Komatsu WA320-8 Wheel Loader Shop Manual VENBM30500 PDF

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Komatsu WA320-8 Wheel Loader Shop Manual VENBM30500 – PDF DOWNLOAD

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Komatsu WA320-8 Wheel Loader Shop Manual VENBM30500 – PDF DOWNLOAD

Language : English
Pages : 3237
Downloadable : Yes
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Komatsu WA320-8 Wheel Loader Shop Manual VENBM30500 – PDF DOWNLOAD

VENBM30500 . 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS . 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING . 44
PRECAUTIONS FOR ADDING . 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE AdBlue/DEF . 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT . 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT . 58
PRACTICAL USE OF KOMTRAX . 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS . 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . 74
HOW TO READ ELECTRICAL WIRE CODE . 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 79
STANDARD TIGHTENING TORQUE TABLE . 82
CONVERSION TABLE . 89
01 SPECIFICATIONS 95
CONTENTS . 96
ABBREVIATION LIST 97
SPECIFICATIONS . 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: WA320-8 . 103
SPECIFICATIONS . 105
SPECIFICATIONS: WA320-8 105
WEIGHT TABLE . 110
WEIGHT TABLE: WA320-8 110
TABLE OF FUEL, COOLANT, AND LUBRICANTS . 112
10 STRUCTURE AND FUNCTION 115
CONTENTS . 116
ABBREVIATION LIST 120
UREA SCR SYSTEM 126
LAYOUT DRAWING OF UREA SCR SYSTEM 126
UREA SCR SYSTEM DIAGRAM 128
FUNCTION OF UREA SCR SYSTEM 129
FUNCTION OF AdBlue/DEF SYSTEM 129
INDUCEMENT STRATEGY 132
COMPONENT PARTS OF UREA SCR SYSTEM . 147
AdBlue/DEF MIXING TUBE . 147
SCR ASSEMBLY . 148
AdBlue/DEF TANK 150
AdBlue/DEF PUMP 152
AdBlue/DEF INJECTOR 153
AdBlue/DEF HOSE 154
AdBlue/DEF TANK HEATING VALVE 155
BOOT-UP SYSTEM . 156
LAYOUT DRAWING OF BOOT-UP SYSTEM . 156
SYSTEM OPERATING LAMP SYSTEM . 158
SYSTEM OPERATING LAMP SYSTEM DIAGRAM . 158
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM . 158
BATTERY DISCONNECT SWITCH 159
FUNCTION OF BATTERY DISCONNECT SWITCH 159
PREHEATING SYSTEM 160
PREHEATING SYSTEM DIAGRAM 160
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 160
OPERATION OF AUTOMATIC PREHEATING SYSTEM . 160
FUNCTION OF MANUAL PREHEATING SYSTEM . 161
OPERATION OF MANUAL PREHEATING SYSTEM 161
ENGINE SYSTEM 162
LAYOUT DRAWING OF ENGINE SYSTEM 162
FUNCTION OF ENGINE SYSTEM 163
ENGINE CONTROL SYSTEM 164
ENGINE CONTROL SYSTEM DIAGRAM 164
FUNCTION OF ENGINE CONTROL SYSTEM 166
OPERATION OF ENGINE CONTROL SYSTEM . 169
AUTOMATIC IDLE STOP SYSTEM . 171
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM . 171
COMPONENT PARTS OF ENGINE SYSTEM . 172
DAMPER . 172
VGT 173
EGR SYSTEM . 177
EGR VALVE 179
EGR COOLER . 181
KCCV SYSTEM 183
KCCV VENTILATOR 185
KDPF . 187
COOLING SYSTEM . 191
LAYOUT DRAWING OF COOLING SYSTEM . 191
SPECIFICATIONS OF COOLING SYSTEM . 192
COOLING FAN CONTROL SYSTEM . 193
COOLING FAN CONTROL SYSTEM DIAGRAM . 193
FUNCTION OF COOLING FAN CONTROL SYSTEM . 193
COMPONENT PARTS OF COOLING SYSTEM 198
COOLING FAN MOTOR 198
CONTROL SYSTEM . 211
LAYOUT DRAWING OF CONTROL SYSTEM . 211
MACHINE MONITOR SYSTEM . 213
MACHINE MONITOR SYSTEM DIAGRAM . 213
FUNCTION OF MACHINE MONITOR SYSTEM . 213
REARVIEW MONITOR SYSTEM 215
REARVIEW MONITOR SYSTEM DIAGRAM 215
FUNCTION OF REARVIEW MONITOR SYSTEM 215
KOMTRAX SYSTEM . 216
KOMTRAX SYSTEM DIAGRAM . 216
FUNCTION OF KOMTRAX SYSTEM . 216
COMPONENT PARTS OF CONTROL SYSTEM 217
MACHINE MONITOR 217
SWITCH PANEL . 235
REARVIEW MONITOR . 236
REARVIEW CAMERA 238
KOMTRAX TERMINAL . 239
MONITOR CONTROLLER . 241
HST CONTROLLER . 246
CAN TERMINATING RESISTOR . 250
ENGINE CONTROLLER 251
ACCELERATOR PEDAL 258
HYDRAULIC SYSTEM . 260
LAYOUT DRAWING OF HYDRAULIC SYSTEM . 260
CLSS . 261
STRUCTURE OF CLSS 261
FUNCTION OF CLSS . 262
COMPONENT PARTS OF HYDRAULIC SYSTEM 264
HYDRAULIC TANK . 264
HYDRAULIC OIL FILTER . 267
STEERING AND WORK EQUIPMENT PUMP . 268
BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP . 281
CONTROL VALVE 282
POWER TRAIN SYSTEM . 312
LAYOUT DRAWING OF POWER TRAIN SYSTEM . 312
OPERATION OF POWER TRAIN SYSTEM 314
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION . 315
HST CONTROL SYSTEM . 317
HST CONTROL SYSTEM DIAGRAM . 317
ENGINE OVERRUN PREVENTION FUNCTION . 318
NEUTRALIZER FUNCTION . 318
HST CHARGE SYSTEM 319
SYSTEM DIAGRAM OF HST CHARGE SYSTEM 319
FUNCTION OF HST CHARGE SYSTEM 319
HST PUMP CONTROL SYSTEM 320
SYSTEM DIAGRAM OF HST PUMP CONTROL SYSTEM 320
DIRECTIONAL SELECTION FUNCTION . 320
ABSORBING TORQUE CONTROL FUNCTION 320
INCHING CONTROL FUNCTION . 321
TRAVEL SPEED ADJUSTMENT FUNCTION (AT LOW SPEED) 321
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION . 322
GEAR SHIFT FUNCTION 322
GEAR SHIFT DISPLAY FUNCTION 324
TRAVEL SPEED ADJUSTMENT FUNCTION . 324
TRANSFER CLUTCH CONTROL FUNCTION . 325
HST SYSTEM PROTECTION FUNCTION . 326
TRANSFER PROTECTION FUNCTION . 326
DIRECTION PROTECTION FUNCTION 326
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 1 326
HST MOTOR 1 OVERRUN PREVENTION FUNCTION 2 327
TRAVEL SPEED LIMITATION FUNCTION . 328
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL . 329
FUNCTION OF MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL . 329
KOMATSU TRACTION CONTROL SYSTEM (KTCS) . 332
KOMATSU TRACTION CONTROL SYSTEM (KTCS) DIAGRAM . 332
FUNCTION OF KOMATSU TRACTION CONTROL SYSTEM (KTCS) . 332
COMPONENT PARTS OF POWER TRAIN SYSTEM 337
DRIVE SHAFT 337
HST PUMP . 339
HST CHARGE PUMP 351
HST MOTOR 353
TRANSFER . 359
AXLE . 367
TORQUE PROPORTIONING DIFFERENTIAL 369
LIMITED SLIP DIFFERENTIAL 374
FINAL DRIVE 378
COMBINATION SWITCH . 380
WORK EQUIPMENT SYSTEM 384
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 384
WORK EQUIPMENT CONTROL SYSTEM 386
WORK EQUIPMENT LEVER OPERATION FUNCTION 386
PZ AUTO TILT-IN COMPENSATION CONTROL FUNCTION 386
WORK EQUIPMENT LOCK SYSTEM . 387
WORK EQUIPMENT LOCK SYSTEM DIAGRAM . 387
FUNCTION OF WORK EQUIPMENT LOCK SYSTEM . 387
BUCKET POSITIONER SYSTEM . 389
BUCKET POSITIONER SYSTEM DIAGRAM . 389
FUNCTION OF BUCKET POSITIONER SYSTEM . 389
OPERATION OF BUCKET POSITIONER SYSTEM 391
FORK POSITIONER SYSTEM . 393
FORK POSITIONER SYSTEM DIAGRAM . 393
FUNCTION OF FORK POSITIONER SYSTEM . 393
OPERATION OF FORK POSITIONER SYSTEM 394
REMOTE POSITIONER SYSTEM . 397
REMOTE BOOM POSITIONER SYSTEM DIAGRAM 397
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM 397
ECSS . 400
ECSS DIAGRAM . 400
FUNCTION OF ECSS . 400
OPERATION OF ECSS 400
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM . 402
SELF-PRESSURE REDUCING VALVE . 402
WORK EQUIPMENT LOCK SOLENOID VALVE . 407
PILOT CIRCUIT ACCUMULATOR 408
ECSS CIRCUIT ACCUMULATOR . 409
MULTIFUNCTION MONO-LEVER . 410
MULTIFUNCTION MONO-LEVER PPC VALVE . 412
STEERING SYSTEM 417
LAYOUT DRAWING OF STEERING SYSTEM 417
STEERING COLUMN 418
STRUCTURE OF STEERING COLUMN . 418
COMPONENT PARTS OF STEERING SYSTEM . 419
PRIORITY VALVE . 419
ORBITROL VALVE . 422
CUSHION VALVE 427
SECONDARY STEERING VALVE . 429
BRAKE SYSTEM . 432
LAYOUT DRAWING OF BRAKE SYSTEM . 432
PARKING BRAKE CONTROL SYSTEM . 434
PARKING BRAKE CONTROL SYSTEM DIAGRAM . 434
