standard for Transfer...............................................................................................................3209 Maintenance Standard for Transfer Mount.........................................................................................................3217 Maintenance Standard for Front Axle.............................................................................................................3218 Maintenance Standard for Rear Axle..............................................................................................................3219 Maintenance Standard for Front Torque Proportioning Differential................................................................................3220 Maintenance Standard for Rear Torque Proportioning Differential.................................................................................3222 Maintenance Standard for Limited Slip Differential..............................................................................................3224 Maintenance Standard for Front Final Drive......................................................................................................3226 Maintenance Standard for Rear Final Drive.......................................................................................................3228 Steering System.....................................................................................................................................3230 Maintenance Standard for Steering Column........................................................................................................3230 Maintenance Standard for Priority Valve.........................................................................................................3231 Maintenance Standard for Steering Cylinder......................................................................................................3232 Maintenance Standard for Secondary Steering Valve...............................................................................................3235 Brake System........................................................................................................................................3236 Maintenance Standard for Brake Circuit Accumulator Charge Valve.................................................................................3236 Maintenance Standard for Slack Adjuster.........................................................................................................3237 Maintenance Standard for Front Brake............................................................................................................3238 Maintenance Standard for Rear Brake.............................................................................................................3239 Maintenance Standard for Parking Brake..........................................................................................................3240 Maintenance Standard for Parking Brake Solenoid Valve...........................................................................................3242 Undercarriage and Frame.............................................................................................................................3243 Maintenance Standard for Frame, Axle Mount and Center Hinge Pin.................................................................................3243 Hydraulic System....................................................................................................................................3254 Maintenance Standard for Hydraulic Tank.........................................................................................................3254 Maintenance Standard for Brake and Cooling Fan Pump and Transfer Lubrication Pump...............................................................3255 Maintenance Standard for Steering and Work Equipment Pump.......................................................................................3256 Maintenance Standard for Servo Valve of Steering and Work Equipment Pump....................................................................3259 Maintenance Standard for Control Valve..........................................................................................................3260 Maintenance Standard for Self-Pressure Reducing Valve...........................................................................................3272 Maintenance Standard for Multifunction Mono-Lever PPC Valve.....................................................................................3274 Maintenance Standard for Work Equipment Lock Solenoid Valve.....................................................................................3276 Work Equipment......................................................................................................................................3277 Maintenance Standard for Work Equipment Linkage.................................................................................................3277 Maintenance Standard for Bucket.................................................................................................................3281 Maintenance Standard for Lift Cylinder..........................................................................................................3282 Maintenance Standard for Bucket Cylinder........................................................................................................3283 CAB Related Parts...................................................................................................................................3284 Maintenance Standard for CAB Mount..............................................................................................................3284 80 Appendix.............................................................................................................................................3285 Table of Contents...................................................................................................................................3286 Precautions Before Work.............................................................................................................................3288 Abbreviation List...................................................................................................................................3289 Air Conditioner System..............................................................................................................................3295 Precautions for Refrigerant.....................................................................................................................3295 Air Conditioner Component.......................................................................................................................3296 Specifications of Air Conditioner...............................................................................................................3298 Structure and Function of Refrigeration Cycle...................................................................................................3299 Outline of Refrigeration Cycle..................................................................................................................3300 Component Parts of Air Conditioner System...........................................................................................................3302 Air Conditioner Unit............................................................................................................................3302 Configuration Diagram of Air Conditioner Unit...............................................................................................3302 Function of Air Conditioner Unit............................................................................................................3303 Component Parts of Air Conditioner Unit.........................................................................................................3304 Function of Evaporator as Air Conditioner Unit Component....................................................................................3304 Function of Inside Air Temperature Sensor as Air Conditioner Unit Component.................................................................3304 Function of Blower Amplifier as Air Conditioner Unit Component..............................................................................3305 Function of Blower OFF Relay as Air Conditioner Unit Component..............................................................................3305 Function of Compressor Clutch Relay as Air Conditioner Unit Component.......................................................................3305 Function of Heater Core as Air Conditioner Unit Component...................................................................................3305 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.................................................................3305 Function of Servo Motor as Air Conditioner Unit Component...................................................................................3305 Function of Expansion Valve as Air Conditioner Unit Component...............................................................................3306 Function of Dual Pressure Switch............................................................................................................3306 Air Conditioner Controller......................................................................................................................3307 Structure of Air Conditioner Controller.....................................................................................................3307 Compressor......................................................................................................................................3308 Structure of Compressor.....................................................................................................................3308 Specifications of Compressor................................................................................................................3308 Function of Compressor......................................................................................................................3308 Condenser.......................................................................................................................................3309 Structure of Condenser......................................................................................................................3309 Specifications of Condenser.................................................................................................................3309 Function of Condenser.......................................................................................................................3309 Receiver Drier..................................................................................................................................3310 Structure of Receiver Dryer.................................................................................................................3310 Specifications of Receiver Dryer............................................................................................................3310 Function of Receiver Dryer..................................................................................................................3310 Air Conditioner Related Sensors.................................................................................................................3311 Function of Sunlight Sensor.................................................................................................................3311 Function of Outside Air Temperature Sensor..................................................................................................3311 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.........................................................................3312 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..............................................................................3314 