OPERATION OF PARKING BRAKE CONTROL SYSTEM 434
COMPONENT PARTS OF BRAKE SYSTEM 438
BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE . 438
PARKING BRAKE SOLENOID VALVE . 442
BRAKE CIRCUIT ACCUMULATOR 444
BRAKE VALVE 446
SLACK ADJUSTER . 449
BRAKE 451
PARKING BRAKE 454
AUTO-GREASING SYSTEM . 456
LAYOUT DRAWING OF AUTO-GREASING SYSTEM . 456
SPECIFICATIONS OF AUTO-GREASING SYSTEM . 457
FUNCTION OF AUTO-GREASING SYSTEM . 459
COMPONENT PARTS OF AUTO-GREASING SYSTEM 460
AUTO-GREASING PUMP . 460
UNDERCARRIAGE AND FRAME 461
FRAME, AXLE MOUNT AND CENTER HINGE PIN . 461
STRUCTURE OF FRAME, AXLE MOUNT AND CENTER HINGE PIN 461
FUNCTION OF FRAME, AXLE MOUNT AND CENTER HINGE PIN . 462
TIRE . 464
FEATURES OF RADIAL TIRE WHEN COMPARED WITH BIAS TIRE . 464
STRUCTURE OF RADIAL TIRE . 464
FUNCTION OF RADIAL TIRE 464
STRUCTURE OF BIAS TIRE . 465
FUNCTION OF BIAS TIRE 465
WORK EQUIPMENT . 466
STRUCTURE OF WORK EQUIPMENT 466
STRUCTURE OF BUCKET 467
CAB AND ITS ATTACHMENTS 468
ROPS CAB . 468
STRUCTURE OF ROPS CAB 468
FUNCTION OF ROPS CAB . 468
CAB MOUNT 469
STRUCTURE OF CAB MOUNT . 469
FUNCTION OF CAB MOUNT 469
20 STANDARD VALUE TABLE 471
CONTENTS . 472
ABBREVIATION LIST 473
STANDARD VALUE TABLE FOR ENGINE 479
STANDARD VALUE TABLE FOR ENGINE: WA320-8 . 479
STANDARD VALUE TABLE FOR MACHINE . 483
STANDARD VALUE TABLE FOR MACHINE: WA320-8 483
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 497
30 TESTING AND ADJUSTING . 501
CONTENTS . 502
ABBREVIATION LIST 506
RELATED INFORMATION ON TESTING AND ADJUSTING . 512
TOOLS FOR TESTING AND ADJUSTING 512
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 521
ENGINE AND COOLING SYSTEM 522
TEST ENGINE SPEED 522
METHOD FOR TESTING ENGINE SPEED 522
TEST BOOST PRESSURE 525
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR . 525
METHOD FOR TESTING BOOST PRESSURE BY TESTING TOOL 526
TESTING EXHAUST GAS TEMPERATURE 528
METHOD FOR TESTING EXHAUST GAS TEMPERATURE . 528
TEST EXHAUST GAS COLOR . 530
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 530
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 532
TEST AND ADJUST VALVE CLEARANCE 534
METHOD FOR TESTING VALVE CLEARANCE . 534
METHOD FOR ADJUSTING VALVE CLEARANCE . 535
TEST COMPRESSION PRESSURE 536
METHOD FOR TESTING COMPRESSION PRESSURE 536
TEST BLOWBY PRESSURE . 541
METHOD FOR TESTING BLOWBY PRESSURE . 541
TEST ENGINE OIL PRESSURE . 544
METHOD FOR TESTING ENGINE OIL PRESSURE . 544
TEST EGR VALVE AND VGT OIL PRESSURE 546
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 546
TEST FUEL PRESSURE . 548
METHOD FOR TESTING FUEL PRESSURE . 549
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 554
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 555
BLEED AIR FROM FUEL SYSTEM . 561
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 561
TEST FUEL CIRCUIT FOR LEAKAGE 563
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 563
HANDLE CYLINDER CUT-OUT MODE OPERATION . 565
HANDLE NO-INJECTION CRANKING OPERATION . 566
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 567
METHOD FOR TESTING KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 567
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 568
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 568
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 569
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 569
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 570
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 570
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT . 570
TEST ALTERNATOR BELT . 572
METHOD FOR TESTING ALTERNATOR BELT . 572
TEST AUTOMATIC TENSIONER . 574
METHOD FOR TESTING AUTOMATIC TENSIONER . 574
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 577
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 577
TEST SCR RELATED FUNCTIONS . 578
TEST AdBlue/DEF PUMP RAISED PRESSURE . 582
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR . 585
TEST AdBlue/DEF LINE HEATER RELAY 1 591
TEST AdBlue/DEF LINE HEATER RELAY 2 595
TEST AdBlue/DEF PUMP HEATER RELAY 599
TEST AdBlue/DEF TANK HEATER VALVE 603
TEST SCR NOx REMOVAL EFFICIENCY 607
CLEAN AdBlue/DEF TANK 611
METHOD FOR CLEANING AdBlue/DEF TANK 611
POWER TRAIN 615
TEST AND ADJUST HST OIL PRESSURE . 615
METHOD FOR TESTING HST OIL PRESSURE 615
METHOD FOR ADJUSTING HST OIL PRESSURE 617
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH . 619
METHOD FOR TESTING THE CONTROL PRESSURE OF TRANSFER CLUTCH . 619
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 621
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 621
STEERING SYSTEM 622
TEST STEERING WHEEL 622
METHOD FOR TESTING STEERING WHEEL 622
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 624
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE ON MACHINE MONITOR 624
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE BY TESTING TOOL . 625
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE . 625
BLEED AIR FROM STEERING CYLINDER CIRCUIT . 627
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT . 627
BRAKE SYSTEM . 628
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 628
METHOD FOR RELEASING REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT . 628
TEST WHEEL BRAKE OIL PRESSURE 629
METHOD FOR TESTING WHEEL BRAKE OIL PRESSURE 629
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE 631
METHOD FOR TESTING BRAKE ACCUMULATOR CHARGE PRESSURE . 631
METHOD FOR ADJUSTING BRAKE ACCUMULATOR CHARGE PRESSURE . 632
TEST BRAKING PERFORMANCE . 633
METHOD FOR TESTING BRAKING PERFORMANCE . 633
TEST BRAKE PEDAL . 634
METHOD FOR TESTING BRAKE PEDAL . 634
BLEED AIR FROM BRAKE CIRCUIT . 635
METHOD FOR BLEEDING AIR FROM BRAKE CIRCUIT . 635
TEST LOWERING OF WHEEL BRAKE PRESSURE 636
METHOD FOR TESTING LOWERING OF WHEEL BRAKE PRESSURE 637
TEST WEAR OF WHEEL BRAKE DISC 639
METHOD FOR TESTING WEAR OF WHEEL BRAKE DISC 639
TEST PARKING BRAKE OIL PRESSURE 641
METHOD FOR TESTING PARKING BRAKE OIL PRESSURE 641
TEST PARKING BRAKE PERFORMANCE . 643
METHOD FOR TESTING PARKING BRAKE PERFORMANCE . 643
RELEASE PARKING BRAKE MANUALLY . 644
METHOD FOR RELEASING PARKING BRAKE MANUALLY 644
TEST WEAR AMOUNT OF PARKING BRAKE DISC . 645
METHOD FOR TESTING WEAR AMOUNT OF PARKING BRAKE DISC . 645
HYDRAULIC SYSTEM . 646
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 646
METHOD FOR RELEASING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT 646
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE 648
METHOD FOR TESTING WORK EQUIPMENT OIL PRESSURE . 648
METHOD FOR ADJUSTING WORK EQUIPMENT OIL PRESSURE . 652
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE 654
METHOD FOR TESTING WORK EQUIPMENT PPC OIL PRESSURE . 654
METHOD FOR ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE . 656
BLEED AIR FROM WORK EQUIPMENT CIRCUIT 658
METHOD FOR BLEEDING REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT . 658
TEST COOLING FAN SPEED . 660
METHOD FOR TESTING COOLING FAN SPEED . 660
TEST COOLING FAN CIRCUIT OIL PRESSURE 661
METHOD FOR TESTING COOLING FAN CIRCUIT OIL PRESSURE 661
BLEED AIR FROM COOLING FAN CIRCUIT . 664
METHOD FOR BLEEDING AIR FROM COOLING FAN CIRCUIT . 664
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS . 666
METHOD FOR TESTING ECSS ACCUMULATOR NITROGEN GAS PRESSURE 666
METHOD FOR CHARGING ECSS ACCUMULATOR WITH NITROGEN GAS . 668
WORK EQUIPMENT . 672
TEST AND ADJUST BUCKET POSITIONER 672
METHOD FOR TESTING BUCKET POSITIONER . 672
METHOD FOR ADJUSTING BUCKET POSITIONER . 672
TEST AND ADJUST BOOM POTENTIOMETER LEVER . 674
METHOD FOR TESTING BOOM POTENTIOMETER LEVER 674
METHOD FOR ADJUSTING BOOM POTENTIOMETER LEVER 674
CAB AND ITS ATTACHMENTS 675
TEST DIRECTIONAL LEVER . 675
METHOD FOR TESTING DIRECTIONAL LEVER . 675
TEST MULTIFUNCTION MONO-LEVER 676
METHOD FOR TESTING MULTIFUNCTION MONO-LEVER 676
TEST ACCELERATOR PEDAL . 678
METHOD FOR TESTING ACCELERATOR PEDAL . 678
ELECTRICAL SYSTEM 680
SET AND ADJUST EACH EQUIPMENT 680
SET AND OPERATE MACHINE MONITOR 684
OPERATOR MODE 688
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 688
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN . 688
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 689
CHECKING FUNCTION OF SERVICE METER AND ODOMETER 690
METHOD FOR SETTING USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 690
SERVICE MODE . 694
METHOD FOR OPERATING SERVICE MODE 694
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION . 697
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION . 703
ABNORMALITY RECORD MENU 716
METHOD FOR CONFIRMING MAINTENANCE RECORD . 721
METHOD FOR OPERATING MAINTENANCE MODE SETTING 724
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 730
DEFAULT MENU . 731
DIAGNOSTIC TESTS MENU 745
ADJUSTMENT MENU 755
METHOD FOR PERFORMING NO-INJECTION CRANKING 789
KOMTRAX SETTINGS MENU 791
METHOD FOR DISPLAYING SERVICE MESSAGE 793
METHOD FOR STARTING UP KOMTRAX TERMINAL 795
ADJUST REARVIEW CAMERA ANGLE . 800
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 800
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 802
HANDLE BATTERY DISCONNECT SWITCH . 803
TEST DIODES 804
METHOD FOR TESTING DIODE USING DIGITAL TESTER 804
METHOD FOR TESTING DIODE USING ANALOG TESTER . 804
AUTO-GREASING DEVICE . 805
BLEED THE AIR OF AUTO-GREASING SYSTEM 805
METHOD FOR BLEEDING THE AIR OF AUTO-GREASING SYSTEM 805
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 808
METHOD FOR CHANGING THE LUBRICATION TIME AND LUBRICATION INTERVAL TIMES 809
Pm CLINIC 811
Pm CLINIC SERVICE 811
Pm CLINIC CHECK SHEET: WA320-8 . 813
40 TROUBLESHOOTING . 821
CONTENTS . 822
ABBREVIATION LIST 834
RELATED INFORMATION ON TROUBLESHOOTING . 840
GENERAL TROUBLESHOOTING POINTS . 840
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM . 841
SEQUENCE OF EVENTS IN TROUBLESHOOTING 853
CHECKS BEFORE TROUBLESHOOTING 855
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 857
WALK-AROUND CHECK 857
TESTING IN ACCORDANCE WITH TESTING PROCEDURE . 859
CHECK FUEL LEVEL AND TYPE 859
FUEL – CHECK FOR FOREIGN MATERIAL 859
CHECK AdBule/DEF LEVEL AND TYPE 860
CHECK FUEL PREFILTER . 860
CHECK MAIN FILTER 862
OIL PAN – CHECK ENGINE OIL LEVEL AND TYPE 863
CHECK COOLANT LEVEL (RESERVOIR TANK) . 864
CHECK CLOGGING OF AIR CLEANER 865
OUTER ELEMENT – CLEAN 866
REPLACE ELEMENT 867
CHECK HYDRAULIC OIL LEVEL 869
CHECK HYDRAULIC OIL STRAINER . 869
CHECK HYDRAULIC FILTER . 872
CHECK THE OIL LEVEL IN THE TRANSFER CASE . 872
CHECK OIL LEVEL IN FRONT AXLE CASE . 874
CHECK OIL LEVEL IN REAR AXLE CASE 875
BLEED AIR FROM FUEL SYSTEM . 875
BLEED AIR FROM HYDRAULIC SYSTEM 875
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod . 876
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 881
PROCEDURE FOR TESTING AND TROUBLESHOOTING 889
SYMPTOM AND TROUBLESHOOTING NUMBERS 891
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 895
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 897
CONNECTORS LIST AND LAYOUT . 900
CONNECTOR CONTACT IDENTIFICATION . 921
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 961
FUSE LOCATION TABLE 967
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 970
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR . 974
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 976
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 982
FAILURE CODES TABLE 984
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1003
FAILURE CODE [2F00MA] 1003
FAILURE CODE [2F00MB] 1006
FAILURE CODE [2G42ZG] 1008
FAILURE CODE [2G43ZG] 1010
FAILURE CODE [6091NX] 1012
FAILURE CODE [7RHYKA] 1014
FAILURE CODE [7RHYKB] 1016
FAILURE CODE [7RHYKY] 1018
FAILURE CODE [879AKA] 1020
FAILURE CODE [879AKB] 1022
FAILURE CODE [879BKA] 1024
FAILURE CODE [879BKB] 1026
FAILURE CODE [879CKA] 1028
FAILURE CODE [879CKB] 1030
FAILURE CODE [879DKZ] 1032
FAILURE CODE [879EMC] 1034
FAILURE CODE [879FMC] 1035
FAILURE CODE [989FN1] 1036
FAILURE CODE [989L00] 1037
FAILURE CODE [989M00] 1038
FAILURE CODE [989N00] 1039
FAILURE CODE [A1U0N3] 1040
FAILURE CODE [A1U0N4] 1042
FAILURE CODE [AA10NX] 1044
FAILURE CODE [AB00KE] 1046
FAILURE CODE [AB00KY] 1048
FAILURE CODE [AQ10N3] 1050
FAILURE CODE [AS00N3] 1052
FAILURE CODE [AS00R2] 1054
FAILURE CODE [AS00R3] 1055
FAILURE CODE [AS00R4] 1056
FAILURE CODE [AS00R5] 1057
FAILURE CODE [AS00R6] 1058
FAILURE CODE [AS00ZK] 1059
FAILURE CODE [AS10KM] 1060
FAILURE CODE [AS10NR] 1061
FAILURE CODE [AS10NT] 1062
FAILURE CODE [B@BAZG] 1063
FAILURE CODE [B@BAZK] 1064
FAILURE CODE [B@BCNS] 1066
FAILURE CODE [B@BCZK] 1067
FAILURE CODE [B@C6NS] 1069
FAILURE CODE [B@CRNS] 1071
FAILURE CODE [CA115] .1072
FAILURE CODE [CA122] .1073
FAILURE CODE [CA123] .1075
FAILURE CODE [CA131] .1077
FAILURE CODE [CA132] .1079
FAILURE CODE [CA144] .1082
FAILURE CODE [CA145] .1084
FAILURE CODE [CA153] .1086
FAILURE CODE [CA154] .1089
FAILURE CODE [CA187] .1091
FAILURE CODE [CA221] .1093
FAILURE CODE [CA222] .1095
FAILURE CODE [CA227] .1097
FAILURE CODE [CA234] .1098
FAILURE CODE [CA238] .1099
FAILURE CODE [CA239] .1101
FAILURE CODE [CA249] .1103
FAILURE CODE [CA256] .1105
FAILURE CODE [CA271] .1107
FAILURE CODE [CA272] .1109
FAILURE CODE [CA322] .1111
FAILURE CODE [CA323] .1113
FAILURE CODE [CA324] .1115
FAILURE CODE [CA325] .1117
FAILURE CODE [CA331] .1119
FAILURE CODE [CA332] .1121
FAILURE CODE [CA343] .1123
FAILURE CODE [CA351] .1124
FAILURE CODE [CA352] .1125
FAILURE CODE [CA356] .1128
FAILURE CODE [CA357] .1130
FAILURE CODE [CA386] .1133
FAILURE CODE [CA428] .1134
FAILURE CODE [CA429] .1136
FAILURE CODE [CA431] .1138
FAILURE CODE [CA432] .1141
FAILURE CODE [CA435] .1145
FAILURE CODE [CA441] .1147
FAILURE CODE [CA442] .1149
FAILURE CODE [CA449] .1150
FAILURE CODE [CA451] .1151
FAILURE CODE [CA452] .1153
FAILURE CODE [CA488] .1155
FAILURE CODE [CA515] .1156
FAILURE CODE [CA516] .1158
FAILURE CODE [CA553] .1160
FAILURE CODE [CA555] .1161
FAILURE CODE [CA556] .1162
FAILURE CODE [CA559] .1163
FAILURE CODE [CA595] .1166
FAILURE CODE [CA687] .1167
FAILURE CODE [CA689] .1169
FAILURE CODE [CA691] .1172
FAILURE CODE [CA692] .1174
FAILURE CODE [CA697] .1176
FAILURE CODE [CA698] .1177
FAILURE CODE [CA731] .1178
FAILURE CODE [CA778] .1180
FAILURE CODE [CA1117] 1185
FAILURE CODE [CA1664] 1186
FAILURE CODE [CA1669] 1188
FAILURE CODE [CA1673] 1189
FAILURE CODE [CA1677] 1190
FAILURE CODE [CA1678] 1191
FAILURE CODE [CA1682] 1192
FAILURE CODE [CA1683] 1194
FAILURE CODE [CA1684] 1196
FAILURE CODE [CA1686] 1198
FAILURE CODE [CA1691] 1199