System Diagram of Air Conditioner...................................................................................................................3317 Input and Output Signals of Air Conditioner Controller..........................................................................................3318 Function of Air Conditioner Controller......................................................................................................3319 Locations of Air Conditioner Parts and Layout of Connectors.........................................................................................3320 Examine Air Conditioner with Self-Diagnosis Function................................................................................................3326 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.............................................................3327 Examine Temperature Control Function................................................................................................................3328 How to Examine Temperature Control Function.....................................................................................................3328 Examine Vent (Mode) Changeover......................................................................................................................3330 How to Examine Vent (Mode) Changeover...........................................................................................................3330 Examine Fresh/Recirc Air Changeover.................................................................................................................3332 How to Examine Fresh/Recirc Air Changeover......................................................................................................3332 Examine Evaporator Temperature Sensor...............................................................................................................3334 Examine Relay.......................................................................................................................................3336 How to Examine Relay............................................................................................................................3336 Air Conditioner Troubleshooting Chart 1.............................................................................................................3338 Air Conditioner Troubleshooting Chart 2.............................................................................................................3339 Failure Code [879AKA]...............................................................................................................................3342 Failure Code [879AKB]...............................................................................................................................3344 Failure Code [879BKA]...............................................................................................................................3346 Failure Code [879BKB]...............................................................................................................................3348 Failure Code [879CKA]...............................................................................................................................3350 Failure Code [879CKB]...............................................................................................................................3352 Failure Code [879DKZ]...............................................................................................................................3354 Failure Code [879EMC]...............................................................................................................................3356 Failure Code [879FMC]...............................................................................................................................3357 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)..........................................................................3358 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)...........................................................................3361 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................................................................3364 Troubleshooting for Fresh/Recirc Air Changeover.....................................................................................................3368 Troubleshooting by Gauge Pressure...................................................................................................................3370 Connect Service Tool................................................................................................................................3373 How to Connect Service Tool.....................................................................................................................3374 Precautions for Disconnection and Connection of Air Conditioner Piping..............................................................................3375 Handle Compressor Oil...............................................................................................................................3377 90 Circuit Diagrams.....................................................................................................................................3379 Table of Contents...................................................................................................................................3380 Abbreviation List...................................................................................................................................3382 Hydraulic Circuit Diagram...........................................................................................................................3388 Symbols Used in Hydraulic Circuit Diagram.......................................................................................................3388 Hydraulic Circuit Diagram.......................................................................................................................3393 Hydraulic Auto-Greasing Diagram (Serial Number: 83001 to 84688).................................................................................3395 Hydraulic Auto-Greasing Diagram (Serial Number: 84689 and up)...................................................................................3397 Electrical Circuit Diagram..........................................................................................................................3399 Symbols Used in Electric Circuit Diagram........................................................................................................3399 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (1/6)................................................................3403 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (2/6)................................................................3405 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (3/6)................................................................3407 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (4/6)................................................................3409 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (5/6)................................................................3411 Electrical Circuit Diagram of Machine (Applicable Machine: 84424 to 86599) (6/6)................................................................3413 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (1/6)..................................................................3415 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (2/6)..................................................................3417 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (3/6)..................................................................3419 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (4/6)..................................................................3421 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (5/6)..................................................................3423 Electrical Circuit Diagram of Machine (Applicable Machine: 86600 and Up) (6/6)..................................................................3425 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (1/8)........................3427 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (2/8)........................3429 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (3/8)........................3431 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (4/8)........................3433 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (5/8)........................3435 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (6/8)........................3437 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (7/8)........................3439 Electrical Circuit Diagram of Machine (Machine with Collision Detection System) (Applicable Machine: 86600 and Up) (8/8)........................3441 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (1/10).................................................................3443 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (2/10).................................................................3445 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (3/10).................................................................3447 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (4/10).................................................................3449 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (5/10).................................................................3451 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (6/10).................................................................3453 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (7/10).................................................................3455 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (8/10).................................................................3457 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (9/10).................................................................3459 Electrical Circuit Diagram of Floor (Applicable Machine: 84424 to 86599) (10/10)................................................................3461 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (1/11)...................................................................3463 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (2/11)...................................................................3465 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (3/11)...................................................................3467 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (4/11)...................................................................3469 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (5/11)...................................................................3471 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (6/11)...................................................................3473 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (7/11)...................................................................3475 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (8/11)...................................................................3477 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (9/11)...................................................................3479 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (10/11)..................................................................3481 Electrical Circuit Diagram of Floor (Applicable Machine: 86600 and Up) (11/11)..................................................................3483 Index....................................................................................................................................................3485
DESCRIPTION:
KOMATSU WA270-8E0 WHEEL LOADER SHOP MANUAL SEN06793-05 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
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 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams
S.S 28/12/24