FAILURE CODE [CA1694] 1202
FAILURE CODE [CA1695] 1205
FAILURE CODE [CA1696] 1206
FAILURE CODE [CA1712] 1208
FAILURE CODE [CA1713] 1211
FAILURE CODE [CA1714] 1213
FAILURE CODE [CA1715] 1214
FAILURE CODE [CA1776] 1215
FAILURE CODE [CA1777] 1218
FAILURE CODE [CA1843] 1221
FAILURE CODE [CA1844] 1223
FAILURE CODE [CA1879] 1226
FAILURE CODE [CA1881] 1229
FAILURE CODE [CA1883] 1231
FAILURE CODE [CA1885] 1235
FAILURE CODE [CA1887] 1237
FAILURE CODE [CA1921] 1239
FAILURE CODE [CA1922] 1242
FAILURE CODE [CA1942] 1247
FAILURE CODE [CA1993] 1248
FAILURE CODE [CA2185] 1251
FAILURE CODE [CA2186] 1253
FAILURE CODE [CA2249] 1255
FAILURE CODE [CA2271] 1256
FAILURE CODE [CA2272] 1259
FAILURE CODE [CA2288] 1262
FAILURE CODE [CA2311] 1263
FAILURE CODE [CA2349] 1264
FAILURE CODE [CA2353] 1267
FAILURE CODE [CA2357] 1269
FAILURE CODE [CA2381] 1270
FAILURE CODE [CA2382] 1273
FAILURE CODE [CA2383] 1276
FAILURE CODE [CA2386] 1279
FAILURE CODE [CA2387] 1281
FAILURE CODE [CA2555] 1282
FAILURE CODE [CA2556] 1285
FAILURE CODE [CA2637] 1287
FAILURE CODE [CA2639] 1289
FAILURE CODE [CA2771] 1292
FAILURE CODE [CA2777] 1298
FAILURE CODE [CA2976] 1301
FAILURE CODE [CA3133] 1303
FAILURE CODE [CA3134] 1306
FAILURE CODE [CA3135] 1308
FAILURE CODE [CA3142] 1312
FAILURE CODE [CA3143] 1313
FAILURE CODE [CA3144] 1314
FAILURE CODE [CA3146] 1317
FAILURE CODE [CA3147] 1318
FAILURE CODE [CA3148] 1319
FAILURE CODE [CA3151] 1321
FAILURE CODE [CA3165] 1327
FAILURE CODE [CA3229] 1329
FAILURE CODE [CA3231] 1331
FAILURE CODE [CA3232] 1333
FAILURE CODE [CA3235] 1337
FAILURE CODE [CA3239] 1339
FAILURE CODE [CA3241] 1342
FAILURE CODE [CA3242] 1345
FAILURE CODE [CA3251] 1348
FAILURE CODE [CA3253] 1350
FAILURE CODE [CA3254] 1353
FAILURE CODE [CA3255] 1356
FAILURE CODE [CA3256] 1360
FAILURE CODE [CA3311] 1362
FAILURE CODE [CA3312] 1364
FAILURE CODE [CA3313] 1367
FAILURE CODE [CA3314] 1368
FAILURE CODE [CA3315] 1369
FAILURE CODE [CA3316] 1372
FAILURE CODE [CA3317] 1373
FAILURE CODE [CA3318] 1374
FAILURE CODE [CA3319] 1377
FAILURE CODE [CA3321] 1378
FAILURE CODE [CA3322] 1380
FAILURE CODE [CA3419] 1383
FAILURE CODE [CA3421] 1385
FAILURE CODE [CA3497] 1387
FAILURE CODE [CA3498] 1388
FAILURE CODE [CA3543] 1389
FAILURE CODE [CA3545] 1396
FAILURE CODE [CA3547] 1398
FAILURE CODE [CA3558] 1399
FAILURE CODE [CA3559] 1401
FAILURE CODE [CA3562] 1403
FAILURE CODE [CA3563] 1405
FAILURE CODE [CA3567] 1408
FAILURE CODE [CA3568] 1412
FAILURE CODE [CA3571] 1416
FAILURE CODE [CA3572] 1418
FAILURE CODE [CA3574] 1420
FAILURE CODE [CA3575] 1422
FAILURE CODE [CA3577] 1424
FAILURE CODE [CA3578] 1426
FAILURE CODE [CA3582] 1428
FAILURE CODE [CA3583] 1434
FAILURE CODE [CA3596] 1436
FAILURE CODE [CA3649] 1438
FAILURE CODE [CA3681] 1440
FAILURE CODE [CA3682] 1445
FAILURE CODE [CA3713] 1451
FAILURE CODE [CA3717] 1454
FAILURE CODE [CA3718] 1455
FAILURE CODE [CA3725] 1456
FAILURE CODE [CA3741] 1459
FAILURE CODE [CA3748] 1460
FAILURE CODE [CA3751] 1463
FAILURE CODE [CA3755] 1465
FAILURE CODE [CA3866] 1467
FAILURE CODE [CA3867] 1470
FAILURE CODE [CA3868] 1473
FAILURE CODE [CA3899] 1477
FAILURE CODE [CA3911] 1479
FAILURE CODE [CA3912] 1483
FAILURE CODE [CA3932] 1485
FAILURE CODE [CA3933] 1487
FAILURE CODE [CA3934] 1489
FAILURE CODE [CA3935] 1492
FAILURE CODE [CA3936] 1494
FAILURE CODE [CA4151] 1496
FAILURE CODE [CA4152] 1500
FAILURE CODE [CA4155] 1504
FAILURE CODE [CA4156] 1507
FAILURE CODE [CA4157] 1510
FAILURE CODE [CA4158] 1512
FAILURE CODE [CA4159] 1513
FAILURE CODE [CA4161] 1514
FAILURE CODE [CA4162] 1517
FAILURE CODE [CA4163] 1520
FAILURE CODE [CA4164] 1522
FAILURE CODE [CA4165] 1524
FAILURE CODE [CA4166] 1526
FAILURE CODE [CA4168] 1528
FAILURE CODE [CA4169] 1531
FAILURE CODE [CA4171] 1533
FAILURE CODE [CA4249] 1536
FAILURE CODE [CA4251] 1538
FAILURE CODE [CA4259] 1540
FAILURE CODE [CA4261] 1543
FAILURE CODE [CA4277] 1546
FAILURE CODE [CA4281] 1549
FAILURE CODE [CA4459] 1552
FAILURE CODE [CA4461] 1555
FAILURE CODE [CA4658] 1558
FAILURE CODE [CA4731] 1562
FAILURE CODE [CA4732] 1563
FAILURE CODE [CA4739] 1564
FAILURE CODE [CA4768] 1565
FAILURE CODE [CA4769] 1567
FAILURE CODE [CA4842] 1570
FAILURE CODE [CA4952] 1573
FAILURE CODE [CA5115] 1575
FAILURE CODE [CA5179] 1578
FAILURE CODE [CA5181] 1580
FAILURE CODE [CA5383] 1582
FAILURE CODE [D110L4] 1584
FAILURE CODE [D160KA] 1586
FAILURE CODE [D160KY] 1588
FAILURE CODE [D191KA] 1589
FAILURE CODE [D191KB] 1591
FAILURE CODE [D191KY] 1593
FAILURE CODE [D192KA] 1594
FAILURE CODE [D192KB] 1595
FAILURE CODE [D192KY] 1596
FAILURE CODE [D19JKZ] 1597
FAILURE CODE [D1B0KA] 1599
FAILURE CODE [D1B0KB] 1601
FAILURE CODE [D1B0KY] 1603
FAILURE CODE [D1B0MC] 1605
FAILURE CODE [D1E6KA] 1607
FAILURE CODE [D1E6KB] 1609
FAILURE CODE [D1E6KY] 1611
FAILURE CODE [D5ZHKA] 1613
FAILURE CODE [D5ZHKB] 1615
FAILURE CODE [D5ZHL6] 1617
FAILURE CODE [D811MC] 1618
FAILURE CODE [D862KA] 1619
FAILURE CODE [D8ALKA] 1620
FAILURE CODE [D8ALKB] 1622
FAILURE CODE [D8AQK4] 1624
FAILURE CODE [D8AQKR] 1628
FAILURE CODE [DAF0KT] 1632
FAILURE CODE [DAF0MB] 1633
FAILURE CODE [DAF0MC] 1634
FAILURE CODE [DAF3KK] 1635
FAILURE CODE [DAF8KB] 1637
FAILURE CODE [DAFDKB] 1638
FAILURE CODE [DAFGMC] 1640
FAILURE CODE [DAFLKA] 1641
FAILURE CODE [DAFLKB] 1643
FAILURE CODE [DAFQKR] 1645
FAILURE CODE [DAJ0KK] 1650
FAILURE CODE [DAJ0KT] 1653
FAILURE CODE [DAJ0MC] 1654
FAILURE CODE [DAJ1KA] 1655
FAILURE CODE [DAJ2KK] 1657
FAILURE CODE [DAJ4KB] 1660
FAILURE CODE [DAJ4KZ] 1662
FAILURE CODE [DAJ5KX] 1664
FAILURE CODE [DAJ6KX] 1666
FAILURE CODE [DAJ9KQ] 1668
FAILURE CODE [DAJLKA] 1669
FAILURE CODE [DAJLKB] 1671
FAILURE CODE [DAJQKR] 1673
FAILURE CODE [DAJRKR] 1678
FAILURE CODE [DAJRMA] 1683
FAILURE CODE [DAZ9KQ] 1684
FAILURE CODE [DAZQKR] 1685
FAILURE CODE [DB2QKR] 1689
FAILURE CODE [DB2RKR] 1695
FAILURE CODE [DD1ALD] 1700
FAILURE CODE [DDAAL6] 1702
FAILURE CODE [DDB2L4] 1704
FAILURE CODE [DDB6L4] 1706
FAILURE CODE [DDD7KA] 1708
FAILURE CODE [DDD7KY] 1710
FAILURE CODE [DDK3KA] 1712
FAILURE CODE [DDK3KB] 1715
FAILURE CODE [DDK6KA] 1718
FAILURE CODE [DDK6KB] 1721
FAILURE CODE [DDNRLD] 1724
FAILURE CODE [DF10KA] 1726
FAILURE CODE [DF10KB] 1729
FAILURE CODE [DGH1KX] 1732
FAILURE CODE [DGR2KB] 1734
FAILURE CODE [DGR2KZ] 1736
FAILURE CODE [DHA4KA] 1738
FAILURE CODE [DHHBKA] 1740
FAILURE CODE [DHHBKY] 1742
FAILURE CODE [DHHCKA] 1744
FAILURE CODE [DHHCKY] 1746
FAILURE CODE [DHPCKA] 1748
FAILURE CODE [DHPCKY] 1750
FAILURE CODE [DHPEKA] 1752
FAILURE CODE [DHPEKY] 1754
FAILURE CODE [DHS8KA] 1756
FAILURE CODE [DHS8KY] 1758
FAILURE CODE [DHS9KA] 1760
FAILURE CODE [DHS9KY] 1762
FAILURE CODE [DHSDKA] 1764
FAILURE CODE [DHSDKY] 1766
FAILURE CODE [DHSNKA] 1768
FAILURE CODE [DHSNKY] 1770
FAILURE CODE [DHT8ZG] 1772
FAILURE CODE [DHTCL6] 1773
FAILURE CODE [DJF1KA] 1775
FAILURE CODE [DK55KA] 1776
FAILURE CODE [DK55KY] 1778
FAILURE CODE [DK55L5] 1780
FAILURE CODE [DK5DKA] 1781
FAILURE CODE [DK5DKY] 1784
FAILURE CODE [DK5DL8] 1787
FAILURE CODE [DK5EKA] 1791
FAILURE CODE [DK5EKY] 1794
FAILURE CODE [DK70KA] 1797
FAILURE CODE [DK70KY] 1799
FAILURE CODE [DKA0KA] 1801
FAILURE CODE [DKA0KY] 1804
FAILURE CODE [DKA0L0] 1806
FAILURE CODE [DLM3KA] 1808
FAILURE CODE [DLM3LC] 1809
FAILURE CODE [DLT3KX] 1811
FAILURE CODE [DLT4KX] 1813
FAILURE CODE [DLT4L0] 1815
FAILURE CODE [DLT4LC] 1816
FAILURE CODE [DPQ1KR] 1818
FAILURE CODE [DPQ2KR] 1821
FAILURE CODE [DPQ3KR] 1824
FAILURE CODE [DSJ0KR] 1828
FAILURE CODE [DT22KB] 1833
FAILURE CODE [DV00KB] 1835
FAILURE CODE [DW26KA] 1836
FAILURE CODE [DW26KB] 1838
FAILURE CODE [DW26KY] 1840
FAILURE CODE [DW4BKA] 1842
FAILURE CODE [DW4BKB] 1844
FAILURE CODE [DW4BKY] 1846
FAILURE CODE [DW4RKA] 1847
FAILURE CODE [DW4RKB] 1849
FAILURE CODE [DW4RKY] 1851
FAILURE CODE [DWM1KA] 1853
FAILURE CODE [DWM1KB] 1854
FAILURE CODE [DWM1KY] 1856
FAILURE CODE [DWN6KA] 1857
FAILURE CODE [DWN6KB] 1859
FAILURE CODE [DWN6KY] 1861
FAILURE CODE [DWN8KA] 1862
FAILURE CODE [DWN8KB] 1863
FAILURE CODE [DWN8KY] 1864
FAILURE CODE [DX19KA] 1865
FAILURE CODE [DX19KB] 1867
FAILURE CODE [DX19KY] 1869
FAILURE CODE [DX20KA] 1871
FAILURE CODE [DX20KB] 1873
FAILURE CODE [DX20KY] 1875
FAILURE CODE [DXAWKA] 1876
FAILURE CODE [DXAWKB] 1879
FAILURE CODE [DXAWKY] 1882
FAILURE CODE [DXH7KA] 1885
FAILURE CODE [DXH7KB] 1887
FAILURE CODE [DXH7KY] 1889
FAILURE CODE [DXH8KA] 1891
FAILURE CODE [DXH8KB] 1893
FAILURE CODE [DXH8KY] 1895
FAILURE CODE [DXHJKA] 1897
FAILURE CODE [DXHJKB] 1899
FAILURE CODE [DXHJKY] 1901
FAILURE CODE [DXHKKA] 1902
FAILURE CODE [DXHKKB] 1904
FAILURE CODE [DXHKKY] 1906
FAILURE CODE [H2K0KA] 1907
FAILURE CODE [H2K0KY] 1909
FAILURE CODE [J141N1] 1911
FAILURE CODE [LA00L3] 1912
FAILURE CODE [M100N1] 1913
FAILURE CODE [M400N1] 1914
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1915
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1915
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK .1923
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1926
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1929
E-5 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING .1931
E-6 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING .1934
E-7 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS) .1936
E-8 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY .1938
E-9 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 1940
E-10 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 1943
E-11 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 1947
E-12 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES NOT OPERATE PROPERLY 1949
E-13 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION .1952
E-14 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 1955
E-15 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED PROPERLY 1958
E-16 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 1959
E-17 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY .1962
E-18 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 1966
E-19 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL .1970
E-20 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP .1972
E-21 RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT UP .1974
E-22 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT WHEN THE PARKING BRAKE IS SET TO ON (PARKING) POSITION 1975
E-23 WHEN FRONT BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 1979
E-24 WHEN REAR BRAKE ACCUMULATOR OIL PRESSURE DROPS, THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP .1980
E-25 INDICATION OF HST OIL TEMPERATURE GAUGE DOES NOT INCREASE, OR HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT UP 1981
E-26 WHEN THE INCHING PEDAL IS DEPRESSED, INCHING FUNCTION DOES NOT WORK OR WHILE THE PEDAL HAS NOT BEEN DEPRESSED, INCHING FUNCTION OPERATES 1982
E-27 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 1984
E-28 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL .1986
E-29 ALARM BUZZER DOES NOT SOUND .1987
E-30 ALARM BUZZER DOES NOT STOP SOUNDING .1988
E-31 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 1989
E-32 SETTING DOES NOT CHANGE WHILE OPERATING THE TRACTION CONTROL SWITCH .1992
E-33 THE REMOTE POSITIONER DOES NOT WORK OR CANNOT BE RELEASED .1994
E-34 THE BUCKET POSITIONER DOES NOT WORK OR CANNOT BE RELEASED .1996
E-35 BRAKE DOES NOT WORK WHEN PARKING BRAKE IS APPLIED OR BRAKE DRAGS WHILE TRAVELING WHEN PARKING BRAKE IS RELEASED .1999
E-36 DIRECTIONAL SELECTOR (FNR) SWITCH MODE IS NOT SELECTED OR NOT RELEASED 2003
E-37 PZ AUTO TILT-IN DOES NOT WORK .2005
E-38 TRACKTION LEVEL DOES NOT DISPLAY MAX WHEN MAX. TRACTION SWITCH IS TURNED ON .2008
E-39 ECSS FUNCTION CANNOT BE SELECTED OR CANNOT BE RELEASED 2010
E-40 HORN DOES NOT SOUND .2012
E-41 HORN DOES NOT STOP SOUNDING .2015
E-42 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 2017
E-43 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT 2019
E-44 CLEARANCE LAMP AND TAIL LAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) .2023
E-45 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT .2027
E-46 BOTH HIGH AND LOW BEAMS OF HEADLAMP DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2031
E-47 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT 2035
E-48 LOW BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) .2037
E-49 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT .2039
E-50 HIGH BEAM OF HEADLAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2041
E-51 FRONT WORKING LAMP DOES NOT LIGHT UP OR GO OUT 2043
E-52 REAR WORKING LAMP DOES NOT LIGHT UP OR GO OUT .2048
E-53 ALL OF TURN SIGNAL LAMPS AND HAZARD LAMPS DO NOT LIGHT UP OR GO OUT .2052
E-54 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT .2055
E-55 TURN SIGNAL LAMPS DO NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2058
E-56 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT .2061
E-57 HAZARD LAMP DOES NOT LIGHT UP OR GO OUT (FOR EUROPEAN UNION) 2065
E-58 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED 2069
E-59 BRAKE LAMP DOES NOT LIGHT OR STAYS LIGHTED (FOR EUROPEAN UNION) .2073
E-60 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT 2077
E-61 BACKUP LAMP DOES NOT LIGHT UP OR DOES NOT GO OUT (FOR EUROPEAN UNION) .2081
E-62 BACKUP BUZZER DOES NOT SOUND OR CONTINUES TO SOUND 2085
E-63 FRONT WIPER DOES NOT OPERATE 2087
E-64 REAR WIPER DOES NOT OPERATE .2091
E-65 WINDOW WASHER DOES NOT OPERATE 2094
E-66 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2097
E-67 [FCS] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2098
E-68 [FLL] IS DISPLAYED ON THE SCREEN OF AUTO-GREASING PUMP 2099
E-69 AUTO-GREASING SYSTEM DOES NOT OPERATE OR STOP .2100
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2101
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2101
FAILURE MODE AND CAUSE TABLE .2102
H-1 MACHINE CAN TRAVEL NEITHER FORWARD NOR REVERSE .2116
H-2 MACHINE CAN NOT TRAVEL FORWARD (MACHINE TRAVELS REVERSE NORMALLY) 2119
H-3 MACHINE CAN NOT TRAVEL REVERSE (MACHINE TRAVELS FORWARD NORMALLY) 2120
H-4 TRAVEL SPEED OF FORWARD TRAVEL AND REVERSE TRAVEL IS SLOW, OR POWER IS LOW .2121
H-5 FORWARD TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS REVERSE NORMALLY) 2125
H-6 REVERSE TRAVEL SPEED IS SLOW OR POWER IS LOW (MACHINE TRAVELS FORWARD NORMALLY) 2126
H-7 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .2127
H-8 MACHINE DOES NOT TURN 2129
H-9 STEERING WHEEL IS HEAVY TO OPERATE .2131
H-10 MACHINE SWAYS OR LARGE SHOCKS ARE MADE WHILE MACHINE TURNS 2133
H-11 MACHINE UNINTENTIONALLY TURNS TO ONE SIDE WHEN MACHINE TRAVELS 2134
H-12 WHEEL BRAKES DO NOT WORK OR ARE WEAK 2135
H-13 WHEEL BRAKES ARE NOT RELEASED OR DRAG .2137
H-14 PARKING BRAKE DOES NOT WORK OR IT IS WEAK .2138
H-15 PARKING BRAKE IS NOT RELEASED OR DRAGS 2139
H-16 BOOM DOES NOT RISE 2141
H-17 BOOM MOVES SLOW OR BOOM LACKS LIFTING FORCE .2144
H-18 RISING BOOM SLOWS DOWN AT CERTAIN HEIGHT 2147
H-19 LIFT CYLINDERS DO NOT SERVE TO HOLD BUCKET ON GROUND 2148
H-20 HYDRAULIC DRIFT OF BOOM IS LARGE 2150
H-21 BOOM MOVES UP AND DOWN DURING OPERATION .2151
H-22 BUCKET DOES NOT TILT BACK .2152
H-23 BUCKET MOVES SLOW OR LACKS TILT-BACK FORCE 2155
H-24 BUCKET DECELERATES DURING TILT-BACK OPERATION .2158
H-25 BUCKET CYLINDER DOES NOT HOLD BUCKET ON GROUND 2159
H-26 HYDRAULIC DRIFT OF BUCKET IS LARGE 2161
H-27 BUCKET TILTS BACK AND FORTH DURING CARRYING LOAD (WORK EQUIPMENT VALVE IN HOLD) .2162
H-28 BOOM AND BUCKET CONTROL LEVERS DO NOT MOVE SMOOTHLY AND ARE HEAVY TO MOVE .2163
H-29 WHEN OPERATING WORK EQUIPMENT ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2164
H-30 LARGE SHOCKS ARE MADE WHEN WORK EQUIPMENT STARTS TO MOVE AND STOPS 2165
H-31 WHEN CERTAIN WORK EQUIPMENT STALLS HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2167
H-32 E.C.S.S. (TRAVEL DAMPER) DOES NOT WORK AND MACHINE PITCHES AND BOUNCES 2168
H-33 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2169
H-34 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2172
TROUBLESHOOTING OF ENGINE (S-MODE) .2173
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2173
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION .2174
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .2175
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) .2176
S-4 ENGINE STARTABILITY IS POOR 2178
S-5 ENGINE DOES NOT PICK UP SMOOTHLY .2180
S-6 ENGINE STOPS DURING OPERATION 2182
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE .2184
S-8 ENGINE LACKS POWER .2185
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2187
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .2189
S-11 OIL BECOMES CONTAMINATED QUICKLY 2190
S-12 FUEL CONSUMPTION IS EXCESSIVE .2191
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .2192
S-14 OIL PRESSURE DROPS 2193
S-15 FUEL MIXES INTO ENGINE OIL 2195
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .2196
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2197
S-18 UNUSUAL NOISE IS HEARD 2198
S-19 VIBRATION IS EXCESSIVE 2199
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2200
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2201
S-22 ACTIVE REGENERATION TAKES TIME 2203
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION .2204
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE .2205
S-25 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) .2207
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM .2208
OUTLINE OF FAILURE DISPLAY .2208
TROUBLESHOOTING FOR FCS 2209
TROUBLESHOOTING FOR AUTO-GREASING PUMP .2210
REPLACEMENT OF PUMP ELEMENT 2213
TROUBLESHOOTING FOR GREASE SUPPLY SYSTEM .2214
REPLACEMENT OF AUTO-GREASING CONTROLLER 2216
PROCEDURE FOR ASSEMBLING WHEN DISASSEMBLING FOR TROUBLESHOOTING 2217
50 DISASSEMBLY AND ASSEMBLY 2219
CONTENTS .2220
ABBREVIATION LIST 2224
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2230
HOW TO READ THIS MANUAL 2230
COATING MATERIALS LIST .2232
SPECIAL TOOLS LIST .2237
SKETCHES OF SPECIAL TOOLS 2259
ENGINE AND COOLING SYSTEM 2273
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2273
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY .2274
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY .2278
REMOVE AND INSTALL INJECTOR ASSEMBLY .2285
METHOD FOR REMOVING INJECTOR ASSEMBLY 2285
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2293
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2303
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY .2304
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY .2315
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2330
METHOD FOR REMOVING EGR VALVE ASSEMBLY .2330
METHOD FOR INSTALLING EGR VALVE ASSEMBLY .2334
REMOVE AND INSTALL EGR COOLER ASSEMBLY .2338
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2338
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2341
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .2346
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2346
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2348
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .2352
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 2352
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 2353
REMOVE AND INSTALL ALTERNATOR BELT .2355
METHOD FOR REMOVING ALTERNATOR BELT 2355
METHOD FOR INSTALLING ALTERNATOR BELT 2358
REMOVE AND INSTALL ALTERNATOR ASSEMBLY .2361
METHOD FOR REMOVING ALTERNATOR ASSEMBLY 2361
METHOD FOR INSTALLING ALTERNATOR ASSEMBLY 2363
REMOVE AND INSTALL AUTOMATIC TENSIONER .2368
METHOD FOR REMOVING AUTOMATIC TENSIONER 2368
METHOD FOR INSTALLING AUTOMATIC TENSIONER 2368
REMOVE AND INSTALL RADIATOR ASSEMBLY .2369
METHOD FOR REMOVING RADIATOR ASSEMBLY 2369
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2372
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2375
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2375
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY .2378
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY .2382
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2382
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2383
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2385
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY .2385
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY .2386
REMOVE AND INSTALL ENGINE ASSEMBLY .2388
METHOD FOR REMOVING ENGINE ASSEMBLY 2389
METHOD FOR INSTALLING ENGINE ASSEMBLY 2408
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .2428
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2428
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2430
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2433
METHOD FOR REMOVING ENGINE REAR OIL SEAL .2433
METHOD FOR INSTALLING ENGINE REAR OIL SEAL .2435
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2439
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY .2439
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY .2446
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2453
METHOD FOR REMOVING FUEL TANK ASSEMBLY .2453
METHOD FOR INSTALLING FUEL TANK ASSEMBLY .2457
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2461
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY .2462
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY .2468
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2473
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2473
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2475
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2478
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR .2478
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR .2479
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2481
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER .2481
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER .2482
REMOVE AND INSTALL KDPF ASSEMBLY .2483
METHOD FOR REMOVING KDPF ASSEMBLY 2485
METHOD FOR INSTALLING KDPF ASSEMBLY 2494
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2507
METHOD FOR DISASSEMBLING KDPF ASSEMBLY .2507
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2512
REMOVE AND INSTALL SCR ASSEMBLY 2517
METHOD FOR REMOVING SCR ASSEMBLY .2518
METHOD FOR INSTALLING SCR ASSEMBLY .2528
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2542
METHOD FOR REMOVING KDPF, SCR ASSEMBLY .2543
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY .2553
REMOVE AND INSTALL KCCV ASSEMBLY .2568
METHOD FOR REMOVING KCCV ASSEMBLY 2568
METHOD FOR INSTALLING KCCV ASSEMBLY 2570
REMOVE AND INSTALL VGT ASSEMBLY 2573
METHOD FOR REMOVING VGT ASSEMBLY .2573
METHOD FOR INSTALLING VGT ASSEMBLY .2580
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2589
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE .2590
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE .2595
REMOVE AND INSTALL AdBlue/DEF INJECTOR .2602
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2602
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2605
REMOVE AND INSTALL AdBlue/DEF PUMP .2610
METHOD FOR REMOVING AdBlue/DEF PUMP 2610
METHOD FOR INSTALLING AdBlue/DEF PUMP 2612
REMOVE AND INSTALL AdBlue/DEF HOSE .2615
METHOD FOR REMOVING AdBlue/DEF HOSE 2615
METHOD FOR INSTALLING AdBlue/DEF HOSE 2623
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2631
METHOD FOR REMOVING AIR CLEANER ASSEMBLY .2631
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY .2634
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .2637
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2638
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2640
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2642
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY .2642
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY .2644
POWER TRAIN 2647
REMOVE AND INSTALL HST PUMP ASSEMBLY .2647
METHOD FOR REMOVING HST PUMP ASSEMBLY 2648
METHOD FOR INSTALLING HST PUMP ASSEMBLY 2654
REMOVE AND INSTALL HST MOTOR1 ASSEMBLY .2663
METHOD FOR REMOVING HST MOTOR1 ASSEMBLY 2663
METHOD FOR INSTALLING HST MOTOR1 ASSEMBLY 2666
REMOVE AND INSTALL HST MOTOR2 ASSEMBLY .2669
METHOD FOR REMOVING HST MOTOR2 ASSEMBLY 2670
METHOD FOR INSTALLING HST MOTOR2 ASSEMBLY 2678
REMOVE AND INSTALL TRANSFER ASSEMBLY .2688
METHOD FOR REMOVING TRANSFER ASSEMBLY 2689
METHOD FOR INSTALLING TRANSFER ASSEMBLY 2693
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY .2700
METHOD FOR DISASSEMBLING TRANSFER ASSEMBLY .2702
METHOD FOR ASSEMBLING TRANSFER ASSEMBLY 2722
REMOVE AND INSTALL FRONT AXLE ASSEMBLY .2747
METHOD FOR REMOVING FRONT AXLE ASSEMBLY 2747
METHOD FOR INSTALLING FRONT AXLE ASSEMBLY 2749
REMOVE AND INSTALL REAR AXLE ASSEMBLY 2752
METHOD FOR REMOVING REAR AXLE ASSEMBLY .2752
METHOD FOR INSTALLING REAR AXLE ASSEMBLY .2756
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY .2760
METHOD FOR DISASSEMBLING AXLE HOUSING ASSEMBLY .2761
METHOD FOR ASSEMBLING AXLE HOUSING ASSEMBLY 2769
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY .2779
METHOD FOR DISASSEMBLING DIFFERENTIAL ASSEMBLY .2780
METHOD FOR ASSEMBLING DIFFERENTIAL ASSEMBLY 2793
UNDERCARRIAGE AND FRAME 2813
REMOVE AND INSTALL CENTER HINGE PIN 2813
METHOD FOR REMOVING CENTER HINGE PIN .2814
METHOD FOR INSTALLING CENTER HINGE PIN .2820
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2831
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY .2831
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY .2837
HYDRAULIC SYSTEM .2842
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY .2842
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2842
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2853
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2863
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY .2863
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY .2869
WORK EQUIPMENT .2875
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .2875
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2876
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2880
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2891
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2892
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2896
CAB AND ITS ATTACHMENTS 2904
REMOVE AND INSTALL OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY .2904
METHOD FOR REMOVING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY 2905
METHOD FOR INSTALLING OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY 2913
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2921
METHOD FOR REMOVING OPERATOR’S CAB GLASS (ADHERED GLASS) .2921
METHOD FOR INSTALLING OPERATOR’S CAB GLASS (ADHERED GLASS) .2922
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .2931
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2931
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2937
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 2944
METHOD FOR REMOVING OPERATOR’S SEAT ASSEMBLY .2944
METHOD FOR INSTALLING OPERATOR’S SEAT ASSEMBLY .2944
REMOVE AND INSTALL SEAT BELT .2946
METHOD FOR REMOVING SEAT BELT 2946
METHOD FOR INSTALLING SEAT BELT 2946
ELECTRICAL SYSTEM 2948
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2948
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY .2948
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY .2952
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .2959
METHOD FOR REMOVING HST CONTROLLER ASSEMBLY 2959
METHOD FOR INSTALLING HST CONTROLLER ASSEMBLY 2961
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY .2963
METHOD FOR REMOVING AIR CONDITIONER CONTROLLER ASSEMBLY 2963
METHOD FOR INSTALLING AIR CONDITIONER CONTROLLER ASSEMBLY 2964
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY .2966
METHOD FOR REMOVING MONITOR CONTROLLER ASSEMBLY 2966
METHOD FOR INSTALLING MONITOR CONTROLLER ASSEMBLY 2969
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2971
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY .2971
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY .2974
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2977
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR .2977
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR .2978
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2979
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR .2979
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR .2980
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR .2982
METHOD FOR REMOVING KDPF TEMPERATURE SENSOR 2982
METHOD FOR INSTALLING KDPF TEMPERATURE SENSOR 2984
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR .2987
METHOD FOR REMOVING KDPF DIFFERENTIAL PRESSURE SENSOR 2987
METHOD FOR INSTALLING KDPF DIFFERENTIAL PRESSURE SENSOR 2990
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2992
METHOD FOR REMOVING SCR TEMPERATURE SENSOR .2992
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR .2993
REMOVE AND INSTALL AMMONIA SENSOR 2995
METHOD FOR REMOVING AMMONIA SENSOR .2995
METHOD FOR INSTALLING AMMONIA SENSOR .2997
REMOVE AND INSTALL SCR OUTLET NOx SENSOR .3000
METHOD FOR REMOVING SCR OUTLET NOx SENSOR 3000
METHOD FOR INSTALLING SCR OUTLET NOx SENSOR 3002
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY .3005
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 3005
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 3006
60 MAINTENANCE STANDARD 3007
CONTENTS .3008
ABBREVIATION LIST 3009
ENGINE AND COOLING SYSTEM 3015
MAINTENANCE STANDARD OF ENGINE MOUNT .3015
MAINTENANCE STANDARD OF DAMPER .3016
MAINTENANCE STANDARD OF COOLING FAN MOTOR 3017
POWER TRAIN 3019
MAINTENANCE STANDARD OF DRIVE SHAFT 3019
MAINTENANCE STANDARD OF TRANSFER .3020
MAINTENANCE STANDARD OF TRANSFER MOUNT .3028
MAINTENANCE STANDARD OF FRONT AXLE .3029
MAINTENANCE STANDARD OF REAR AXLE 3030
MAINTENANCE STANDARD OF FRONT TORQUE PROPORTIONING DIFFERENTIAL 3031
MAINTENANCE STANDARD OF REAR TORQUE PROPORTIONING DIFFERENTIAL .3033
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL 3035
MAINTENANCE STANDARD OF FINAL DRIVE 3037
STEERING SYSTEM 3039
MAINTENANCE STANDARD OF STEERING COLUMN 3039
MAINTENANCE STANDARD OF PRIORITY VALVE .3040
MAINTENANCE STANDARD OF STEERING CYLINDER 3041
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE .3044
BRAKE SYSTEM .3045
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE .3045
MAINTENANCE STANDARD OF SLACK ADJUSTER .3046
MAINTENANCE STANDARD OF FRONT BRAKE 3047
MAINTENANCE STANDARD OF REAR BRAKE .3048
MAINTENANCE STANDARD OF PARKING BRAKE 3049
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE .3051
UNDERCARRIAGE AND FRAME 3052
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN .3052
HYDRAULIC SYSTEM .3057
MAINTENANCE STANDARD OF HYDRAULIC TANK .3057
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP .3058
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP .3059
MAINTENANCE STANDARD OF SERVO VALVE OF STEERING AND WORK EQUIPMENT PUMP 3062
MAINTENANCE STANDARD OF CONTROL VALVE 3063
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE .3075
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE .3077
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE .3079
WORK EQUIPMENT .3080
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE .3080
MAINTENANCE STANDARD OF BUCKET .3084
MAINTENANCE STANDARD OF LIFT CYLINDER 3086
MAINTENANCE STANDARD OF BUCKET CYLINDER 3087
CAB AND ITS ATTACHMENTS 3088
MAINTENANCE STANDARD OF CAB MOUNT 3088
80 APPENDIX 3089
CONTENTS .3090
ABBREVIATION LIST 3092
AIR CONDITIONER SYSTEM .3098
PRECAUTIONS FOR REFRIGERANT 3098
AIR CONDITIONER COMPONENT 3099
SPECIFICATIONS OF AIR CONDITIONER 3101
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3102
OUTLINE OF REFRIGERATION CYCLE .3103
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3105
AIR CONDITIONER UNIT .3105
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3105
FUNCTION OF AIR CONDITIONER UNIT .3106
COMPONENT PARTS OF AIR CONDITIONER UNIT 3107
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .3107
FUNCTION OF INSIDE AIR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3107
FUNCTION OF BLOWER AMPLIFIER AS AIR CONDITIONER UNIT COMPONENT .3108
FUNCTION OF BLOWER OFF RELAY AS AIR CONDITIONER UNIT COMPONENT .3108
FUNCTION OF COMPRESSOR CLUTCH RELAY AS AIR CONDITIONER UNIT COMPONENT 3108
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3108
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3108
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3108
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3109
FUNCTION OF DUAL PRESSURE SWITCH .3109
AIR CONDITIONER CONTROLLER .3110
STRUCTURE OF AIR CONDITIONER CONTROLLER 3110
COMPRESSOR .3111
STRUCTURE OF COMPRESSOR 3111
SPECIFICATIONS OF COMPRESSOR .3111
FUNCTION OF COMPRESSOR .3111
CONDENSER 3112
STRUCTURE OF CONDENSER .3112
SPECIFICATIONS OF CONDENSER 3112
FUNCTION OF CONDENSER 3112
RECEIVER DRIER .3113
STRUCTURE OF RECEIVER DRIER 3113
SPECIFICATIONS OF RECEIVER DRIER .3113
FUNCTION OF RECEIVER DRIER .3113
SENSORS FOR AIR CONDITIONER SYSTEM .3114
FUNCTION OF SUNLIGHT SENSOR 3114
FUNCTION OF AMBIENT TEMPERATURE SENSOR .3114
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3115
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3117
AIR CONDITIONER SYSTEM DIAGRAM .3120
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .3121
FUNCTION OF AIR CONDITIONER CONTROLLER .3122
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3123
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3129
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .3130
CHECK TEMPERATURE CONTROL FUNCTION .3131
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION .3131
TEST VENT (MODE) CHANGEOVER 3133
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3133
TESTING FRESH/RECIRC AIR CHANGEOVER 3135
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .3135
TEST EVAPORATOR TEMPERATURE SENSOR .3137
TEST RELAYS 3139
METHOD FOR TESTING RELAYS 3139
AIR CONDITIONER TROUBLESHOOTING CHART 1 3141
AIR CONDITIONER TROUBLESHOOTING CHART 2 3142
FAILURE CODE [879AKA] 3145
FAILURE CODE [879AKB] 3147
FAILURE CODE [879BKA] 3149
FAILURE CODE [879BKB] 3151
FAILURE CODE [879CKA] 3153
FAILURE CODE [879CKB] 3155
FAILURE CODE [879DKZ] 3157
FAILURE CODE [879EMC] 3159
FAILURE CODE [879FMC] 3160
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) .3161
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3164
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) .3167
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3171
TROUBLESHOOTING USING GAUGE PRESSURE .3173
CONNECTION OF SERVICE TOOL .3176
METHOD FOR CONNECTING SERVICE TOOL .3177
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3178
HANDLE COMPRESSOR OIL 3180
90 CIRCUIT DIAGRAMS 3183
CONTENTS .3184
ABBREVIATION LIST 3185
HYDRAULIC CIRCUIT DIAGRAM 3191
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3191
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3195
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3196
HYDRAULIC AUTO-GREASING DIAGRAM 3197
ELECTRICAL CIRCUIT DIAGRAM .3198
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM .3198
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/7) 3202
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/7) 3203
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/7) 3204
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/7) 3205
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/7) 3206
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/7) 3207
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/7) 3208
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (1/9) 3209
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (2/9) 3210
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (3/9) 3211
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (4/9) 3212
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (5/9) 3213
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (6/9) 3214
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (7/9) 3215
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (8/9) 3216
ELECTRICAL CIRCUIT DIAGRAM OF FLOOR (9/9) 3217
INDEX 3218

DESCRIPTION:

Komatsu WA320-8 Wheel Loader Shop Manual VENBM30500 – PDF DOWNLOAD

 SERIAL NUMBERS

• H70051 and up
• 85001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24